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TABLE OF CONTENTS GENERAL INFORMATION

0A 0B

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

WORKSHOP MANUAL TROOPER (UX)

1A 2A 3C 3D 3E 4A1 4A2 4B1 4B2 4C 4D1 4D2

FOREWORD
This manual includes special notes, important points, service data, precautions, etc. That are needed for the maintenance, adjustments, service, removal and installation of vehicle components. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. All rights are reserved to make changes at any time without notice. Arrangement of the material is shown in the table of contents on the right-hand side of this page. A black spot on the first page of each section can be seen on the edge of the book below each section title. These point to a more detailed table of contents preceding each section. 5A 5B 5C 5D 6A 6B 6C 6D1 6D2 6D3 6E 6F 6G 6H 6J 7A 7A1 7B 7C 8A 8B 8C 8D 8E 8F 8G 8H 8I 8J 9A 9J 9J1 10A

This manual applies to 2002 models.

SECTION
GENERAL INFORMATION
TROOPER

0A1

GENERAL INFORMATION
CONTENTS
General Information . . . . . . . . . . . . . . . . . . . . . Maintenance and Lubrication . . . . . . . . . . . . . 0A 0B

General Information
CONTENTS
General Repair Instruction . . . . . . . . . . . . . . . . Illustration Arrows . . . . . . . . . . . . . . . . . . . . . . . Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . Theft Prevention Standard . . . . . . . . . . . . . . . . 0A1 0A2 0A3 0A6 Lifting Instructions . . . . . . . . . . . . . . . . . . . . . . . Standard Bolts Torque Specifications . . . . . . Abbreviations Charts . . . . . . . . . . . . . . . . . . . . Service Parts Identification Plate . . . . . . . . . . 0A12 0A14 0A15 0A16

General Repair Instruction

1. If a floor jack is used, the following precautions are recommended. Park vehicle on level ground, block front or rear wheels, set jack against the recommended lifting points (see Lifting Instructions in this section), raise vehicle and support with chassis stands and then perform the service operations. 2. Before performing service operations, disconnect ground cable from the battery to reduce the chance of cable damage and burning due to short circuiting. 3. Use a cover on body, seats and floor to protect them against damage and contamination. 4. Brake fluid and antifreeze solution must be handled with reasonable care, as they can cause paint damage. 5. The use of proper tools and recommended essential and available tools, where specified, is important for efficient and reliable performance of service repairs. 6. Use genuine Isuzu parts. 7. Used cotter pins, plastic clips, gaskets, Orings, oil seals, lock washers and selflocking nuts should be discarded and new ones should be installed, as normal function of the parts cannot be maintained if these parts are reused. 8. To facilitate proper and smooth reassembly operation, keep disassembled parts neatly in groups. Keeping fixing bolts and nuts separate is very important, as they vary in hardness and design depending on position of installation.

9. Clean the parts before inspection or reassembly. Also clean oil ports, etc. using compressed air, and make certain they are free from restrictions. 10. Lubricate rotating and sliding faces of the parts with oil or grease before installation. 11. When necessary, use a sealer on gaskets to prevent leakage. 12. Carefully observe all specifications for bolt and nut torques. 13. When removing or replacing parts that require refrigerant to be discharged from the air conditioning system, be sure to use the Vehicle Refrigerant Recovery and Recycling Equipment (VRRRE) to recover and recycle Refrigerant134a. 14. When a service operation is completed, make a final check to be sure the service has been done properly and the problem has been corrected. 15. SUPPLEMENTAL RESTRAINT SYSTEM The vehicle is equipped with a Supplemental Restraint System (SRS) Air Bags. This system is not to be serviced without consulting the appropriate service information. Consult Section 9J SRS System if work is to be done on the front of the vehicle such as bumper, sheet metal, seats, wiring, steering wheel or column. Also review SRS system information if any arc welding is to be done on the vehicle. The SRS system equipped vehicle can be identified by: 1. AIR BAG warning light on the instrument panel. 2. A Code J or K for fifth digit of Vehicle Identification Number.

0A2

GENERAL INFORMATION

Illustration Arrows
Arrows are designed for specific purposes to aid your understanding of technical illustrations. Arrow Type Application Arrow Type Application D Ambient/Clean air flow D Cool air flow

Front of vehicle

Up Side

D Gas other than ambient air D Hot air flow

Task Related

D Ambient air mixed with another gas D Can indicate temperature change

View Detail

Motion or direction

View Angle

Lubrication point oil or fluid

Dimension (1:2)

Lubrication point grease

Sectioning (1:3)

Lubrication point jelly

GENERAL INFORMATION

0A3

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

905R200005

F00R200010

0A4

GENERAL INFORMATION

Engine Serial Number

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

F06R200001

Transmission Serial Number

Manual : Stamped into the lower side of the transmission.

220RW084

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

0A5

240R200028

0A6

GENERAL INFORMATION

Theft Prevention Standard

The 11 major components listed below will be marked with 17 digit VIN at the stage of production. In addition its service parts will be marked with manufacturer s trade mark, R mark and DOT mark. Reference Figure No. 0A-10 ENGINE COMPONENT 1 6VE1 INDICATION PRODUCTION VIN plate SERVICE PARTS

0A-11

TRANSMISSION

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

VIN plate

0A-11

BODY

VIN label

Anti Theft Stamping/Plate/Label

STAMPING/PLATE LABEL

PRODUCTION

SERVICE PARTS

GENERAL INFORMATION

0A7

Anti Theft Stamping/Label/Plate Location

The stamping, label and plate locations are indicated by arrows in the illustration below. NOTE: A. VIN plate locations for production. B. Stamping locations for service parts. Engine

901RW195

Manual Transmission (AR5)

901RX021

0A8

GENERAL INFORMATION

Automatic Transmission (THM)

901RW197

GENERAL INFORMATION
Body

0A9

901RW113

Legend (3) Engine Hood (4) Front Door (5) Rear Door

(6) Fender (7) Rear Quarfer Panel (8) Front Bumper

0A10
Body

GENERAL INFORMATION

901RW114

Legend (9) Back Door Left Side

(10) Back Door Right Side (11) Rear Bumper

GENERAL INFORMATION

0A11

Body Label Instructions

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

901RW083

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

901RY00057

0A12

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

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

Lifting Points and Supportable Point Locations

C00RW003

Lifting Point: Front D When using a floor jack, lift on the center of the skid plate.

545RS001

GENERAL INFORMATION
Supportable Point: Front D Position the chassis stands at the bottom of the frame sidemember, behind the front wheel. Supportable Point: Rear

0A13

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

501RS003

501RW002

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

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

420RS002

420RS001

0A14

GENERAL INFORMATION

Standard Bolts Torque Specifications

The torque values given in the following table should be applied where a particular torque is not specified. Strength Class 4.8 Refined 8.8 Non-Refined 9.8

Bolt Identification

Bolt Diameter Pitch (mm)

M 6X1.0 M 8X1.25 M 10X1.25 * M10X1.5 M12X1.25 * M12X1.75 M14X1.5 * M14X2.0 M16X1.5 * M16X2.0 M18X1.5 M20X1.5 M22X1.5 M24X2.0 48 (36) 818 Nm (613 lb ft) 2134 Nm (1525 lb ft) 2033 Nm (1425 lb ft) 4974 Nm (3654 lb ft) 4569 Nm (3351 lb ft) 77115 Nm (5685 lb ft) 72107 Nm (5379 lb ft) 104157 Nm (77116 lb ft) 100149 Nm (74110 lb ft) 151226 Nm (111166 lb ft) 206310 Nm (152229 lb ft) 251414 Nm (185305 lb ft) 359539 Nm (265398 lb ft) 510 Nm (47 lb ft) 1223 Nm (917 lb ft) 2846 Nm (2034 lb ft) 2845 Nm (2033 lb ft) 6191 Nm (4567 lb ft) 5784 Nm (4262 lb ft) 93139 Nm (69103 lb ft) 88131 Nm (6597 lb ft) 135204 Nm (100150 lb ft) 130194 Nm (95143 lb ft) 195293 Nm (144216 lb ft) 270405 Nm (199299 lb ft) 363544 Nm (268401 lb ft) 431711 Nm (318524 lb ft) 1730 Nm (1222 lb ft) 3763 Nm (2746 lb ft) 3660 Nm (2744 lb ft) 76114 Nm (5684 lb ft) 72107 Nm (5379 lb ft) 114171 Nm (84126 lb ft) 107160 Nm (79118 lb ft) 160240 Nm (118177 lb ft) 153230 Nm (113169 lb ft) 230345 Nm (169255 lb ft) 317476 Nm (234351 lb ft) 425637 Nm (313469 lb ft) 554831 Nm (409613 lb ft)

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

GENERAL INFORMATION

0A15

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

ETC Electronic Throttle Control ETR Electronically Tuned Receiver EVAP Evaporation Emission Exh Exhaust F Degrees Fahrenheit Fed Federal (All States Except Calif.) FF Front Drive Front Engine FL Fusible Link FLW Fusible Link Wire FP Fuel Pump FRT Front ft Foot FWD Front Wheel Drive 4WD Four Wheel Drive 4 x 4 Four Wheel Drive 4 A/T Four Speed Automatic Transmission/Transaxle Gal Gallon GEN Generator GND Ground Gov Governor g Gram Harn Harness HC Hydrocarbons HD Heavy Duty Hg Hydrargyrum (Mercury) HiAlt High Altitude HO2S Heated Oxygen Sensor HVAC HeaterVentAirConditioning IAC Idle Air Control IAT Intake Air Temperature IC Integrated Circuit / Ignition Control ID Identification / Inside Diameter IGN Ignition INJ Injection IP Instrument Panel IPC Instrument Panel Cluster Int Intake ISC Idle Speed Control J/B Junction Block kg Kilograms km Kilometers km/h Kilometer per Hour kPa Kilopascals kV Kilovolts (thousands of volts) kW Kilowatts KS Knock Sensor L Liter lb ft Foot Pounds lb in Inch Pounds LF Left Front LH Left Hand LR Left Rear LS Left Side LWB Long Wheel Base L4 InLine Four Cylinder Engine MAF Mass Air Flow MAN Manual MAP Manifold Absolute Pressure Max Maximum MC Mixture Control MFI Multiport Fuel Injection MIL Malfunction Indicator Lamp Min Minimum mm Millimeter MPG Miles Per Gallon

0A16

GENERAL INFORMATION
TFT Transmission Fluid Temprature TOD Torque On Demand TP Throttle Position TRANS Transmission/Transaxle TURBO Turbocharger TVRS Television & Radio Suppression TVV Thermal Vacuum Valve TWC Three Way Catalytic Converter 3 A/T Three Speed Automatic Transmission/Transaxle 2WD Two Wheel Drive 4 x 2 Two Wheel Drive Ujoint Universal Joint V Volt(s) VAC Vacuum VIN Vehicle Identification Number VRRRE Vehicle Refrigerant Recovery and Recycling Equipment Vref ECM Reference Voltage VSS Vehicle Speed Sensor VSV Vacuum Switch Valve V6 Six Cylinder V Engine V8 Eight Cylinder V Engine W Watt(s) w/ With w/b Wheel Base w/o Without WOT Wide Open Throttle

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

Service Parts Identification Plate

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

905RW007

SECTION
MAINTENANCE AND LUBRICATION
TROOPER

0B1

GENERAL INFORMATION
Maintenance and Lubrication
CONTENTS
Maintenance Schedule List . . . . . . . . . . . . . . . Explanation of Complete Vehicle Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Fluids and Lubricants . . . . 0B1 0B5 0B8 Lubricant Viscosity Chart . . . . . . . . . . . . . . . . . Recommended Liquid Gasket . . . . . . . . . . . Recommended Thread Locking Agents . . . Maintenance Service Data . . . . . . . . . . . . . . . . 0B9 0B11 0B11 0B12

Maintenance Schedule List

Normal Vehicle Use
The maintenance instructions in this Maintenance Schedule are based on the assumption that the vehicle will be used as designed: D to carry passengers and cargo within the limitations specified on the tire placard located on the inside of the glove compartment door; D to be driven on reasonable road surfaces within legal operating limits; D to be driven on a daily basis, as a general rule, for at least several miles/kilometers; D to be driven on unleaded fuel Unusual or severe operating conditions will require more frequent vehicle maintenance, as specified in the following sections. [Severe Driving Condition] ITEMS REPLACE AIR CLEANER FILTER CHANGE ENGINE OIL AND OIL FILTER CHANGE AUTOMATIC TRANSMISSION FLUID CHANGE FRONT AND REAR AXLE OIL REPLACE TIMING BELT CHANGE POWER STEERING FLUID

Severe Driving Conditions

If the vehicle is usually operated under any of the severe driving conditions listed below, it is recommended that the applicable maintenance services be performed at the specified interval shown in the chart below. Severe driving conditions: D Towing a trailer, using a camper or car top carrier. D Repeated short trips of less than 8 Km (5 miles) with outside temperature remaining below freezing. D Extensive idling and/or low speed driving for long distances, such as police, taxi or doortodoor delivery use. D Operating on dusty, rough, muddy or salt spread roads.

INTERVAL See explanation of service, page 0B5 Every 3,000 miles (4,800 km) or 3 months Every 20,000 miles (32,000 km) Every 15,000 miles (24,000 km) Every 100,000 miles (160,000 km) Every 30,000 miles (48,000 km)

0B2

MAINTENANCE AND LUBRICATION

Mileage Only Items

02UBSOM51

MAINTENANCE AND LUBRICATION

0B3

Mileage/Months

02UBSOM31

0B4

MAINTENANCE AND LUBRICATION

02UBSOM41

MAINTENANCE AND LUBRICATION

0B5

Explanation of Complete Maintenance Schedule

Vehicle

Valve Clearance Adjustment

Incorrect valve clearance will result in increased engine noise and reduced engine output. Retorque the camshaft bracket bolts before checking and adjusting the valve clearance. Check and adjust the valve clearance whenever excessive engine noise occurs.

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

Front and Rear Axle Lubricant Replacement

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

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

Front Wheel Bearings Lubricant Replacement

Clean and repack the front wheel bearings at 30,000 miles (48,000 km) intervals. Refer to DRIVE SHAFT SYSTEM (SEC. 4C).

Manual Transmission Lubricant Replacement

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

Radiator Core and Air Conditioning Condenser Cleaning

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

Fluid Level Check

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

Transfer Case Lubricant Replacement

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

Extension Lubricant Level Check (2WD only)

Check oil level at 15,000 miles (24,000 km) and 30,000 miles (48,000 km) and after every 30,000 miles (48,000 km) or operation thereafter.

Air Cleaner Element Replacement

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

Spark Plug Replacement

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

Cooling System Service

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

Timing Belt Replacement

Replace the timing belt at every 100,000 miles (160,000 km). Failure to replace the timing belt may result in serious damage to the engine.

0B6

MAINTENANCE AND LUBRICATION

normal highway speeds means a wheel balancing is needed. Check tire pressure when the tires are cold (include the spare). Maintain pressure as shown in the tire placard, which is located on the driver s door lock pillar.

Battery fluid level Check fluid level in the battery.

Fluid Leak Check

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

Steering System Operation

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

Engine Oil and Oil Filter Replacement

Always use API SE, SF, SG, SH or ILSAC GF-1, GF-2 quality oils of the proper viscosity. When choosing an oil, consider the range of temperatures the car will be operated in before the next oil change. Then, select the recommended oil viscosity from the chart. Always change the oil and the oil filter as soon as possible after driving in a dust storm.

Brake Systems Operation

Watch for the BRAKE light coming on. Other signs of possible brake trouble are such things as repeated pulling to one side when braking, unusual sounds when braking or between brake applications, or increased brake pedal travel. If you note one of these conditions, repair the system at once. For convenience, the following should be done when wheels are removed for rotation: Inspect lines and hoses for proper hookup, bindings, leaks, crack, chafing etc. Inspect disc brake pads for wear and rotors for surface condition. Inspect other brake parts, including parking brake drums, linings etc., at the same time. Check parking brake adjustment. Inspect the brakes more often if habit or conditions result in frequent braking.

Engine Cooling System Inspection

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

Parking Brake and Transmission Park Mechanism Operation

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

Exhaust System Inspection

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

Fuel Cap, Fuel Lines, and Fuel Tank Inspection

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

Drive Belt Inspection

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

Starter Safety Switch Operation (Automatic Transmission)

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

Wheel Alignment, Balance and Tires Operation

Uneven or abnormal tire wear, or a pull right or left on a straight and level road may show the need for a wheel alignment. A vibration of the steering wheel or seat at

Starter Safety Switch Operation (Manual Transmission)

To check, place the shift lever in Neutral, push the clutch pedal halfway and try to start. The starter should not

MAINTENANCE AND LUBRICATION

crank. The starter should crank only when the clutch pedal is fully depressed.

0B7

Clutch Control Lubrication

Lubricate the clutch pedal bushing, the clevis pin, and pedal spring every 15,000 miles (24,000 km) or 6 months. If a squeaking noise arises from around the bushing or the clevis pin at the clutch pedal arm when the clutch pedal is depressed, lubricate them.

Accelerator Linkage Lubrication

Lubricate the accelerator pedal fulcrum pin with chassis grease.

Steering and Suspension Inspection

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

Clutch Pedal Free Play Inspection

Note the clutch pedal free play. It should be 5 15 mm (0.2 0.6 in). Adjust clutch control when there is little or no free play.

Body and Chassis Lubrication

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

Accelerator Linkage Inspection

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

Propeller Shaft Inspection and Lubrication

Except TOD model : yoke and universal joints with grease containing MOS2 (disulfide molybdenum type grease) at the interval shown in the Maintenance Schedule. All models : check for play in normal direction of rotation of sliding yoke and universal joints. Also check the propeller shaft flangetopinion bolts for proper torque to 63 Nm (46 lb ft) for front and rear propeller shaft.

Automatic Transmission Fluid Replacement

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

Auto Cruise Control Inspection

Check to see if the clearance between cruise link and accelerator link is normal. Also, check that their properly connected.

Brake Pedal Free Play Inspection

Note the brake pedal free play. It should be 610 mm (0.230.39 in). Adjust brake control when there is little or no free play.

Clutch Lines and Hoses Inspection

Check lines and hoses for proper attachment, binding, leaks, cracks, chafing, deterioration, etc. Any questionable parts should be replaced or repaired at once. When abrasion or wear is evident on lines or hoses, the cause must be corrected.

0B8

MAINTENANCE AND LUBRICATION

Recommended Fluids and Lubricants

USAGE Engine Engine coolant Brake system Power steering system Automatic transmission Manual transmission Rear axle and front axle FLUID/LUBRICANT API SE, SF, SG, SH or ILSAC GF-1, GF-2 Engine oil (See oil chart on the following page for proper viscosity) Mixture of water and good quality ethylene glycol base type antifreeze. DOT-3 hydraulic brake fluid. DEXRON -III Automatic transmission fluid. DEXRON -III Automatic transmission fluid. Engine oil (See oil chart on following page for proper viscosity) GL-5 gear lubricant (Standard differential) GL-5 Limited slip differential gear lubricant together with limited slip differential lubricant additive (Part No. 8-01052-358-0) or equivalent (If equipped with optional limited slip differential) (See oil chart in this section for proper viscosity) Engine Oil Chassis grease DOT-3 hydraulic brake fluid Engine oil Chassis grease Engine oil Chassis grease Chassis grease Wheel bearing grease GL-5 gear lubricant (SAE 75W-90) SAE40 (Areas where ambient temperatures of 32C (90F) and higher are regularly encountered.) SAE5W30SF (Other areas) DEXRON -III Automatic transmission fluid. DEXRON -III Automatic transmission fluid. Grease containing MoS2 or multipurpose type grease NLGI No.2 Engine oil Washer fluid Synthetic light weight engine oil (SAE 5W-30) Chassis grease

Clutch system a. Pivot points b. Clutch fork joint c. Master cylinder Hood latch assembly a. Pivots and spring anchor b. Release pawl Hood and door hinges Chassis lubrication Parking brake cables Front wheel bearings Shift on the fly system Transfer Case (Except TOD and 2WD model)

TOD system Extension assembly Propeller shafts (Except TOD model) Sliding yoke and Univeral joint Body door hinge pins and linkage, fuel door hinge, rear compartment lid hinges Windshield washer solvent Key lock cylinder Accelerator linkage

MAINTENANCE AND LUBRICATION

0B9

Lubricant Viscosity Chart

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

Oil Viscosity Chart for Gasoline Engine

905RT011

Oil Viscosity Chart for Manual Transmission and Transfer Case

B00RW002

0B10

MAINTENANCE AND LUBRICATION

Oil Viscosity Chart for Front Axle

B00RW003

Oil Viscosty Chart for Rear Axle

B00RW004

MAINTENANCE AND LUBRICATION

0B11

Recommended Liquid Gasket

Type RTV* Silicon Base Water Base Solvent Brand Name Three Bond 1207B Three Bond 1207C Three Bond 1215 Three Bond 1280 Three Bond 1281 Three Bond 1141E Three Bond 1104 Belco Bond 4 Belco Bond 401 Belco Bond 402 LOCTITE 515 LOCTITE 518 LOCTITE 17430 Manufacturer Three Bond Three Bond Three Bond Three Bond Three Bond Three Bond Three Bond Isuzu Isuzu Isuzu Loctite Loctite Loctite Remarks For Engine Repairs For Axle Case Repairs T/M Repairs T/M For Engine Repairs For Engine Repairs

Anaerobic

All

* RTV: Room Temperature Vulcanizer NOTE: 1. It is very important that the liquid gaskets listed above or their exact equivalent be used on the vehicle. 2. Be careful to use the specified amount of liquid gasket. Follow the manufacturer s instructions at all times. 3. Be absolutely sure to remove all lubricants and moisture from the connecting surfaces before applying the liquid gasket. The connecting surfaces must be perfectly dry. 4. Do not apply LOCTITE 17430, LOCTITE 515 and LOCTITE 518 between two metal surfaces having a clearance of greater than 0.25 mm (0.01 in). Poor adhesion will result. Application Steps 1. Completely remove all lubricant and moisture from the bolts and the female-threaded surfaces of the parts to be joined. The surfaces must be perfectly dry. 2. Apply LOCTITE to the bolts.

Recommended Thread Locking Agents

LOCTITE Type LOCTITE 242 LOCTITE 262 LOCTITE 271 LOCTITE Color Blue Red Red
F00RW014

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

0B12

MAINTENANCE AND LUBRICATION

Maintenance Service Data

Service Data and Specifications
ENGINE Valve clearance (cold) Spark plug type Spark plug gap CLUTCH BRAKE WHEEL ALIGNMENT Clutch pedal free play Brake pedal free play Parking brake travel Toe-in Camber Caster PROPELLER SHAFT WHEEL AND TIRES Flange torque Size Wheel nut torque Tire inflation pressure (Front) * Tire inflation pressure (Rear) * Unless otherwise specified on tire information label on the vehicle. Intake 0.280.05 mm (0.0110.002 in) Exhaust 0.30.05 mm (0.0120.002 in) K16PR-P11/PK16PR11/RC10PYP4 1.05 mm (0.04 in) 515 mm (0.200.59 in) 610 mm (0.240.39 in) 67 notches 02 mm (00.08 in) 030 21045 63 Nm (46 lb ft) (Except TOD model) 43 Nm (32 lb ft) (TOD model) P245/70R16 118 Nm (87 lb ft) 210 kPa (30 psi) 240 kPa (35 psi)

Approximate Capacities
Items Fuel tank * Crankcase Coolant Transmission Transfer Transfer with TOD Extention Axle Shift on the fly system Power steering Air conditioning (R-134a) Rear Front (4WD vehicle only) Oil Change with Filter Oil Change without Filter M/T A/T Manual Automatic Metric Measure 85 L 4.7 L 4.0 L 8.5 L 8.8 L 2.7 L 8.6 L 1.45 L 1.9 L 0.185 L 3.0 L 1.4 L 0.12 L 1.0 L 0.8 L U.S. Measure 22.5 Gal. 5.0 Qt 4.2 Qt 9.0 Qt 9.3 Qt 2.86 Qt 9.1 Qt 1.5 Qt 2.0 Qt 0.195 Qt 3.2 Qt 1.5 Qt 0.13 Qt 1.1 Qt 1.76 lb

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

SECTION
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
TROOPER

1A1

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

HVAC SYSTEMS
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . Heating and Ventilation System . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Individual Inspection . . . . . . . . . . . . . . . . . . . Heater Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater Unit and Associated Parts . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater Core and / or Mode Door . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater Mode Control Link Unit . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater Temperature Control Link Unit . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blower Assembly . . . . . . . . . . . . . . . . . . . . . . . . Blower Assembly and Associated Parts . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blower Link Unit and / or Mode door . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . Blower Motor and Associated Parts . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Heater Duct, Defroster Nozzle and Ventilation Duct . . . . . . . . . . . . . . . . . . . . . . . . . Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Center and / or Drive Side Vent . . . . . . . . . . . 1A3 1A3 1A3 1A8 1A9 1A12 1A14 1A14 1A15 1A15 1A16 1A16 1A16 1A17 1A17 1A18 1A18 1A18 1A19 1A19 1A19 1A19 1A19 1A20 1A20 1A20 1A21 1A21 1A21 1A21 1A22 1A23 1A23 1A23 1A23 1A24 1A24 1A24 1A25 1A25 Center Vent, Drive Side Vent and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Lever Assembly and / or Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Lever Assembly, Control Cable and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel Illumination Bulb . . . . . . . . . . . . Control Panel Illumination Bulb and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resistor and Associated Parts . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Conditioning System . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Individual Inspection . . . . . . . . . . . . . . . . . . . General Repair Procedure . . . . . . . . . . . . . . Compressor Assembly . . . . . . . . . . . . . . . . . . . Compressor Assembly and Associated Parts (6VE1) . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . New Compressor Installation . . . . . . . . . . . . Condenser Assembly . . . . . . . . . . . . . . . . . . . . Condenser Assembly and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Receiver / Drier . . . . . . . . . . . . . . . . . . . . . . . . . Receiver / Drier and Associated Parts . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Switch and Associated Parts . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Evaporator Assembly . . . . . . . . . . . . . . . . . . . . 1A25 1A25 1A25 1A26 1A26 1A26 1A28 1A29 1A29 1A29 1A29 1A30 1A30 1A30 1A30 1A31 1A31 1A39 1A47 1A48 1A56 1A56 1A56 1A57 1A57 1A58 1A58 1A58 1A58 1A59 1A59 1A59 1A59 1A60 1A60 1A60 1A60 1A61

1A2

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

1A61 1A61 1A62 1A62 1A62 1A63 1A63 1A64 1A64 1A64 1A64 1A65 1A65 1A65 1A66 1A67 1A70 1A70 1A70 1A71 1A72 1A72 1A72 1A74 1A74 1A76 1A76 1A76 1A76 1A76 1A76 1A77 1A77 1A77 1A78 1A80 1A81 1A81 1A81 1A82 1A83 1A88 1A89 1A90 1A91 1A92 Overview of Construction, Movement and Control of Major Parts of Automatic Air Conditioner System . . . . . . . . . . . . . . . . . . . Overview of Automatic Control of Automatic Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting, Its Overview and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . Auto Air Conditioner Control Unit Power Supply Diagnosis . . . . . . . . . . . . . . . . . . . . . Performance and Movement checklist for Automatic Air Conditioner Related Parts . Troubleshooting With Self-Diagnosis Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection By Failed Location . . . . . . . . . . . . . Inspection of the Sensors . . . . . . . . . . . . . . . Inspection of the Intake Actuator System . Inspection of the Mix Actuator System . . . . Inspection of the Mode Actuator System . . Inspection of the Fan Motor System . . . . . . Inspection of the Magnetic Clutch System Condenser Fan Diagnosis . . . . . . . . . . . . . . Individual Inspection . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . Power Transistor . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Heater/Air Conditioner Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . In Car Sensor . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ambient Sensor . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sun Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Duct Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mode Actuator . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mix Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intake Actuator . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Evaporator Assembly and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Thermostat, Evaporator Core and/or Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Conditioning Switch and Illumination Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Conditioning Switch, Illumination Bulb and Associated Parts . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refrigerant Line . . . . . . . . . . . . . . . . . . . . . . . . . Refrigerant Line and Associated Parts . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data And Specifications . . . . . . . . . . . . . Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Precaution . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Magnetic Clutch Assembly (DKV-14G Type) Parts Location View . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . Oil Specification . . . . . . . . . . . . . . . . . . . . . . . Handling of Oil . . . . . . . . . . . . . . . . . . . . . . . . Compressor Oil Check . . . . . . . . . . . . . . . . . Checking and Adjusting Oil Quantity for Used Compressor . . . . . . . . . . . . . . . . . . . . . Checking and Adjusting for Compressor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . Contamination of Compressor Oil . . . . . . . . Oil Return Operation . . . . . . . . . . . . . . . . . . . Replacement of Component Parts . . . . . . . Main Data and Specifications . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Air Conditioning System . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Full Automatic Air Conditioner Parts Configuration . . . . . . . . . . . . . . . . . . . . . . . . . Refrigerant Line and Associated Parts . . . . Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . Functions and Features . . . . . . . . . . . . . . . . Automatic Air Conditioner Block Diagram . Control Panel Layout . . . . . . . . . . . . . . . . . . . Air Control Functions . . . . . . . . . . . . . . . . . . . Operation and Functions of Control Panel Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1A94 1A98 1A102 1A102 1A103 1A105 1A107 1A111 1A111 1A115 1A118 1A121 1A124 1A126 1A129 1A132 1A135 1A135 1A135 1A135 1A135 1A135 1A135 1A136 1A136 1A136 1A136 1A136 1A136 1A137 1A137 1A137 1A137 1A137 1A137 1A138 1A138 1A138 1A138 1A138 1A138 1A139 1A139 1A139

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

1A3

Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.

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

Heating and Ventilation System

General Description
Heater
When the engine is warming up, the warmed engine coolant is sent out into the heater core. The heater system supplies warm air into the passenger compartment to warm it up. Outside air is circulated through the heater core of the heater unit and then back into the passenger compartment. By controlling the mixture of outside air and heater core air, the most comfortable passenger compartment temperature can be selected and maintained. The temperature of warm air sent to the passenger compartment is controlled by the temperature control knob. This knob acts to open and close the air mix door, thus controlling the amount of air passed through the heater core. The air selector knob, with its different modes, also allows you to select and maintain the most comfortable passenger compartment temperature. The air source select lever is used to select either FRESH for the introduction of the outside air, or RECIRC for the circulation of the inside air. When the lever is set to FRESH, the outside air is always taken into the passenger compartment. When setting the lever to RECIRC position, the circulation of air is restricted only to the inside air with no introduction of the outside air and the air in the passenger compartment gets warm quickly. However, the lever is normally set to FRESH to prevent the windshield from clouding.

1A4

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

640R200001

Legend (1) Side Defroster Hose (2) Vent Box (3) Upper Center Vent Box (4) Lower Center Vent Box (5) Blower Assembly (6) Control Lever Assembly (7) Evaporator Assembly

(8) (9) (10) (11) (12) (13) (14)

Duct Heater Unit Rear Heater Duct Lap Vent Nozzle Vent Box Side Defroster Hose Defroster Nozzle

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

1A5

Control Lever Assembly

The vehicle has cable-type-control to control the mode and temperature of the heater unit and the mode door for the air source of the blower assembly. The fan control is used to control the amount of air sent out by the resistor at four levels from LOW to HIGH.

865RW007

Legend (1) Air Source Select Lever (2) Air Select Knob

(3) Fan Control Knob (Fan Switch) (4) Air Conditioning (A/C) Switch (W/ A/C) (5) Temperature Control Knob

1A6

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Ventilation
Set AIR SOURCE SELECT LEVER to FRESH position and turn on the blower fan. Heating can be done in this lever position, sending in fresh air from outside. The blower fan also serves to deliver fresh outside air to the vehicle interior to assure adequate ventilation.

C01RS001

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

1A7

Air Select Knob

The air select knob allows you to direct heated air into the passenger compartment through different outlets. 1. Vent In this position, air is discharged from the upper air outlet. Air quantity is controlled by the fan control knob. 2. Bi-Level In this position, air flow is divided between the upper air outlets and the floor air outlets, with warmer air delivered to the floor outlets than the air delivered to the upper air outlets. 3. Foot In this position, air flow is delivered to the foot while sending approx 30% op total amount air to the wind shield. 4. Def/Foot In this position, air flow is delivered to the foot, while sending approx. 40% of total amount of air to the windshield. Selecting this mode allows air conditioning system to work when the fan switch is turned to on position, even if the A/C switch is off. 5. Defrost In this position, most of the air is delivered to the windshield and a small amount is delivered to the side windows. Moving the air source select lever to the CIRC position provides quickest heat delivery by closing the blower assembly mode door. In this position, outside air is not delivered to the passenger compartment. Selecting this mode allows air conditioning system to work when the fan switch is turned to on position, even if the A/C switch is off.

C01RW001

Air Source Select Lever

The intake of outside air and the circulation of inside air are controlled by sliding this lever left or right.

Temperature Control Knob

When the temperature control knob is in the COLD position, the air mix door closes to block the air flow to the heater core. When the temperature control knob is in the HOT position, the air mix door opens to allow air to pass through the heater core and heat the passenger compartment Placing the knob in a intermediate position will cause a lesser or greater amount air to reach the heater core. In this mode the passenger compartment temperature can be regulated

Fan Control Knob

This knob controls the blower motor speed to regulate the amount of air delivered to the defrost, foot, and ventilation ducts: 1. Low 2. Medium Low 3. Medium High 4. High

1A8

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Wiring Diagram

D01R200019

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

1A9

Diagnosis
Heating Cycle diagnosis
Condition No heating or insufficient heating. Possible cause Blower motor does not run or runs improperly. Engine coolant temperature is low. Correction Refer to FAN CONTROL LEVER (FAN SWITCH) DIAGNOSIS. Check the engine coolant temperature after warming up the engine and check the thermostat. Replace as necessary. Add engine coolant as required. Check if the water hose to the heater core is clogged, collapsed or twisted. Repair or replace as necessary. Clean or replace as necessary. Repair the temperature control link unit or mode doors. Repair or replace as necessary. Repair Repair Repair. Adjust.

Insufficient engine coolant. Circulation volume of engine coolant is insufficient. Heater core clogged or collapsed. The heater cores is not provided with air sent from the blower motor. Duct connections unsealing. Control lever moves but mode door does not operate. The mode door cannot be set to the mode selected. defective or

Cable attaching clip is not correct. Link unit of heater assembly defective. or blower

Link unit of heater unit or blower assembly defective. Control cable is not adjusted.

1A10 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Fan Control Lever (Fan Switch) Diagnosis

Current flows to the blower motor through the heater and the A/C relay (B-36) to activate the rotation of the blower motor by turning ON the fan control knob (fan switch). Blower motor speed is controlled in stages by the resistor, by operating the switch from LOW to HIGH. For the inspection of the relays, switches and units in each table, refer to INDIVIDUAL INSPECTION in this section.

D01R200020

Condition Blower motor does not run. Blower motor does not run in certain position (s). Blower motor does not stop at OFF position.

Possible cause

Correction Refer to Chart A Refer to Chart B, C, D and E Refer to Chart F

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A11

Chart A Blower Motor Dose Not Run

Step 1 2 3 4 5 6 Is relay (B-36) OK? Is fuse C-19 (25A) OK? Is resistor OK? Is fan control knob OK? Go to Step 5 Is blower motor OK? 1. Turn the ignition switch ON. 2. Turn fan control knob ON. 3. Check to see if battery voltage is present at chassis side connector terminal No. B5-1 Is there a battery voltage? Go to Step 6 Poor ground or open circuit either between chassis side connector terminal No. B5-2 and No. I41-2 or No. I18-1 and body ground (No. B-2). Action Yes Go to Step 2 Go to Step 3 Go to Step 4 No Replace Replace Replace Replace control lever assembly. Replace

Open circuit between No. C-19 (25A) fuse and No. B5-1.

Chart B Blower Motor Does Not Run At Low Position

Step 1 2 Is resistor OK? Is fan control knob (Fan Switch) OK? Action Yes Go to Step 2 Open circuit between chassis side connector terminal No. I41-1 and No.I18-2. No Replace

Replace control lever assembly.

Chart C Blower Motor Dose Not Run At Medium Low Position

Step 1 2 Is resistor OK? Is fan control knob (Fan Switch) OK? Action Yes Go to Step 2 Open circuit between the chassis side connector terminal No. I41-4 and No. I18-5. No Replace

Replace control lever assembly.

Chart D Blower Motor Dose Not Run At Medium High Position

Step 1 2 Is resistor OK? Is fan control knob (Fan Switch) OK? Action Yes Go to Step 2 Open circuit between chassis side connector terminal No. I41-6 and No. I18-3. No Replace

Replace control lever assembly.

1A12 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Chart E Blower Motor Dose Not Run At High Position

Step 1 2 Is resistor OK? Is fan control knob (Fan Switch) OK? Action Yes Go to Step 2 Open circuit between Chassis side connector terminal No. I41-3 and No. I18-6. No Replace

Replace control lever assembly.

Chart F Blower Motor Does Not Stop In The OFF Position

Step 1 Action Is the fan control knob (Fan Switch) OK? Yes Short circuit between chassis side connector terminal No. B5-2 and No. I41-2,No. I41 -3 and No. I18-6, No. I41-6 and No. I18-3, No. I41-4 and No. I18-5 or No. I41-1 and No. I18-2 No

Replace control lever assembly.

Individual Inspection
Blower Motor
1. Disconnect the blower motor (B-5) connector from the blower motor. 2. Connect the battery positive terminal to the No. 1 terminal of the blower motor and the negative to the No. 2. 3. Be sure to check to see if the blower motor operates correctly.

Resistor
1. Disconnect the resistor (I-41) connector. 2. Check for continuity and resistance between the terminals of the resistor.

840R200011

873RS005

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A13

Fan switch position 1 2 3 4 Resistor terminals with continuity 12 24 26 23 Resistance 2.4 W 0.90 W 0.28 W

Heater & A/C Relay

1. Disconnect the heater and the A/C relay (B-36). D When removing the connector for relay, unfasten the tang lock of the connector by using a screwdriver, then pull the relay (1) out.

Fan Control Knob (Fan Switch)

1. Check for continuity between the terminals of the fan switch.

825RS001

2. Check for continuity between the heater and the A/C relay (B-36) terminals.

865RS001

Fan switch position OFF 1 2 3 4

Switch connector terminals with continuity No continuity 124 145 134 146

825RS002

Condition Normal When battery voltage is applied between 1 3

Relay terminals with continuity 1 3 (Approx 85105W) 24

1A14 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Heater Unit
Heater Unit and Associated Parts

860RY00005

Legend (1) Instrument Panel Assembly (2) Instrument Panel Center Bracket (3) Resistor (4) Duct (5) Evaporator Assembly (A/C only) (6) Rear Heater Duct

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

Heater Unit Assembly Center Ventilation Lower Duct Driver Lap Vent Nozzle Water Hose Electro Thermo Connector (With A/C) Resistor Connector

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A15

Removal
1. Disconnect the battery ground cable. 2. Drain the engine coolant. 3. Discharge and recover refrigerant (with air conditioning) D Refer to Refrigerant Recovery in this section. 4. Remove the Instrument panel assembly. D Refer to Instrument Panel Assembly in Body and Accessories section. 5. Disconnect the water hoses at the heater unit. 6. Disconnect resistor connector. 7. Remove duct. 8. Remove evaporator assembly (A/C only). D Refer to Evaporator Assembly in this section. 9. Remove instrument panel center bracket. D Refer to Cross Beam Assembly in Body and Accessories section. 10. Remove rear heater duct. 11. Remove heater unit assembly. 12. Remove driver lap vent nozzle. 13. Remove center ventilation lower duct.

Installation
To install, follow the removal steps in the reverse order, noting the following points: 1. When handling the PCM and the control unit, be careful not to make any improper connection of the connectors. 2. Adjust the control lever assembly cables. D Refer to Control Lever Assembly in this section. 3. When installing the heater unit, defroster nozzle and center vent duct, be sure that the proper seal is made, without any gap between them.

1A16 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Heater Core and / or Mode Door

Disassembled View

860RS001

Legend (1) Case (Temperature Control) (2) Mode Door (3) Duct

(4) Heater Unit (5) Case (Mode Control) (6) Heater Core

Removal
1. Disconnect the battery ground cable. 2. Drain the engine coolant. 3. Discharge and recover refrigerant (with conditioning). D Refer to Refrigerant Recovery in this section. 4. Remove heater unit. D Refer to Heater Unit in this section. 5. Remove duct.

6. Remove case (Mode control) and do not remove link unit at this step.

air

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A17

7. Remove case (Temperature control). Separate two halves of core case. 9. Pull out the mode door while raising up the catch of the door lever.

860R200007

860RS004

8. Remove heater core (1).

Inspection
Check for foreign matter in the heater core, stains or core fin damage.

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

860R200006

1A18 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Heater Mode Control Link Unit

Disassembled View

860RS005

Legend (1) Case (Mode Control) (2) Heater Unit (3) Mode Sub-lever

(4) (5) (6) (7)

Clip Door Lever Rod Washer and Mode Main Lever

Removal
1. Disconnect the battery ground cable. 2. Drain engine coolant. 3. Discharge and recover refrigerant (with air conditioning). D Refer to Refrigerant Recovery in this section. 4. Remove heater unit. D Refer to Heater Unit in this section. 5. Remove the case (Mode control) from heater unit. 6. Remove washer and the mode main lever. 7. Remove rod. 8. Press the tab of the sub-lever inward, and take out the sub-lever. 9. Pull out the door lever while raising up the catch of the door lever.
860RS006

10. Remove clip.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A19

Installation
To install, follow the remove steps in the reverse order, noting the following points: 1. Apply grease to the mode sub-lever and to the abrasive surface of the heater unit.

2. After installing the link unit, check to see if the link unit operates correctly.

Heater Temperature Control Link Unit

Disassembled View

860RS007

Legend (1) Case (Temperature control) (2) Clip (3) Door Lever

(4) (5) (6) (7)

Clip Heater Unit Rod Sub-lever

Removal
1. Disconnect the battery ground cable. 2. Drain engine coolant. 3. Discharge and recover refrigerant (with air conditioning). D Refer to Refrigerant Recovery in this section. 4. Remove heater unit. D Refer to Heater Unit in this section. 5. Remove the case (Temperature control) from the heater unit. 6. Remove rod. 7. Remove sub-lever.

8. Pull out the door lever while raising up the catch of the door lever. 9. Remove clip.

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

1A20 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Blower Assembly
Blower Assembly and Associated Parts

873RY00003

Legend (1) Electro Thermo Connector (2) Blower Motor Connector (3) Resistor Connector (4) Dash Side Trim Panel (RH)

(5) (6) (7) (8) (9)

Blower Assembly Duct Evaporator Assembly (A/C only) Heater Unit Instrument Panel Assembly

Removal
1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant (with air conditioning). D Refer to Refrigerant Recovery in this section. 3. Remove instrument panel assembly. D Refer to Instrument Panel Assembly in Body and Accessories section.

4. Disconnect resistor connector. 5. Remove duct. 6. Remove evaporator assembly (A/C only). D Refer to Evaporator Assembly in this section. 7. Remove dash side trim panel (RH). 8. Disconnect blower motor connector. 9. Remove blower assembly.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A21

Installation
To install, follow the removal steps in the reverse order, noting the following point: 1. Adjust the control lever assembly cables. D Refer to Control Lever Assembly in this section.

Blower Link Unit and / or Mode door

Disassembled View

873RS001

Legend (1) Upper Case (2) Mode Door (3) Lower Case

(4) Sub Lever (5) Door Lever (6) Blower Assembly

Removal
1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant (with conditioning). D Refer to Refrigerant Recovery in this section. 3. Remove blower assembly. D Refer to Blower Assembly in this section. air

1A22 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

4. Remove lower case. 5. Separate the upper case and slit the lining parting face with a knife.

873RS002

6. Pull out the mode door while lifting up the catch of door lever. 7. Remove sub-lever. 8. Remove door lever.

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

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A23

Blower Motor
Blower Motor and Associated Parts

873R200006

Legend (1) Blower Motor Connector

(2) Blower Motor Assembly (3) Attaching Screw

Removal
1. Disconnect the battery ground cable. 2. Remove blower motor connector. 3. Remove attaching screw. 4. Remove blower motor assembly.

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

1A24 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Rear Heater Duct, Defroster Nozzle and Ventilation Duct

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

874RS017

Legend (1) Center Defroster Nozzle (2) Side Defroster Nozzle (3) Side Ventilation Duct (4) Center Ventilation Upper Duct (5) Center Ventilation Lower Duct

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

Center Console Rear Heater Duct Driver Lap Duct Cross Beam Assembly Instrument Panel Assembly

Removal
1. Disconnect the battery ground cable. 2. Remove instrument panel assembly. D Refer to Instrument Panel Assembly in Body and Accessories section. 3. Remove center ventilation upper duct. 4. Remove side ventilation duct. 5. Remove center ventilation lower duct.

6. Remove driver lap duct. 7. Remove center console. 8. Remove rear heater duct. D Refer to Consoles in Body and Accessories section. 9. Remove cross beam assembly. D Refer to Cross Beam Assembly in Body and Accessories section.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A25

10. Remove side defroster nozzle. 11. Remove center defroster nozzle.

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

Center and / or Drive Side Vent

Center Vent, Drive Side Vent and Associated Parts

740RS003

Legend (1) Center Vent (2) Meter Cluster Assembly (3) Lower Cluster Assembly

(4) Front Console Assembly (5) Instrument Panel Driver Lower Cover Assembly (6) Side Vent

Removal
1. Disconnect the battery ground cable. 2. Remove front console assembly. 3. Remove lower cluster assembly. 4. Remove instrument panel driver lower cover assembly. 5. Remove meter cluster assembly. D Refer to Instrument Panel Assembly in Body and Accessories section.

6. Remove screws and the center vent from center cluster while prying up the center vent catch portions. 7. Remove screws and the side vent from the center cluster while prying up the vent catch portions.

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

1A26 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Control Lever Assembly and / or Control Cable

Control Lever Assembly, Control Cable and Associated Parts

865RS011

Legend (1) Instrument Panel Passenger Lower Cover Assembly (2) Glove Box (3) Fan Switch and Air Conditioning Switch Connector (4) Temp Control Link Connection (5) Control Cable (6) Blower Assembly Connection

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

Attaching Screws Control Lever Assembly Mode Control Link Connection Front Console Assembly Lower Cluster Assembly Instrument Panel Driver Lower Cover Assembly (13) Meter Cluster Assembly

Removal
1. Disconnect the battery ground cable. 2. Remove front console assembly. 3. Remove lower cluster assembly. 4. Remove glove box.

5. Remove instrument panel passenger lower cover assembly. 6. Remove instrument panel driver lower cover assembly. 7. Remove meter cluster assembly. D Refer to Instrument Panel Assembly in Body and Accessories section.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A27

8. Remove attaching screws. D Remove the four attaching screws.

865RS010

9. Pull the control lever assembly out and disconnect the fan switch and air conditioning switch connectors.

865RS009

10. Remove control lever assembly. 11. Remove control cable.

1A28 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Installation
To install, follow the removal steps in the reverse order, noting the following points: 1. Adjust the control cable.

865RY00013

D Air source control cable. 1. Slide the control lever to the left (CIRC position). 2. Connect the control cable at the CIRC position of the link unit of the blower assembly and secure it with the clip. D Temperature control cable. 1. Turn the control knob to the left (MAX COLD position). 2. Connect the control cable at the COLD position of the temperature control link of the heater unit and secure it with the clip. D Air select control cable 1. Turn the control knob to the right (DEFROST position). 2. Connect the control cable at the DEFROST position of the mode control link of the heater unit and secure it with the clip. 2. Check the control cable operation.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A29

Control Panel Illumination Bulb

Control Panel Illumination Bulb and Associated Parts

865RS007

Legend (1) Control Lever Assembly

(2) Bulb Socket (3) Illumination Bulb

Removal
1. Disconnect the battery ground cable. 2. Remove control lever assembly. D Refer to Control Lever Assembly in this section. 3. Pull out the bulb socket from the panel by turning it counterclockwise. 4. Pull the illumination bulb from the socket.

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

1A30 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Resistor
Resistor and Associated Parts

874RW005

Legend (1) Glove Box (2) Duct (Heater only) (3) Resistor Connector (4) Resistor

(5) Front Console (6) Lower Cluster (7) Instrument Panel Passenger Lower Cover Assembly

Removal
1. Disconnect the battery ground cable. 2. Remove front console. 3. Remove lower cluster. 4. Remove glove box. 5. Remove instrument panel passenger lower cover assembly. D Refer to Instrument Panel Assembly in Body and Accessories section. 6. Remove resistor connector. 7. Remove duct (heater only). 8. Remove resistor.

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

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A31

Air Conditioning System

General Description
Air Conditioning Refrigerant Cycle Construction

C01RS003

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

(9) (10) (11) (12) (13) (14) (15) (16) (17)

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

1A32 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

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

Compressor
The compressor performs two main functions: It compresses low-pressure and low-temperature refrigerant vapor from the evaporator into high-pressure and high-temperature refrigerant vapor to the condenser. It pumps refrigerant and refrigerant oil through the air conditioning system. This vehicle is equipped with six-cylinder axle plate compressor (3). The specified amount of the compressor oil is 240cm3 (8.0 fl. oz.). The oil used in the HFC-134a system compressor differs from that used in R-12 systems. Also, compressor oil to be used varies according to the compressor model. Be sure to avoid mixing two or more different types of oil. If the wrong oil is used, lubrication will be poor and the compressor will seize or malfunction. The magnetic clutch connector is a waterproof type.

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

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

Magnetic Clutch
The compressor is driven by the drive belt from the crank pulley of the engine. If the compressor is activated each time the engine is started, this causes too much load to the engine. The magnetic clutch (1) transmits the power from the engine to the compressor and activates it when the air conditioning is ON. Also, it cuts off the power from the engine to the compressor when the air conditioning is OFF. Refer to Compressor in this section for magnetic clutch repair procedure.

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

Expansion
The expansion valve lowers the pressure of the refrigerant liquid so that it can easily vaporize. The process of lowering the pressure to encourage vaporization before the liquefied refrigerant is sent to the evaporator is called expansion. In addition, the expansion valve controls the flow rate of the refrigerant liquid while decreasing the pressure. That is, the quantity of refrigerant liquid vaporized inside the evaporator is determined by the quantity of heat which must be removed at a prescribed vaporization temperature. It is important that the quantity of refrigerant be controlled to exactly the right value.
871R200002

Condenser
Also, it functions to cool and liquefy the high-pressure and high-temperature vapor sent from the compressor by the radiator fan or outside air. A condenser may malfunction in two ways: it may leak, or it may be restricted. A condenser restriction will result in excessive compressor discharge pressure. If a partial restriction is present, the refrigerant expands after passing through the restriction. Thus, ice or frost may form immediately after the restriction. If air flow through the condenser or radiator is

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A33

blocked, high discharge pressures will result. During normal condenser operation, the refrigerant outlet line will be slightly cooler than the inlet line. The vehicle is equipped with the parallel flow type condenser. A larger thermal transmission area on the inner surface of the tube allows the radiant heat to increase and the ventilation resistance to decrease. The refrigerant line connection has a bolt at the block joint, for easy servicing. The condenser assembly (3) is located in front of the radiator. It provides rapid heat transfer from the refrigerant to the cooling fins.

875R200025

Triple Pressure Switch

Triple pressure switch is installed on the upper part of the receiver/drier. This switch is constructed with a unitized type of two switches. One of them is a low and high pressure switch (Dual pressure switch) to switch ON or OFF the magnetic clutch as a result of irregularly highpressure or low pressure of the refrigerant. The other one is a medium pressure switch (Cycling switch) to switch ON or OFF the condenser fan sensing the condenser high side pressure.
875R200025

Receiver / Drier
The receiver/drier (2) performs four functions: D As the quantity of refrigerant circulated varies depending on the refrigeration cycle conditions, sufficient refrigerant is stored for the refrigeration cycle to operate smoothly in accordance with fluctuations in the quantity circulated. D The liquefied refrigerant from the condenser is mixed with refrigerant gas containing air bubbles. If refrigerant containing air bubbles. Is sent to the expansion valve, the cooling capacity will decrease considerably. Therefore, the liquid and air bubbles are separated and only the liquid is sent to the expansion valve. D The receiver/drier utilizes a filter and drier to remove the dirt and water mixed in the cycling refrigerant. D The sight glass, installed on top of the receiver/drier, shows the state of the refrigerant. A receiver/drier may fail due to a restriction inside the body of the unit. A restriction at the inlet to the receiver/drier will cause high pressure. Outlet restrictions will be indicated by low pressure and little or no cooling. An excessively cold receiver/drier outlet may indicate a restriction. The receiver/drier of this vehicle is made of aluminum with a smaller tank. It has a 300cc refrigerant capacity. The refrigerant line connection has a bolt at the block joint, for easy servicing.

Compressor Low-pressure control High-pressure control

ON (kPa/psi) 206.030.0 (29.84.3) 2353.6196.1 (341.328.4) ON (kPa/psi) 1471.098.1 (213.314.2)

OFF (kPa/psi) 176.524.5 (25.63.6) 2942.0196.1 (426.628.4) OFF (kPa/psi) 1078.7117.7 (156.417.1)

Condenser fan Medium-pressure control

1A34 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

875R200025

874RY00003

Expansion Valve
This expansion valve (1) is an internal pressure type and it is installed at the evaporator intake port. The expansion valve converts the high pressure liquid refrigerant sent from the receiver/drier to a low pressure liquid refrigerant by forcing it through a tiny port before sending it to the evaporator (2). This type of expansion valve consists of a temperature sensor, diaphragm, ball valve, ball seat, spring adjustment screw, etc. The temperature sensor contacts the evaporator outlet pipe, and converts changes in temperature to pressure. It then transmits these to the top chamber of the diaphragm. The refrigerant pressure is transmitted to the diaphragms bottom chamber through the external equalizing pressure tube. The ball valve is connected to the diaphragm. The opening angle of the expansion valve is determined by the force acting on the diaphragm and the spring pressure. The expansion valve regulates the flow rate of the refrigerant. Accordingly, when a malfunction occurs to this expansion valve, both discharge and suction pressure get low, resulting in insufficient cooling capacity of the evaporator. The calibration has been changed to match the characteristics of HFC-134a.

Evaporator
The evaporator cools and dehumidifies the air before the air enters the passenger compartment. High-pressure liquid refrigerant flows through the expansion valve (2) into the low-pressure area of the evaporator. The heat in the air passing through the evaporator core (1) is lost to the cooler surface of the core, thereby cooling the air. As heat is lost between the air and the evaporator core surface, moisture in the vehicle condenses on the outside surface of the evaporator core and is drained off as water. When the evaporator malfunctions, the trouble will show up as an inadequate supply of cool air. The cause is typically a partially plugged core due to dirt, or a malfunctioning blower motor. The evaporator core with a laminate louver fin is a single-sided tank type where only one tank is provided under the core.

874RY00007

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A35

Electronic Thermostat
The thermostat consists of the thermo sensor (1) and thermostat unit (4) which functions electrically to reduce the noises being generated while the system is in operation. The electronic thermo sensor (1) is mounted at the evaporator core (2) outlet and senses the temperature of the cool air from the evaporator (3). Temperature signals are input to the thermostat unit. This information is compared by the thermo unit and results in the output to operate the A/C thermostat relay and turn the magnetic clutch ON or OFF to prevent evaporator freeze-up. A characteristic of the sensor is that the resistance decreases as the temperature increases and the resistance increases as the temperature decreases.

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

852RW011

Legend (1) Pressure Resistance Layer (Polyester Braid) (2) Moisture Resistance AND Outer Protector Layer (3) Heat Resistance Layer (4) Heat Resistance Core Layer (Neoprene) (5) Low Permeation Layer (Nylon Barner)

874RX022

1A36 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Air Conditioning Parts

852R200014

Legend (1) Liquid Line (High-Pressure Pipe) (2) O-ring (3) Discharge Line (High-Pressure Hose) (4) Pressure Switch (5) Receiver Drier (6) Condenser Assembly

(7) (8) (9) (10) (11) (12) (13)

Drive Belt Relay Compressor Drain Hose Suction Line (Low-Pressure Hose) Evaporator Assembly A/C Switch

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A37

Wiring Diagram

D01R200017

1A38 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

D01R200018

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A39

Diagnosis
Air Conditioning Cycle Diagnosis
Condition No cooling or insufficient cooling. Possible cause Magnetic clutch does not run. Compressor is not rotating properly. Drive belt is loose or broken. Compressor is not rotating properly. Magnetic clutch face is not clean and slips. Compressor is not rotating properly. Incorrect clearance between magnetic drive plate and pulley. Compressor is not rotating properly. Compressor oil leaks from the shaft seal or shell. Compressor is not rotating properly. Compressor is seized. Insufficient or excessive charge of refrigerant. Leaks in the refrigerant system. Correction Refer to Magnetic Clutch Diagnosis in this section. Adjust the drive belt to the specified tension or replace the drive belt. Clean the magnetic clutch face or replace. Adjust the clearance. Refer to Compressor in this section. Replace the compressor

Replace the compressor Discharge and recover the refrigerant. Recharge to the specified amount. Check the refrigerant system for leaks and repair as necessary. Discharge and recover the refrigerant. Recharge to the specified amount. Clean the condenser or replace as necessary. Repair the link unit. Replace the expansion valve. Check the electronic thermostat and replace as necessary. Check the evaporator core and replace or clean the core. Check the evaporator and duct connection, then repair as necessary. Refer to Fan Control Knob (Fan Switch) Diagnosis in this section.

Condenser is clogged or insufficient radiation. Temperature control link unit of the heat unit is defective. Unsteady operation due to a foreign substance in the expansion valve. Poor operation of the electronic thermostat. Insufficient velocity of cooling air. Evaporator clogged or frosted. Air leaking from the cooling unit or air duct. Blower motor properly. *For the execution of the charging and discharging operation in the table above, refer to Recovery, Recycling, Evacuating and Charging in this section. does not rotate

1A40 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Checking The Refrigerant System With Manifold Gauge

Since Refrigerant-134a (HFC-134a) is used in the air conditioning system in this vehicle, be sure to use manifold gauges, charging hoses and other air conditioning service tools for HFC-134a when checking the refrigerant system. Conditions: D D D D D D D Run the engine at idling Air conditioning switch is ON Run the blower motor at HIGH position Temperature control lever set to MAX COLD Air source selector lever at CIRC Open the engine hood Close all the doors

Normal Pressure: D At ambient temperature: approx. 2530C (7786F). D At low-pressure side: approx. 147.1294.2 kPa (21.342.7 psi). D At high-pressure side: approx. 1372.91863.3 kPa (199.1270.2 psi). Refer to the table on the refrigerant pressure-temperature relationship in this section. HFC-134a Pressure-Temperature Relationship Pressure (kPa) 36 67 104 147 196 255 314 392 471 569 677 785 912 1059 1216 (psi) 5.3 9.7 15 21 28 37 45 57 68 82 98 114 132 154 176 Temperature (C) 20 15 10 5 0 5 10 15 20 25 30 35 40 45 50 (F) 4.4 5 14 23 32 41 50 59 68 77 86 95 104 113 122

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A41

Connect The Manifold Gauge Low-pressure hose (LOW) Suction side High pressure hose (HI) Discharge side

901RS137

Legend (1) Low Side (2) High Side

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

Possible cause Condenser clogged or dirty. Cooling fan properly. does not operate

Correction Clean the condenser fins Check the cooling fan operation. Discharge and recover refrigerant. Recharge to specified amount. Evacuate and charge refrigerant system.

Excessive refrigerant in system.

Air in system.

Insufficient refrigerant in system.

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

Clogged or defective expansion valve.

1A42 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Condition Discharge (High Gauge) Pressure Abnormally Low. Frost or dew on refrigerant line before and after the receiver/drier or expansion valve, and low pressure gauge indicates vacuum. Discharge (High Gauge) Pressure Abnormally Low. High and low pressure gauge balanced quickly. (After turned off A/C) Suction (Low Gauge) Pressure Abnormally High. Low pressure gauge (Low pressure gauge is lowered after condenser is cooled by water.) Suction (Low Gauge) Pressure Abnormally High. Low pressure hose temperature. (Low pressure hose temperature around the compressor refrigerant line connector is lower than around evaporator.) Suction (Low Gauge) Pressure Abnormally High. High and low pressure gauge balanced quickly. (After turned off A/C) Suction (Low Gauge) Abnormally Low. Insufficient cooling. Pressure Possible cause Restriction caused by debris or moisture in the receiver/drier. Correction Check system for restriction and replace the receiver/drier.

Compressor seal defective Poor compression due to a defective compressor gasket. Excessive refrigerant in system.

Repair or replace the compressor. Repair or replace the compressor.

Discharge and recover refrigerant Recharge to specified amount.

Unsatisfactory valve operation due to defective temperature sensor of expansion valve. Expansion valve opens too long. Compressor gasket is defective.

Replace the expansion valve.

Replace the expansion valve. Repair or replace the compressor.

Insufficient refrigerant in system.

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

Suction (Low Gauge) Pressure Abnormally Low. Frost on the expansion valve inlet line Suction (Low Gauge) Pressure Abnormally Low Receiver/drier inlet and outlet refrigerant line temperature. (A distinct difference in temperature develops.) Suction (Low Gauge) Pressure Abnormally Low. Expansion valve outlet refrigerant line. (Not cold and low pressure gauge indicates vacuum.) Suction (Low Gauge) Pressure Abnormally Low. When the refrigerant line is clogged or blocked, the low pressure gauge reading will decrease, or a vacuum reading may be shown. Suction (Low Gauge) Pressure Abnormally Low. Evaporator core is frozen.

Expansion valve clogged.

Receiver/Drier clogged.

Replace the receiver/drier.

Expansion valve temperature sensor is defective.

Replace the expansion valve.

Clogged or blocked refrigerant line.

Replace refrigerant line.

Thermo switch defective.

Replace thermo switch.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A43

Condition Suction (Low Gauge) and Discharge (High Gauge) Pressure Abnormally High. Insufficient cooling. Suction (Low Gauge) and Discharge (High Gauge) Pressure Abnormally High. Suction (Low) pressure hose (Not cold). Suction (Low Gauge) and Discharge (High Gauge) Pressure Abnormally Low. Insufficient cooling A/C Air Conditioning Possible cause Excessive refrigerant in system. Correction Discharge and recover the refrigerant, the Recharge to the specified amount. Clean the condenser fins. Evacuate and charge refrigerant.

Condenser clogged or dirty. Air in system.

Insufficient refrigerant in system.

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

1A44 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Magnetic Clutch Diagnosis

D08R200260

When the air conditioning switch and the fan control knob (fan switch) are turned on with the engine running, current

flows through the thermostat and the compressor relay to activate the magnetic clutch.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A45

The air conditioning can be stopped by turning off the air conditioning switch or the fan control knob (fan switch). However, even when the air conditioning is in operation, the electronic thermostat, the pressure switch or the Powertrain Control Module (PCM) is used to stop the air conditioning temporarily by turning off the magnetic clutch in the prearranged conditions to reduce the engine load which is being caused by the rise in the engine coolant temperature, and the acceleration of the vehicle, etc. For the inspection of the relays, switches and units in the table, refer to Individual Inspection in this section.

Magnetic Clutch Does Not Run

Step 1 2 3 Action Are No. C-20 (10A) fuse and No. C-19 (25A) fuse OK? Are heater and A/C (B-36), thermostat (X-5), and compressor (X-7) relays OK? Is pressure switch (triple pressure switch) OK? Go to Step 4 4 5 Are air conditioning switch and fan control knob (Fan Switch) OK? 1. Turn the ignition switch ON (Engine is running). 2. Air conditioning switch and fan control knob (Fan Switch) ON. 3. Check to see if battery voltage is present at chassis side connector terminal No. E3-1. Is there a battery voltage? 6 Check to see if continuity between compressor side connector terminal No. E3-1 and the magnetic clutch side connector terminal. Is there a continuity? 7 Check to see if battery voltage is present at chassis side connector terminal No. C89-2 Is there a battery voltage? 8 1. Disconnect thermostat relay (X-5). 2. Check to see if battery voltage is present at the chassis side relay terminal NO. X5-2 Is there a battery voltage? 9 Check to see if voltage (approx. 10V) is present between chassis side relay terminal No. X5-1 and No. X5-3. Is there a battery voltage? 10 1. Reconnect thermostat relay and disconnect compressor relay (X-7). 2. Check to see if battery voltage is present at the chassis side relay terminal No. X7-2. Is there a battery voltage? 11 Check to see if continuity between chassis side relay terminal No. X7-4 and the chassis side connector terminal No. E3-1. Is there a continuity? 12 Check to see if battery voltage is present between chassis side relay terminal No. X7-1 and No. X7-3. Is there a battery voltage? 13 Check to see if battery voltage is present at chassis side relay terminal No. X7-1. Is there a battery voltage? Go to Step 15 Go to Step 13 Go to Step 14 Open circuit between No. C-20 (10A) fuse and No. X7-1. Go to Step 12 Open circuit. Go to Step 11 Go to Step 10 Go to Step 16 Open circuit between No. X5-4 and No. X7-2. Go to Step 9 Go to Step 8 Go to Step 6 Go to Step 7 Go to Step 5 Yes Go to Step 2 Go to Step 3 No Replace Replace Switch defective or insufficient refrigerant. Replace

Magnetic clutch defective.

Compressor defective. Open circuit between No.C-20 (10A) fuse and No. C89-2. Open circuit between No. C89-1 and No.X5-2.

1A46 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Magnetic Clutch Does Not Run (Contd)

Step 14 Action Check to see if battery voltage is present at chassis side connector terminal No. E21-F4. Is there a battery voltage? Yes Power train control module (PCM) defective. Refer to Driveability and Emissions in Engine section. Power train control module (PCM) defective. Refer to Driveability and Emissions in Engine section. No

Open circuit between No. X7-3 and No. E21-F4.

15

Check to see if continuity between chassis side relay terminal No. X5-4 and chassis side connector terminal No. E21-F45. Is there a continuity?

Open circuit

16

Check to see if battery voltage is present at chassis side relay terminal No. X5-1. Is there a battery voltage? Go to Step 17 Go to Step 20 Open circuit between No.I23-6 and No.B4-3. Open circuit between No. X5-3 and No. B4-1. Open circuit between No. B4-2 and No. I18-4 or poor ground (Fan Switch Ground Circuit). Open circuit between No. C-20 (10A) fuse and No.I23-2. 1. Reconnect thermostat relay. 2. Check to see if battery voltage is present at chassis side connector terminal No. B4-3. Is there a battery voltage? Go to Step 18 Check to see if battery voltage (appox 10V) is present at chassis side connector terminal No. B4-1. Is there a battery voltage? Go to Step 19

17

18

19

Check to see if continuity between chassis side connector terminal No. B4-2 and No. I18-4. Is there a continuity? Electronic thermostat defective.

20

Check to see if battery voltage is present at chassis side connector terminal No. I23-2. Is there a battery voltage?

Open circuit between X5-1 and No.I23-6.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A47

Individual Inspection
Fan Control Knob (Fan Switch) And Air Conditioning (A/C) Switch
1. Check for continuity between the fan switch and the A/C switch side connector terminals.

Heater And A/C (B-36), Thermostat (X-5) And Compressor (X-7) Relay
1. Disconnect relays and check for continuity and resistance between relay terminals. D For handling of these relays, refer to Heater &A/C Relay in this section.

865RS002

825RS003

Fan swtich position OFF 1 2 3 4 A/C switch position OFF ON

Fan switch connector terminals with continuity No continuity 124 145 134 146 A/C switch connector terminals with continuity 16 126

Condition Normal When battery voltage is applied between 1 3

Relay terminals with continuity 1 3 (Approx 85105W) 24

1A48 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

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

D When disconnecting or reconnecting the lines, use two wrenches to support the line fitting, to prevent from twisting or other damage. D Always install new O-rings whenever a connection is disassembled. D Before connecting any hoses or lines, apply new specified compressor oil to the O-rings. D When removing and replacing any parts which require discharging the refrigerant circuit, the operations described in this section must be performed in the following sequence: 1. Use the J-39500 (ACR4: HFC-134a Refrigerant Recovery / Recycling / Recharging / System) or equivalent to thoroughly discharge and recover the refrigerant. 2. Remove and replace the defective part. 3. After evacuation, charge the air conditioning system and check for leaks.

Repair Of Refrigerant Leaks

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

875R200033

General Repair Procedure

Precautions For Replacement or Repair of Air Conditioning Parts
There are certain procedures, practices and precautions that should be followed when servicing air conditioning systems: D Keep your work area clean. D Always wear safety goggles and protective gloves when working on refrigerant systems. D Beware of the danger of carbon monoxide fumes caused by running the engine. D Beware of discharged refrigerant in enclosed or improperly ventilated garages. D Always disconnect the negative battery cable and discharge and recover the refrigerant whenever repairing the air conditioning system. D When discharging and recovering the refrigerant, do not allow refrigerant to discharge too fast; it will draw compressor oil out of the system. D Keep moisture and contaminants out of the system. When disconnecting or removing any lines or parts, use plugs or caps to close the fittings immediately. Never remove the caps or plugs until the lines or parts are reconnected or installed.

852RS003

When connecting the refrigerant line at a block joint, securely insert the projecting portion of the joint portion into the connecting hole on the unit side and secure with a bolt. Apply the specified compressor oil to the O-rings prior to connecting.

Condenser Fan
1. Disconnect the condenser fan connector. 2. Connect the battery positive terminal to the condenser fan side connector terminal No.C-75-1 and negative to the No.C-75-2.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A49

3. Check that condenser fan is rotating correctly. O-rings (2) must be closely aligned with the raised portion (1) of refrigerant line.

875R200026

CAUTION: Compressor (PAG) oil to be used varies according to the compressor model. Be sure to apply oil specified for the model of compressor.

850RW003

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

850RW002 850RW004

1A50 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

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

Inspection flow of refrigerant leak

Step 1 Action 1. Evacuate the refrigerant system. 2. Charge the refrigerant. Is there any refrigerant leak? 2 1. Operate the compressor for more than 5 minutes to raise the pressure on the high pressure side. Is there any refrigerant leak at high pressure components? Inspection steps Check the components of the air conditioner to see if there occurs any refrigerant leak along the flow of refrigerant. NOTE: D To avoid an error in the detection of refrigerant leak, make sure there is no refrigerant vapor or cigarette smoke around the vehicle before conducting the inspection. Also, select a location where the refrigerant vapor will not be blown off by wind. D Inspection should be conducted chiefly on the pipe connections and sections where a marked oil contamination is found. When refrigerant is leaking, oil inside is also leaking at the same time. D It is not possible to visually check the leak from inside the cooling unit. Follow the method below when checking. Remove the drain hose or resistor of the cooling unit, and insert a leak detector to see if there occurs any leak. High pressure side 1. Discharger section of compressor 2. Inlet/outlet section of condenser 3. Inlet/outlet section of receiver driver 4. Inlet section of cooling unit Low pressure side 1. Outlet section of cooling unit 2. Intake section of compressor Major checking points of refrigerant leak Compressor D Pipe connection D Sealing section of shaft Yes Repair refrigerant system Repair refrigerant system No

Go To Step 2 Compressor operation to be confirmed

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

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A51

Leak at Refrigerant Line Connections

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

D HFC-134a and R-12 should never be mixed as their compositions are not the same. D HFC-134a PAG oil tends to absorb moisture more quickly than R-12 mineral oil and, therefore, should be handled more carefully. D Keep HFC-134a containers stored below 40C (100F). WARNING: D SHOULD HFC-134A CONTACT YOUR EYE(S), CONSULT A DOCTOR IMMEDIATELY. D DO NOT RUB THE AFFECTED EYE(S). INSTEAD, SPLASH QUANTITIES OF FRESH COLD WATER OVER THE AFFECTED AREA TO GRADUALLY RAISE THE TEMPERATURE OF THE REFRIGERANT ABOVE THE FREEZING POINT. D OBTAIN PROPER MEDICAL TREATMENT AS SOON AS POSSIBLE. SHOULD THE HFC-134A TOUCH THE SKIN, THE INJURY MUST BE TREATED THE SAME AS SKIN WHICH HAS BEEN FROSTBITTEN OR FROZEN.

Leaks In The Hose

If the compressor inlet or outlet hose is leaking, the entire hose must be replaced. The refrigerant hose must not be cut or spliced for repair. 1. Locate the leak. 2. Discharge and recover the refrigerant. 3. Remove the hose assembly. D Cap the open connections at once. 4. Connect the new hose assembly. D Use two wrenches to prevent twisting or damage to the hose fitting. D Tighten the hose fitting to the specified torque. 5. Evacuate, charge and test the system.

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

Recovery, Recycling, Evacuation and Charging of HFC-134a

Air conditioning systems contain HFC-134a. This is a chemical mixture which requires special handling procedures to avoid personal injury. D Always wear safety goggles and protective gloves. D Always work in a well-ventilated area. Do not weld or steam clean on or near any vehicle-installed air conditioning lines or components. D If HFC-134a should come in contact with any part of the body, flush the exposed area with cold water and immediately seek medical help. D If it is necessary to transport or carry any container of HFC-134a in a vehicle, do not carry it in the passenger compartment. D If it is necessary to fill a small HFC-134a container from a large one,never fill the container completely. Space should always be allowed above the liquid for expansion.

1A52 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

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

Evacuation of The Refrigerant System

901RS142

Legend (1) Low Side (2) High Side NOTE: Explained below is a method using a vacuum pump. Refer to the ACR4(or equivalent) manufacturer s instructions when evacuating the system with a ACR4(or equivalent). Air and moisture in the refrigerant will cause problems in the air conditioning system. Therefore, before charging the refrigerant, be sure to evacuate air and moisture thoroughly from the system. 1. Connect the gauge manifold. D High-pressure valve (HI) Discharge-side.
901RS141

D Low-pressure valve (LOW) Suction-side. 2. Discharge and recover the refrigerant. 3. Connect the center hose of the gauge manifold set to the vacuum pump inlet. 4. Operate the vacuum pump, open shutoff valve and then open both hand valves. 5. When the low-pressure gauge indicates approximately 750 mmHg (30 inHg), continue the evacuation for 5 minutes or more. 6. Close both hand valves and stop the vacuum pump. 7. Check to ensure that the pressure does not change after 10 minutes or more. D If the pressure changes, check the system for leaks. D If leaks occur, retighten the refrigerant line connections and repeat the evacuation steps. 8. If no leaks are found, again operate the vacuum pump for 20 minutes or more. After confirming that the gauge manifold pressure is at 750 mmHg (30 inHg), close both hand valves. 9. Close positive shutoff valve. Stop the vacuum pump and disconnect the center hose from the vacuum pump.

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

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

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A53

Charging The Refrigerant System

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

D Direct charging with a weight scale charging station method 1. Make sure the evacuation process is correctly completed. 2. Connect the center hose of the manifold gauge to the weight scale. 3. Connect the low pressure charging hose of the manifold gauge to the low pressure side service valve of the vehicle. 4. Connect the high pressure charging hose of the manifold gauge to the high pressure side service valve of the vehicle.

901RS141 901RS143

Legend (1) Low Side (2) High Side

Legend (1) Low Side (2) High Side (3) Refrigerant Container (4) Weight Scale

1A54 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

5. Place the refrigerant container(3) up right on a weight scale(4). Note the total weight before charging the refrigerant. a. Open the refrigerant container valve. b. Open the low side vale on the manifold gauge set. Refer to the manufacturer s instructions for a weight scale charging station. 8. When finished with the refrigerant charging, close the low pressure valve of the manifold gauge and container valve. 9. Check for refrigerant leaks.

Checking The A/C System

1. Run the engine and close all the vehicle doors. 2. Turn A/C switch ON, set the fan switch to its highest position. 3. Set the air source lever to CIRC, set the temperature lever to the full cool position. 4. Check the high and low pressure of the manifold gauge. D Immediately after charging refrigerant, both high and low pressures might be slightly high, but they settle down to the pressure guidelines shown below: D The ambient temperature should be between 2530C (7786F). D The pressure guideline for the high-pressure side is approximately 1372.91863.3 kPa (199.1270.2 psi). D The pressure guideline for the low-pressure side is approximately 147.1294.2 kPa (21.342.7 psi). D If an abnormal pressure is found, refer to Checking The Refrigerant System With Manifold Gauge in this section. 5. Put your hand in front of the air outlet and move the temperature control lever of the control panel to different positions. Check if the outlet temperature changes as selected by the control knob. Reading Sight Glass The sight glass provides accurate diagnosis only under the following conditions. If the vehicle can be tested under these conditions, check the sight glass appearance and compare to the chart below. D Engine speed idle D A/C switch ON D Blower fan operating at highest speed D Air source selector lever at RECIRC D Temperature control lever at coldest position D Ambient temperature below 30C (86F) and humidity below 70% (See NOTE 1) D High side pressure less than 1667.1 kPa (241.7 psi) (See NOTE 2) NOTE: 1. If the vehicle cannot be moved to a testing location that meets these specifications, then the sight glass cannot be used for diagnosis. You must discharge and recover the refrigerant, then recharge the system with the specified amount of refrigerant. Then continue checking the system performance. NOTE: 2. If the high side pressure is greater than stated, the sight glass cannot be used for diagnosis. You must discharge and recover the refrigerant, then recharge the system with the specified amount of refrigerant. Then continue checking system performance.

901RS144

6. Perform a system leak test: D Charge the system with approximately 200 g (0.44 lbs) of HFC-134a. D Make sure the high pressure valve of the manifold gauge is closed. D Check to ensure that the degree of pressure does not change. D Check for refrigerant leaks by using a HFC-134a leak detector. D If a leak occurs, recover the refrigerant. Repair the leak and start all over again from the first step of evacuation. 7. If no leaks are found, continue charging refrigerant to the air conditioning system. D Charge the refrigerant until the scale reading decreases by the amount of the charge specified. Specified amount: 800 g (1.76 lbs) D If charging the system becomes difficult: 1. Run the engine at idle and close all the vehicle doors. 2. Turn A/C switch ON. 3. Set the fan switch to its highest position. 4. Set the air source selector lever to CIRC. 5. Slowly open the low side valve on the manifold gauge set. WARNING: BE ABSOLUTELY SURE NOT TO OPEN THE HIGH PRESSURE VALVE OF THE MANIFOLD GAUGE. SHOULD THE HIGH PRESSURE VALVE BE OPENED, THE HIGH PRESSURE REFRIGERANT WOULD FLOW BACKWARD, AND THIS MAY CAUSE THE REFRIGERANT CONTAINER TO BURST.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A55

High and low pressure pipe temperature The high pressure pipe is hot and the low pressure pipe is cold. There is a distinct difference in temperature between them. Almost transparent. A flow of bubbles can be seen, but they disappear when the throttle is opened. The high pressure pipe is warm and the low pressure pipe is cool. There is no great difference in temperature between them. A flow of bubbles always can be seen. It appears sometimes transparent, and sometimes frothy. There is litttle difference in temperature between the high pressure pipe and the low pressure pipe. Something like fog faintly can be seen. The high pressure pipe is hot and the low pressure pipe is slightly warm. There is a defference in temperature between them. Even at idle with the fan at HI” (with the window fully open), the bubbles cannnot be seen.

Slight glass condition

Air conditioning cycle condition

OK

NG (Not enough refrigerant)

NG (Almost no refrigerant)

NG (Too much refrigerant)

1A56 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Compressor Assembly
Compressor Assembly and Associated Parts (6VE1)

852R200013

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

(5) (6) (7) (8) (9)

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

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

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A57

4. Remove serpentine belt. D Move serpentine belt tensioner to loose side using wrench then remove serpentine belt. 4. Connect magnetic clutch harness connector.

New Compressor Installation

The new compressor is filled with 150cm3 (5.0fl.oz.)of compressor oil and nitrogen gas. When mounting the compressor on the vehicle, perform the following steps; 1. Gently release nitrogen gas from the new compressor. D Take care not to let the compressor oil flow out. D Inspect O-rings and replace if necessary.

850R200001

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

871R200003

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

Installation
1. Install compressor. D Tighten the compressor fixing bolts to the specified torque. Torque: 19 Nm (14 lbft) 2. Connect refrigerant line connector. D Tighten the refrigerant line connector fixing bolts to the specified torque. Torque: 15 Nm (11 lbft) D O-rings cannot be reused. Always replace with new ones. D Be sure to apply new compressor oil to the O-rings when connecting refrigerant lines. 3. Install serpentine belt. D Move serpentine belt tensioner to loose side using wrench, then install serpentine belt to normal position.
871R200004

1A58 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Condenser Assembly
Condenser Assembly and Associated Parts

875R200027

Legend (1) Refrigerant Line (2) Pressure Switch Connector (3) Front Bumper Assembly

(4) Radiator Grille (5) Engine Hood Front End Stay (6) Condenser Assembly

Removal
1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. D Refer to Refrigerant Recovery in this section. 3. Remove radiator grille. 4. Remove front bumper assembly. D Refer to Bumpers in Body and Accessories section. 5. Remove engine hood front end stay. 6. Disconnect pressure switch connector. 7. Disconnect refrigerant line. D When removing the line connector, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line. 8. Remove condenser assembly. D Handle with care to prevent damaging the condenser or radiator fin.

Installation
1. Install condenser assembly. D If installing a new condenser, be sure to add 30cm3 (1.0 fl. oz.) of new compressor oil to a new one. D Tighten the condenser fixing bolts to the specified torque. Torque: 6 Nm (52 lbin) 2. Connect refrigerant line. D Tighten the inlet line connector fixing bolt to the specified torque. Torque: 15 Nm (11 lbft) D Tighten the outlet line connector fixing bolt to the specified torque. Torque: 6 Nm (52 lbin) D O-rings cannot be reused. Always replace with new ones.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A59

D Be sure to apply new compressor oil to the O-rings when connecting the refrigerant line. 3. Connect pressure switch connector. 4. Install engine hood front end stay. 5. Install front bumper assembly. 6. Install radiator grille.

Receiver / Drier
Receiver / Drier and Associated Parts

875R200034

Legend (1) Pressure Switch Connector (2) Refrigerant Line

(3) Radiator Grille (4) Receiver / Drier

Removal
1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. D Refer to Refrigerant Recovery in this section. 3. Remove radiator grille. 4. Disconnect pressure switch connector. 5. Disconnect refrigerant line. D When removing the line connected part, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line. 6. Remove receiver/drier. D Loosen the bolt, then, using care not to touch or bend the refrigerant line, carefully pull out the receiver/drier.

Installation
To install, follow the removal steps in the reverse order, noting the following points: 1. If installing a new receiver/drier, be sure to add 30cm3 (1.0 fl. oz.) of new compressor oil to a new one. 2. Put the receiver/drier in the bracket and connect with the refrigerant line. Check that no excessive force is imposed on the line. Fasten the bracket bolt to the receiver/drier. 3. Tighten the refrigerant line to the specified torque. Torque: 6 Nm (52 lbin) 4. O-rings cannot be reused. Always replace with new ones. 5. Be sure to apply new compressor oil to the O-rings when connecting the refrigerant line.

1A60 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Pressure Switch
Pressure Switch and Associated Parts

875R200028

Legend (1) Pressure Switch Connector

(2) Pressure Switch (3) Radiator Grille

Removal
1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. D Refer to Refrigerant Recovery in this section. 3. Remove radiator grille. 4. Disconnect pressure switch connector. 5. Disconnect pressure switch. D When removing the switch connected part, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line.

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

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A61

Evaporator Assembly
Evaporator Assembly and Associated Parts

874RT002

Legend (1) Resistor and Electronic Thermostat Connector (2) Drain Hose (3) Refrigerant Line (4) Passenger Knee Bolster Reinforcement Assembly

(5) Instrument Panel Passenger Lower Cover Assembly (6) Glove Box (7) Front Console Assembly (8) Lower Cluster Assembly (9) Evaporator Assembly

Removal
1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. D Refer to Refrigerant Recovery in this section. 3. Remove front console assembly. 4. Remove lower cluster assembly. 5. Remove glove box. 6. Remove instrument panel passenger lower cover assembly. 7. Remove passenger knee bolster reinforcement assembly. D Refer to Instrument Panel Assembly in Body and Accessories section. 8. Disconnect resistor (2) and electronic thermostat connector (1).
874RY00009

1A62 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

9. Disconnect drain hose. 10. Disconnect refrigerant line. D Use a back-up wrench when disconnecting and reconnecting the refrigerant lines. D When removing the refrigerant line connected part, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line. 11. Remove evaporator assembly. 1. To install a new evaporator assembly, add 50cm3 (1.7 fl. oz.) of new compressor oil to the new core. 2. Tighten the refrigerant outlet line to the specified torque. Torque: 25 Nm (18 lbft) 3. Tighten the refrigerant inlet line to the specified torque. Torque: 15 Nm (11 lbft) 4. O-rings cannot be reused. Always replace with new ones. 5. Be sure to apply new compressor oil to the O-rings when connecting lines.

Installation
To install, follow the removal steps in the reverse order, noting the following points:

Electronic Thermostat, Evaporator Core and/or Expansion Valve

Disassembled View

874R200016

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

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

Lining Evaporator Core Electronic Thermostat Attaching Screw Upper Case

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A63

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

8. Remove evaporator core.

874RY00006

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

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

874RS006

D Lift to remove the upper case.

874RY00005

874RX021

1A64 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

4. O-rings cannot be reused. Always replace with new ones. 5. Be sure to apply new compressor oil to the O-rings when connecting lines. 6. Be sure to install the sensor and the insulator on the place where they were before. 7. To install a new evaporator core, add 50cm3 (1.7 fl. oz.) of new compressor oil to the new core. 8. Tighten the refrigerant lines to the specified torque. Refer to Main Data and Specifications for Torque Specifications in this section. 9. Apply an adhesive to the parting face of the lining when assembling the evaporator assembly.

Air Conditioning Switch and Illumination Bulb

Air Conditioning Switch, Illumination Bulb and Associated Parts

865RS003

Legend (1) Control Lever Assembly

(2) Illumination Bulb (3) A/C Switch

Removal
1. Disconnect the battery ground cable. 2. Remove control lever assembly. D Refer to Control Lever Assembly in this section. 3. Lift up the catch portion (1) of the switch and remove the air conditioning switch (2) while pushing it toward the outside.

865RS004

4. Turn the illumination bulb counterclockwise to remove.

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

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A65

Refrigerant Line
Refrigerant Line and Associated Parts

852R200016

Legend (1) Clip and Clamp (2) Suction Line (Low Pressure Hose) (3) Liquid Line (High-Pressure Pipe)

(4) (5) (6) (7)

Discharge Line (High Pressure Hose) Air Cleaner Radiator Grille Suction Line (Low-Pressure Pipe)

Removal
1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. D Refer to Refrigerant Recovery in this section. 3. Remove radiator grille. 4. Remove air cleaner. 5. Remove clip and clamp. 6. Disconnect liquid line (High-pressure pipe).

7. Disconnect suction line (Low-pressure pipe) using a back-up wrench. 8. Disconnect suction line (Low-pressure hose) using a back-up wrench. 9. Disconnect discharge line (High-pressure hose) using a back-up wrench. D Use a backup wrench when disconnecting and reconnecting the refrigerant lines.

1A66 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

D When removing the refrigerant line connecting part, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line.

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

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A67

Main Data And Specifications

General Specifications
Heater Unit Temperature control Capacity Air flow HEATER CORE Type Element dimension Radiating area EVAPORATOR ASSEMBLY Capacity Air flow EVAPORATOR CORE Type Element dimension EXPANSION VALVE Type THERMOSTAT SWITCH Type Electronic thermostat OFF: Below 1.00.5C (33.80.9F) ON: Above DIFF 2.00.5C (35.60.9F) Parallel flow type 16.3 kw (14000 Kcal./hr.) 800 m3/h f252 Assembly includes sight glass with triple pressure switch 300 cm3 (10 fl.oz.) Triple pressure switch Low pressure control ON: 206.030.0 kPa (29.84.3 psi) OFF: 176.519.6 kPa (25.62.8 psi) Medium pressure control ON: 1471.098.1 kPa (213.314.2 psi) OFF: 1078.7117.7 kPa (156.417.7 psi) High pressure control ON: 2353.6196.1 kPa (341.328.4 psi) OFF: 2942.0196.1 kPa (426.628.4 psi) Internal pressure equalizer type Al-laminate louver fin type 235 mm (9.3 in.) 225.3 mm (8.9 in.) 60 mm (2.4 in.) 4.9 kw (4200 Kcal./hr.) 470 m#/hr Plate and corrugate fin type 171 mm (6.7 in.) 161 mm (6.3 in.) 25 mm (0.98 in.) Approx. 0.75 m@ Reheat air mix system 4.3 kw (3700 Kcal./hr.) 280 m#/h

CONDENSER Type Radiation performance CONDENSER FAN Air flow Fan size RECEIVER/DRIER Type Internal volume PRESSURE SWITCH Type

1A68 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

REFRIGERANT Type Specified amount HFC-134a 800 g (1.76 lbs.)

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A69

Torque Specifications

852R200015

874R200018

1A70 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Compressor
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). REFER TO THE SRS COMPONENT LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS ON-VEHICLE SERVICE INFORMATION. FAILURE TO FOLLOW CAUTIONS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems. see if the drive plate can be rotated. If rotation is impossible, the compressor is seized. Low discharge pressure may be due to a faulty internal seal of the compressor, or a restriction in the compressor. Low discharge pressure may also be due to an insufficient refrigerant charge or a restriction elsewhere in the system. These possibilities should be checked prior to servicing the compressor. If the compressor is inoperative, but is not seized, check to see if current is being supplied to the magnetic clutch coil terminals. The compressor oil used in the HFC134a system compressor differs from that used in R12 systems. Also, compressor oil to be used varies according to the compressor model. Be sure to avoid mixing two or more different types of oil. If the wrong oil is used, lubrication will be poor and the compressor will seize or malfunction.

DKV-14G Type Compressor

DKV14G is equipped with fivevane rotary compressor. These vanes are built into a rotor which is mounted on a shaft. When the shaft rotates, the vanes built into the cylinder block assembly are operated by centrifugal force. This changes the volume of the spare formed by the rotor and cylinder, resulting in the intake and compression of the refrigerant gas. The discharge valve and the valve stopper, which protects the discharge valve, are built into the cylinder block assembly. There is no suction valve but a shaft seal is installed between the shaft and head; a trigger valve, which applies back pressure to the vanes, is installed in the cylinder block and a refrigerant gas temperature sensor is installed in the front head. The specified quantity of compressor oil is contained in the compressor to lubricate the various parts using the refrigerant gas discharge pressure.

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

871RX002

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A71

Diagnosis
Condition Noise from compression Possible cause Defective rotor/piston Defective shaft Noise from magnetic clutch Defective bearing Defective clutch Clearance between drive plate and pulley not standard Insufficient cooling Defective gasket Defective rotor/reed valve Defective trigger valve/suction valve Not rotating Defective rotor/piston Defective shaft Rotating parts insufficient oil Oil and/or gas leakage Defective seal Defective O-ring seized due to Correction Replace compressor/cylinder and shaft assembly Replace compressor/cylinder and shaft assembly Replace magnetic clutch Replace magnetic clutch Adjust the clearance or replace magnetic clutch Replace compressor/gasket Replace compressor/valve plate Replace compressor/suction valve Replace compressor/cylinder and shaft assembly Replace compressor/cylinder and shaft assembly Replace compressor Replace compressor/shaft seal Replace

1A72 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Magnetic Clutch Assembly (DKV-14G Type)

Parts Location View

871R200001

Legend (1) Drive Plate bolt (2) Drive Plate (3) Snap Ring

(4) (5) (6) (7)

Pulley Assembly Field Coil Shim (s) Lead Wire

Removal
1. Using drive plate holder J-7624 (1) to prevent the drive plate from rotating, then remove the drive plate bolt.

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

871R200014

3. Remove shim (s).

871R200013

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A73

4. Remove snap ring (1) by using snap ring pliers. 6. Loosen screw and disconnect the field coil wire connector.

871R200012

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

871R200009

7. Loosen three screws and remove the field coil.

871R200010 871R200008

1A74 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Inspection and Repair

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

3. Install pulley assembly by using pulley installer J-33940-A (2) and drive handle J-8092 (1).

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

Coil
Check coil for loose connector or cracked insulation.

Installation
1. Install field coil. D Align the located portion (1) of the field coil and compressor.
871R200011

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

871R200006

D Tighten the mounting screw to the specified torque. Torque: 5Nm (44 lb in) 2. Connect the lead wire connector with the rubber hold and tighten the screw.
871R200007

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A75

7. Install drive plate bolt by using drive plate holder J-7624 (1) to prevent the drive plate from rotating. D Check to be sure that the clutch clearance is between 0.3-0.6 mm (0.01-0.02 in.)

871R200013

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

871R200015

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

1A76 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Compressor Oil
Oil Specification
D The HFC-134a system requires a synthetic (PAG) compressor oil whereas the R-12 system requires a mineral compressor oil. The two oils must never be mixed. D Compressor (PAG) oil varies according to compressor model. Be sure to use oil specified for the model of compressor. D Always use HFC-134a Vane Rotary Type Compressor Oil (AIPDN Part No.2-90188-301-0) (Charging Amount) more than 90 cm3 (3.0 fl.oz) less than 90 cm3 (3.0 fl.oz) (Collected Amount) same as collected amount 90 cm3 (3.0 fl.oz)

7. Install the compressor, then evacuate, charge and perform the oil return operation. 8. Check system operation. When it is impossible to preform oil return operation, the compressor oil should be checked in the following order: 1. Discharge and recover refrigerant and remove the compressor. 2. Drain the compressor oil and measure the extracted oil with a measuring cylinder. 3. Check the oil for contamination. 4. If more than 90 cm3 (3.0 fl. oz.) of oil is extracted from the compressor, supply the same amount of oil to the compressor to be installed. 5. If the amount of oil extracted is less than 90 cm3 (3.0 fl. oz.), recheck the compressor oil in the following order. 6. Supply 90 cm3 (3.0 fl. oz.) of oil to the compressor and install it onto the vehicle. 7. Evacuate and recharge with the proper amount of refrigerant. 8. Perform the oil return operation. 9. Remove the compressor and recheck the amount of oil. 10. Adjust the compressor oil, if necessary. (Collected Amount) more than 90 cm3 (3.0 fl.oz) less than 90 cm3 (3.0 fl.oz) (Charging Amount) same as collected amount 90 cm3 (3.0 fl.oz)

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

Compressor Oil Check

The oil used to lubricate the compressor is circulating with the refrigerant. Whenever replacing any component of the system or a large amount of gas leakage occurs, add oil to maintain the original amount of oil. Oil Capacity Capacity total in system: 150cm3 (5.0 fl.oz) Compressor (Service parts) charging amount: 150 cm3 (5.0 fl.oz)

Checking and Adjusting Oil Quantity for Used Compressor

1. Perform oil return operation. Refer to Oil Return Operation in this section. 2. Discharge and recover refrigerant and remove the compressor. 3. Drain the compressor oil and measure the extracted oil with a measuring cylinder. 4. If the amount of oil drained is much less than 90 cm3 (3.0 fl. oz.), some refrigerant may have leaked out. Conduct a leak tests on the connections of each system, and if necessary, repair or replace faulty parts. 5. Check the compressor oil contamination. (Refer to Contamination of Compressor Oil in this section.) 6. Adjust the oil level following the next procedure below.

Checking and Adjusting for Compressor Replacement

150 cm3 (5.0 fl.oz.) of oil is charged in compressor (service parts). So it is necessary to drain the proper amount of oil from the new compressor. 1. Perform oil return operation. 2. Discharge and recover the refrigerant and remove the compressor. 3. Drain the compressor oil and measure the extracted oil. 4. Check the compressor oil for contamination.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A77

5. Adjust the oil level as required. (Amount of oil drained from used compressor) less than 90 cm3 (3.0 fl.oz) more than 90 fl.oz) cm3 (3.0 (Draining amount of oil from new compressor) Same as drained amount 90 cm3 (3.0 fl.oz)

Replacement of Component Parts

When replacing the system component parts, supply the following amount of oil to the component parts to be installed. (Component parts to be installed) Evaporator Condenser Receiver/dryer Refrigerant line (one piece) (Amount of Oil) 50 cm3 (1.7 fl. oz.) 30 cm3 (1.0 fl. oz.) 30 cm3 (1.0 fl. oz.) 10 cm3 (0.3 fl. oz.)

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

Contamination of Compressor Oil

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

Oil Return Operation

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

1A78 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Main Data and Specifications

General Specifications
COMPRESSOR Model Type Number of vanes Rotor diameter Stroke Displacement Maximum speed Direction of rotation Lubrication system Lubricant DKV-14G Vane rotary type 5 64 mm (2.52 in.) 8.75 mm (0.34 in.) 140 cm3 (47.3 fl.oz.) 7,000 rpm (up to 8,500 rpm) Clockwise (Front-side view) Pressure differential type R-134a Vane Rotary Type Compressor Oil (AIPDN Part No.2-90188-301-0) 150 cm3 (5.0 fl.oz.) Refrigerant Shaft seal Weight MAGNETIC CLUTCH Type Rated voltage Current consumption Starting torque Direction of rotation Weight Electromagnetic single-plate dry clutch 12 Volts D.C. 3.7 A 49 Nm (36 lbft) Clockwise (Front-side view) 2.8 kg Refrigerant-134a (R-134a), 700 g (1.54 lbs.) Lip type 3.5 kg

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A79

Torque Specifications

871R200005

1A80 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Special Tools
ILLUSTRATION TOOL NO. TOOL NAME ILLUSTRATION TOOL NO. TOOL NAME

J-7624 Drive plate holder

J-33940-A Pulley installer

J-33944-A Drive plate puller

J-8092 Drive handle

J-33944-4 Forcing screw

J-38424 Pulley puller pilot

J-8433 Pulley puller

J-24092-2 Pulley puller leg

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A81

Automatic Air Conditioning System

General Description
Using a variety of sensors, this automatic heater and air conditioner accurately senses outside air temperature, solar radiation quantity, evaporators blowing temperature, and interior temperature, then enters these data to the automatic heater/air conditioner control unit (equipped with the built-in micro-computer). The data provided to the control unit enables to automatically control blow temperature and blow air quantity, turn on or off the compressor and switch the blow port as well as switching between the fresh air intake and interior air circulation. Resetting the automatic function allows you to switch to the manual control mode. The self-diagnoisis function of the automatic heater and air conditioner control unit (with the builtin microcomputer) allows the unit to access and diagnose a failed part easier and quicker.

Full Automatic Air Conditioner Parts Configuration

865R200051

Legend (1) Sun Sensor (2) Lower Center Vent Box (3) Evaporator Assembly (4) Duct Sensor (5) Intake Actuator

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

Blower Unit Automatic Air Conditioner Control Unit In Car Sensor Heater Unit Mode Actuator Mix Actuator

1A82 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Refrigerant Line and Associated Parts

852R200017

Legend (1) Liquid Line (High Pressure Pipe) (2) O Ring (3) Discharge Line (High Pressure Hose) (4) Pressure Switch (5) Receiver Drier (6) Ambient Sensor

(7) (8) (9) (10) (11) (12) (13)

Condenser Assembly Drive Belt Compressor Drain Hose Suction Line (Low-Pressure Hose) Evaporator Assembly A/C Switch

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A83

Circuit Diagram
6VE1 Engine

D01R200012

1A84 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

D01R200013

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A85

D01R200021

1A86 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

D01R200015

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A87

D01R200016

1A88 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Functions and Features

Automatic interior temperature control This function enables to maintain the interior temperature at the level specified from the temperature control switch despite of changes in factors such as vehicle speeds, outside air temperature and number of passengers. Maximum cooling and heating function You can select FC (Full cool, namely maximum cooling temperature) or FH (Full heat, maximum heating temperature) from the temperature control lever. Automatic air flow control Air flow is automatically and consecutively fine tuned according to the specified interior temperature and changes in aperture of the heater unit mix door. Mode (blow port) control This function automatically selects either one of the VENT, BI-LEVEL, FOOT or DEF mode for the blow port according to changes of temperature on the blow port. Using the mode switch allows you to select a desired blow port manually. Intake (switching between the fresh air intake and circulation of interior air) control The intake (switching between fresh air intake and circulation of interior air) mode automatically selects either FRESH (fresh air intake), MIX or RECIRC (interior air circulation) according to changes of the blow port temperature. Using the intake switch allows you to select a desired intake port manually (in the manual operation, FRESH and RECIRC modes alone are available). Pressing the DEF (defrost) mode switch selects the FRESH (fresh air intake). Cooler start-up timing control This function is used for maintaining the air flow at LOW level until the evaporator is sufficiently cooled down. It is intended to prevent a large volume of hot air being blowing into inside of a vehicle when the cooler is turned on in hot summer season. Heater start-up timing control This function is used for maintained the air flow at LOW level and also for maintaining the defrost mode until temperature of coolant in the heater core is sufficiently heated. It is intended to prevent a large volume of cool air being blown into inside of a vehicle when the heater is turned on in cold winter season. Solar radiation quantity offset control The photodiode on the sun sensor determines solar radiation quantity accurately to offset interior temperature quickly. Switch position storing function This function is used for storing switch positions being selected in the immediately preceding operation, namely the last time the ignition has been turned off. It simplifies the setup procedures when restarting

the system. Self-diagnosis function The self-diagnosis function turned on from the panel switch makes your troubleshooting easier (for detail of this function, refer to the section titled Self-Diagnosis).

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A89

Automatic Air Conditioner Block Diagram

F01R200006

1A90 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Control Panel Layout

865RY00024

Legend (1) Auto Switch (2) Mode Switch (3) DEF/FOOT Switch (4) DEF Switch

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

Intake Switch Fan Switch Air Conditioning Switch Temperature Control Knob

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A91

Air Control Functions

C01RY00004

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

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

FOOT Door Sub Air Mix Door Heater Unit Heater Core Evaporator Unit Blower Unit

1A92 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Operation and Functions of Control Panel Switches

Auto Switch
1. Pressing this switch turns on the automatic control mode. It resets all manual switches except that for the fan control. However, when the Manual REC is selected for the intake or the Manual Open is selected, the modes are maintained. 2. It causes the A/C (air conditioner) to the ON mode (this function, however, available only when the fan is turned on and also the compressor is turned on because of the given outside air temperature level). Indication D The AUTO LED is turned off. D Currently selected mode for the Mode and Intake are respectively indicated. D The A/C LED remains turned on even if the compressor has been turned off because of the given outside air temperature level. Pressing the air conditioning switch in this state turns off the A/C LED.

Mode Switch
1. Pressing the VENT, B/L or FOOT switch selects the corresponding mode. 2. When the Auto is selected for the Mode and Intake, pressing the mode switch fixes the Intake to the immediately preceding status. Indication D The AUTO LED is turned off. D Currently selected blow port is indicated.

DEF Switch
Press this switch to select the DEF mode. Blow port DEF Intake port Auto FRESH *1 A/C ON mode *2 MIX Auto

*1: When the manual REC is selected for the Intake, the manual REC is maintained. *2: The ON mode is enabled only when the fun is turned on, and also the compressor is turned on because of the given outside air temperature level. Indication D The AUTO LED is turned off.

D The DEF LED and the A/C LED are turned on. D The indication of the intake LED depends on the system condition.

F01RX006

Intake Switch
Pressing this switch sequentially selects a different intake port in the following order.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A93

F01RX005

Indication D The Auto LED maintains unaffected. D Currently selected intake port is indicated.

Fan Switch
1. Sets the fan to the specified mode. 2. Even when the fan switch is turned off, status display for the Mode, Intake is maintained.

Temperature Control Knob

1. This knob is operable only when the fan is turned on. It may be used for the MAX control of each block except the fan. 2. When the manual mode is selected for the fan control, this manual mode is maintained. MAX Control

F01RX007

Mix MAX/COOL MAX/HEAT Full cool Full hot

Fan MAX/HI AUTO/HI

Mode VENT FOOT*3

Intake REC*1 FRESH

A/C ON mode*2 Current status is maintained

*1: In the A/C: OFF mode, FRESH shall be selected. *2: The ON mode is available only when ON is selected for the fan as well as for the cold outside air ON/OFF selection. *3: When the MAX control is selected from the DEF mode, this DEF mode shall be maintained.

1A94 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Indication D As long as the MAX control is selected, the immediately preceding indication shall be maintained for the AUTO. D Status display is provided for others.

Air Conditioning Switch

Pressing this switch turns on or off the A/C (air conditioning) control. (The compressor remains turned off if the fan is turned off and also the compressor has been turned off because of the given outside air temperature level.) Indication 1. The A/C LED remains turned on even if the compressor has been turned off because of the given outside air temperature level. In this case, however, the AUTO or DEF switch must be turned on and the A/C ON mode must also be turned on (by the MAX/C mode). 2. Pressing the A/C switch from the above state (1) turns off the A/C LED.

865RY00020

Legend (1) In Car Sensor (2) Automatic Air Conditioner Control Unit

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

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

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

875R200029

Legend (1) Ambient Sensor (2) Condenser Assembly

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A95

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

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

860RY00007

826RY00012

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

Legend (1) Sun Sensor

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

874RY00011

Legend (1) Evaporator Assembly (2) Power Transistor

1A96 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

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

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

860RW026

Legend (1) Output Axis (2) Motor (3) Printed Circuit Board (4) Sliding Contact
860R200008

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

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

C01RX016

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A97

Movement of Mix Actuator

Position of the air mix door is determined by the controller on the automatic air conditioner control unit. As the heat or cool side of the controller is grounded, the transistor on the driver is activated and, thus, the motor rotation is turned on. The sliding contact connected to the motor sends the position detection signal from the potentiometer to the automatic air conditioner control unit. As the set temperature and interior temperature are balanced, the controller returns to the neutral and the motor rotation is stopped. I-45 (+) side 8 6 (-) side 6 8 Rotation direction Clockwise Counter clockwise Remarks Full heat side Full cool side

Movement of Mode Actuator

As target position of the mode door is decided on the controller of the control unit, the control unit reads the position detection signal from the actuator to select the clockwise or counter clockwise motor rotation direction. Grounding the controller VENT or DEF side after the direction selection activates the transistor on the driver, thus turning on the motor rotation. Accompanying the motor rotation, the sliding contact rotates, too. When the target position is reached, the controller on the control unit returns to the neutral and the motor stops. Conduction pin (+) side 5 1 (-) side 1 5 Rotation direction Clockwise Counter clockwise Remarks VENT to DEF direction DEF to VENT direction

C01RX005

C01RX017

1A98 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Movement of Intake Actuator

The controller on the automatic air conditioner control unit selects an intake mode to be used. As the Terminal No.5 I-49 is grounded via the sliding contact on the terminal plate, the transistor on the driver is activated, thus turning on the motor rotation. Then, accompanying move of the motor, the sliding contact rotates until grounding of the Terminal No.5 I-49 is removed, thus stopping the motor. Grounding terminal No.5 I-49 Rotation direction Clockwise Remarks RE-CIRCULATIONMIXF RESH

Interior Temperature Control

The automatic air conditioner control unit operates on the setup temperature signal from the temperature control switch and other sensor signals to derive the total signal. Then, the control unit compares this signal against the signal from the potentiometer to determine rotation direction of the mix actuator. The mix actuator moves the air mix door to the aperture specified by the total signal so that the specified interior temperature is achieved. If the compressor is turned off in the A/C (air conditioning) mode, aperture of the air mix door is offset according to the outside air temperature or the specified interior temperature. This function removes the difference in the blowing temperature in this state and that of when the compressor is turned on. When FH or FC is selected for the setup temperature, the air mix door is accordingly fixed to the Full Heat or Full Cool mode. When the VENT mode is selected, aperture of the air mix door is controlled so that excessively heated air may not be blown from the VENT blow port.

C01RX006

Overview of Automatic Control of Automatic Air Conditioner

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

C01RY00011

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A99

Air Flow Control

In the Auto Mode D The automatic air conditioner control unit operates on the setup temperature signal and other sensor signals to derive the total signal. Then, the control unit adjusts base potential of the power transistor to match it to the voltage pattern of the target fan so that stage-less fan speed control can be achieved. When solar radiation quantity is detected in the VENT or B/L mode, the control unit increases the minimum fan voltage to offset. When FH or FC is selected from the temperature control switch, air flow is accordingly fixed to MAX HI or AUTO HI. In the Manual Mode D Air flow specified from the fan switch is entered to the automatic air conditioner control unit as the manual signal. The signal modifies the air flow to the level specified from the fan switch so that the required fan voltage is attained.

Mode (Blow Port) Control

The automatic air conditioner control unit operates on the setup temperature from the control switch, and temperature and solar radiation quantify from the sensors to determine the total mode control signal. According to the pattern specified by this signal, the control unit selects either one of the VENT, BI-LEVEL, FOOT or DEF/FOOT mode. The mode actuator determines the rotation direction comparing the target position against the current position being determined by the position detection signal. When FH or FC is selected for the temperature from the temperature control switch, mode is accordingly fixed to the VENT or FOOT. D In the manual operation of the mode switch, you can select a desired blow port mode pressing the corresponding mode switch. D Operating the DEF mode switch selects the DEF for the blow port mode.

C01RY00009

C01RY00008

1A100 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Intake (Fresh air/interior air switching) Control

In the Full Auto mode, the automatic air conditioner control unit operates on the setup temperature signal and other sensor input signals to derive the total signal. According to the pattern specified by this signal, the control unit provides the intake control. When the fan is turned off or the A/C (air conditioning) is turned off, the intake is fixed to the FRESH mode. When FC or FH is selected from the control switch, the intake mode is accordingly fixed to the RECIRC or FRESH. In the Manual Operation D Pressing the FRESH (fresh air intake) or the RECIRC (room air circulation) accordingly selects the FRESH or RECIRC mode. When the DEF Mode Switch is depressed D The intake mode is fixed to the FRESH. When the MANU REC is selected, however, the mode is fixed the RECIRC. When the Mode Switch is depressed D If the automatic intake control is selected, the intake is fixed to the currently selected mode.

Compressor Control
In the automatic control mode, the automatic air conditioner control unit turns on or off the compressor with the evaporator antifreeze mechanism using the duct sensor. And, when outside air is detected to be low through the ambient sensor signal, the control unit turns off the compressor using the compressor control function. Manual Control D In the automatic control mode, pressing the A/C (air conditioning) switch turns off the compressor. D Pressing the DEF mode switch automatically turns on the compressor.

C01R200019

Heating Start Timing Control

When the automatic air conditioner is started, heating is turned on under following conditions. D The detected temperature of thermo unit is 58C (136F) or less. D The temperature setting signal and the total signal by each sensor meet the condition of heating. When the detected temperature by the coolant temperature sensor is 58C (136F) or less, the blower fan motor is set to work at low speed and the DEF mode is selected. When the detected temperature by the coolant temperature sensor is 25C (77F) or more, the blow mode changes automatic control. And the blower fan speed is controlled to be lineally up from LO to MAX HI.

C01RY00012

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A101

840R200012

Cooling Start Timing Control

When the automatic air conditioner is started, cooling is turned on under following conditions. D The in car sensor is 30C (86F) or more. D The temperature setting signal and the signals from each sensor meet the specified condition. The blower fan speed is set to LO for maximum 7 seconds when cooling start conditions meet, and then, is controlled to be lineally up to MAX HI by 5.32%/S.

C06RY00001

1A102 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Troubleshooting
Troubleshooting, Its Overview and Procedures
The full automatic heater and air conditioner equips with the Self-Diagnosis Function to check its major components. This function makes access to the sensors, actuators and blower fan motor system easier when checking them up and, when a failed part is located, this function restores its original performance. When implementing the troubleshooting, this self-diagnosis function narrows the range to be searched at the first step, then check relevant parts one by one according to the Checking Procedures by Failed Location. As for a location this function is unappreciable, the system accurately determines characteristics of a given trouble and checks relevant parts according to the Checking Procedures by Failed Location. The following illustrates basic troubleshooting flow.

Basic Troubleshooting Flow

F01RX009

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A103

Auto Air Conditioner Control Unit Power Supply Diagnosis

This check is required because a trouble on the auto amplifier (control unit) power supply circuit or grounding circuit prevents accurate troubleshooting.

D08R200263

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

Possible cause

Correction Refer to Chart A

1A104 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Chart A: Check of Auto Amplifier Power Supply System

Step Action Value(s) Yes No

1 2 3

Is the fuse C16 normal? Is the fuse C20 normal? Disconnect the auto A/C control unit connector I32. Is the battery voltage applied between the harness side connector terminal No.I328 and the ground? Approx. 12V Go to Step 5 Go to Step 3 Go to Step 2

Replace the fuse Replace the fuse

Go to Step 4

Repair an open circuit between the fuse C16 and terminal No.I328. Is the action complete? Go to Step 4 Go to Step 7 Go to Step 6 Is there continuity between the harness side connector terminal No.I3216 and the ground? Repair an open circuit between terminal No.I3216 and the ground No.B2. Is the action complete? Go to Step 5 Turn the lighting switch on. Is the battery voltage applied between the harness side connector terminal No.I3210 and the ground? Approx. 12V Go to Step 9 Go to Step 8

5 6

Repair an open circuit between the lighting switch and terminal No.I3210. Is the action complete? Go to Step 7 Turn the starter switch on. Is the battery voltage applied between the harness side connector terminal No.I327 and the ground? Approx. 12V Go to Step 10

10

Repair an open circuit between the fuse C20 and terminal No.I327. Is the action complete? Verify repair

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A105

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

Performance Check Using the Manual Switch

No. Item Blowing temperature (check movement of air mix door) Checking Approach Condition Auto switch must be turned on(FANAUTOMODE AUTO) Operation 1. Select FC for the setup temperature. 2. Select FH for the setup temperature. Then, select the MAX Control. 1. Turn the fan knob off. 2. Turn the fan knob from LOW to HI. Push the mode switch to change the blow port mode sequentially from the VENT through BI-LEVEL, FOOT up to DEF. Turn the LED off using the interior/outside air switch (this introduces the outside air intake mode). Then, the set fan knob to HI and press the interior/outside switch to turn on the LED. Push the OFF switch. 1. Push the Auto switch. 2. Push the Air Conditioner switch. Acceptance criteria 1. Cold air shall be blown out. 2. Hot air shall be blown out.

Airflow volume(check movement of the mode door) Blowing temperature(chec k movement of the mode door)

Set temperature to 25C (77F).

1. The fan shall be stopped, thus stopping air blow, too. 2. Airflow volume shall change from LOW to HI. LED corresponding to each mode shall be turned on and the blow port mode shall be switched smoothly.

Set temperature to 25C (77F). Set the fan knob to HI.

The interior/outside air switching mode (check movement of intake door)

Set temperature to 25C (77F).

The LED indication shall be switched from OFF to ON accompanying a change in air blowing sound.

Compressor 5

Set the temperature to 18C (64.4F) (FC). (Outside air temperature is 0C (32F) or above and interior temperature at ordinary temperature.)

1. As the fan knob is set to the Auto position, the A/C switch LED shall come on and the compressor shall be turned on. 2. As the A/C LED comes off, the compressor shall be turned off.

1A106 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Check of Auto Function

No. Item Checking Approach Condition Operation Acceptance criteria The LED shall come on. Cold air shall be blown out. The following LEDs shall come on: Select FC for the temperature. D Blow port mode: D Intake mode D Fan speed: MAX Hi D A/C

The following phenomena shall be recognized.

1 Auto function FAN KNOB AUTO MODE SW AUTO Change the temperature gradually starting with 20C (68F) up to 30C (86F). D Temperature of blown air: Cold air is changed to hot air. D Change in the air flow volume. D The blow port mode LED indication changes in the following sequence:

Cold air shall be blown out. The following LEDs shall come on. Select FH for the temperature. D Blow port mode: D Fan speed: Max Hi.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A107

Troubleshooting With Self-Diagnosis Function

Overview of Self-Diagnosis Function
The self-diagnosis is implemented in 3 steps for each target. For detail of check procedure contained in each step, refer to the relevant section of Check Procedure by Failed Location listed in the SelfDiagnosis Operation Procedure. For turning on the self-diagnosis function and switching of the check step, refer to the flow chart given below. You can reset the selfdiagnosis function by turning the ignition switch off or turning the DEF switch on for 5 seconds.

Self-Diagnosis Operation Procedure

Step Action Value(s) Yes No

1. Set the IG to the OFF position. 2. Apply 60W bulb light to the sun sensor. 3. Set the temperature setting lever on the automatic heater/air conditioner panel to the center position 25C (77F). 4. Set the fan switch on the same panel to the Auto position. Is the action complete? Go to Step 2 While pushing both the Auto switch and the DEF switch on the automatic heater/air conditioner panel, start the engine. Is the current trouble diagnosing function turned on approximately in 10 seconds? Go to Step 3 Go to Step 4 Go to Step 5 Refer to *1. Refer to *2. Repair or replace the output equipment or repair the harness

3 4 5

Does the A/C LED flash every 0.5 second interval? Push the A/C switch once. Does the A/C LED flash every 0.5 second interval? Refer to *3 chart Check of Output Equipment. Does each output equipment function normally according to operation of the temperature setting level?

6 Push the DEF switch for 5 seconds consecutively or turn on and off the IG. Is the action complete?

Go to Step 6

Go to Step 1

1A108 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

*1Displaying the Current Trouble Diagnosing Table

Start the engine while holding down both the Auto switch and the DEF switch on the control panel, and the table will appear in approximately 10 seconds to the indicator lamp (LED) of the air conditioning switch. Result of the diagnosis along the following 9 items will be shown one by

one in 0.5 second interval irrespective of presence or absence of a trouble for a given item. When the display 9 items is completed, it is repeated with 3 seconds of interval in between. A failed item is indicated by flashing of the LED that is repeated 3 times within 0.5 seconds. If a trouble is indicated, you can locate the failed section by knowing when in the total sequence it has been displayed.

F01RX010

Item for Current Trouble Diagnosis

F01RY00008

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A109

As shown above, display of result along nine items is repeated with 3-second interval in between. Note 1: When checking the sun sensor, apply sufficient light using a 60W bulb. Otherwise, it can be diagnosed as failed. Note 2: If the temperature setting lever is set on both ends {one set to 18C (64.4F), blue scale = Full cool and the other to 31C (87.8F), red scale = Full hot}, they can be diagnosed as failed. Note 3: Likewise, the fan switch can be diagnosed as failed if set on both ends. past trouble diagnosis will appear on the indicator lamp (LED) of the air conditioning switch. Results of the diagnosis along the following five items are displayed one by one in 0.5 second interval irrespective of presence or absence of a trouble. A failed item is indicated by flashing of the LED that is repeated 3 times within 0.5 seconds. You can locate the failed section by counting in what sequence it has been displayed. Past trouble code can be cleared by disconnecting one of the following sources for at least thirty (30) seconds. NOTE: To prevent system damage, the ignition key must be OFF when disconnecting or reconnecting battery power. D The No.16 fuse (Room lamp, Clock) D The negative battery cable. (Disconnecting the negative battery cable will result in the loss of other on-board memory data, such as preset radio tuning).

*2Displaying the Past Trouble Diagnosing Table

The past trouble diagnosis displays only the items on which trouble has recurred 16 times in the past. If you press the air conditioning switch once while the current trouble diagnosis is taking place, display of the

F01RX011

F01RY00007

1A110 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

*3Check of Output Equipment

F01R200005

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A111

Inspection By Failed Location

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

F01RY00005

1A112 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Chart 1: In Car Sensor

D08R200264

Step

Action

Value(s)

Yes

No

Disconnect the in car sensor connector. (No.I-34) Is performance of the sensor normal? (Refer to the later section on Individual Inspection) Go to Step 2 Go to Step 4 Replace the in car sensor Go to Step 3

2 3

Is there continuity between the harness side connector No.I331 and No.I343? Repair an open circuit between terminal No.I331 and No.I343. Is the action complete?

Go to Step 2 Go to Step 6

Go to Step 5

4 5

Is there continuity between the harness side connector No.I3311 and No.I344? Repair an open circuit between terminal No.I3311 and No.I344. Is the action complete?

Go to Step 4 Verify repair

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

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A113

Chart 2: Ambient Sensor

D08R200265

Step

Action

Value(s)

Yes

No

Disconnect ambient sensor connector. (No.C86) Is performance of the ambient sensor normal? (Refer to the later section on Individual inspection) Go to Step 2

Replace the ambient sensor

Connect the ambient sensor connector.

Refer to the later section Is resistance between the harness side connector on Individual No.I332 and No.I3311 normal? inspection Repair an open circuit between terminal No.I332 and No.C861 or No.I3311 and No.C862. Is the action complete?

Go to Step 4

Go to Step 3

Verify repair Verify repair

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

1A114 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Chart 3: Sun Sensor

D08R200266

Step

Action

Value(s)

Yes

No

Disconnect the sun sensor connector. (No.I35) Is performance of the sun sensor normal? (Refer to the later section on individual inspection) Go to Step 2 Go to Step 4 Replace the sun sensor. Go to Step 3

2 3

Is there continuity between the harness side connector terminal No.I333 and No.I351? Repair an open circuit between terminal No.I333 and No.I351. Is the action complete?

Go to Step 2 Go to Step 6

Go to Step 5

4 5

Is there continuity between the harness side connector terminal No.I3311 and No.I352? Repair an open circuit between terminal No.I3311 and I352. Is the action complete?

Go to Step 4 Verify repair

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

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A115

Inspection of the Intake Actuator System

D08R200267

1A116 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Condition Does not work at all Control failure

Possible cause

Correction Refer to Chart A Refer to Chart B

Chart A: Does Not Work At All

Step Action Value(s) Yes No

1 2 3 4

Is the fuse FL1 normal? Is the fuse C20 normal? Is the relay B36 normal? Turn on the ignition switch. (the engine is run.) Is the battery voltage applied between the harness side connector terminal No.I493 and ground? Approx 12V Go to Step 6 Go to Step 4 Go to Step 3 Go to Step 2

Replace the fuse Replace the fuse Replace the relay

Go to Step 5

Repair an open circuit between terminal No.I493 and No.B364. Is the action complete? Approx 12V Go to Step 4 Go to Step 8 Go to Step 6 Go to Step 10 Verify repair Verify repair Go to Step 7 Go to Step 9 Is the battery voltage applied between the harness side connector terminal No.I494 and ground? Replace the intake actuator motor. Is the action complete? Is there continuity between the harness side connector terminal No.I3211 and No.I494? Repair an open circuit between No.I3211 and I494. Is the action complete? Replace the auto air conditioner control unit. Is the action complete?

6 7 8 9 10

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A117

Chart B: Failure on the Intake Control

Step Action Value(s) Yes No

1 2 3 4 5 6

Is the fuse No.C20 normal? Is the relay No.B36 normal? Turn on the ignition switch. (the engine is run.) Is the intake actuator stopped? Replace or repair the auto air conditioner control unit. Is the action complete? Is there continuity between the harness side connector terminal No.I495 and No.I3311? Repair an open circuit between terminal No.I495 and No.I3311. Is the action complete? Go to Step 5 Go to Step 9 Verify repair Go to Step 7 Go to Step 5 Go to Step 3 Go to Step 2

Replace the fuse Replace the relay Go to Step 4 Go to Step 6

Go to Step 8

7 8

Is there continuity between the harness side connector terminal No.I496 and No.I3312? Repair an open circuit between terminal No.I496 and No.I3312. Is the action complete?

Go to Step 7 Go to Step 11

Go to Step 10

9 10

Is there continuity between the harness side connector terminal No.I491 and No.I3313? Repair an open circuit between terminal No.I491 and I33-13. Is the action complete?

Go to Step 9 Go to Step 13

Go to Step 12

11 12

Is there continuity between the harness side connector terminal No.I492 and No.I3314? Repair an open circuit between harness No.I492 and No.I3314. Is the action complete?

Go to Step 11

13

1. Disconnect the intake actuator connector No.I49. 2. Is the battery voltage applied between harness side connector terminal No.I496 and ground? No.I492 and ground? No.I491 and ground? Replace or repair the intake actuator. Is the action complete?

Go to Step 14 Verify repair Verify repair

Go to Step 15

14 15

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

1A118 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Inspection of the Mix Actuator System

D08R200268

Condition Does not work at all Control failure

Possible cause

Correction Refer to Chart A Refer to Chart B

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A119

Chart A: Does Not work At All

Step Action Value(s) Yes No

1. Turn on the ignition switch (the engine is run). 2. Disconnect the mix actuator connector (I45). 3. Short-circuit the chassis harness side connector terminal No.I453 and No.I457. 4. Using the temperature control lever, select FH for the temperature. Is the battery voltage applied on a regular interval basis between the harness side connector terminal No.I456 (-) and No.I458 (+)?

Go to Step 3 Varify repair

Go to Step 2

2 3

Replace the auto air conditioner control unit. Using the temperature control lever, select FC for the temperature. Is the battery voltage applied on a regular interval basis between the harness side connector terminal No.I456 (+) and No.I458 (-)?

Go to Step 5 Verify repair Go to Step 7

Go to Step 4 Go to Step 6

4 5 6

Replace the auto air conditioner control unit. Is there continuity between the harness side connector terminal No.I326 and No.I456? Repair an open circuit between terminal No.I326 and No.I456. Is the action complete? Go to Step 5 Go to Step 9 Go to Step 8 Is there continuity between the harness side connector terminal No.I325 and No.I458? Repair an open circuit between terminal No.I325 and No.I458. Is the action complete? Verify repair Verify repair Replace the mix actuator. Is the action complete?

7 8

1A120 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Chart B: Mix Actuator Control Failure

Step Action Value(s) Yes No

Turn the ignition switch (the engine is run). Dose the mix actuator fully stroke when FH and FC of the temperature control lever? Go to Step 3 Varify repair Go to Step 5 Go to Step 2 Go to Step 4

2 3 4

Repair or replace the air mix door or the link unit. Is the action complete? Is there continuity between the harness side connector terminal No.I453 and No.I3311? Repair an open circuit between terminal No.I453 and No.I3311. Is the action complete? Go to Step 3 Go to Step 7 Go to Step 6 Is there continuity between harness side connector terminal No.I457 and No.I335? Repair an open circuit between terminal No.I457 and No.I335. Is the action complete? Go to Step 5 Is there continuity between the harness side connector terminal No.I452 and No.I3315? Go to Step 9 Go to Step 8 Repair an open circuit between terminal No.I452 and No.I3315. Is the action complete? Go to Step 7 Is sum of the voltage between the following chassis harness side connector terminals approximately 5V? No.I3315 and No.I335, No.I335 and No.I3311 Replace the actuator. Is the action complete? Verify repair Verify repair Replace the auto air conditioner control unit. Is the action complete?

5 6

Go to Step 11

Go to Step 10

10 11

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A121

Inspection of the Mode Actuator System

D08R200269

Condition Does not work at all Control failure

Possible cause

Correction Refer to Chart A Refer to Chart B

1A122 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Chart A: Does Not Work At All

Step Action Value(s) Yes No

1. Turn on the ignition switch (the engine is run). 2. Disconnect the mode actuator connector (B69) 3. Select VENT pressing the mode actuator. Is the battery voltage provided on a regular interval between the harness side connector terminal No.B691 (+) and No.B695 (-)?

Go to Step 3 Varify repair

Go to Step 2

2 3

Replace the auto air conditioner control unit. Is the action complete? Turn on the DEF mode switch. Is the battery voltage provided on a regular interval between the chassis side connector terminal No.B695 (+) and No.B691 (-)?

Go to Step 5 Varify repair Go to Step 7

Go to Step 4 Go to Step 6

4 5 6

Replace the auto air conditioner control unit. Is there continuity between the harness side connector terminal No.B691 and No.I324? Repair an open circuit between terminal No.B691 and No.I324. Is the action complete? Go to Step 5 Go to Step 9 Go to Step 8 Is there continuity between the harness side connector terminal No.B695 and No.I323? Repair an open circuit between terminal No.B695 and No.I323. Is the action complete? Verify repair Verify repair Replace the mode actuator.

7 8

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A123

Chart B: Mode Actuator Control Failure

Step Action Value(s) Yes No

Turn on the ignition switch (the engine is run). Dose the mode actuator fully stroke when the defrost mode and the vent mode are selected? Go to Step 3 Go to Step 1 Go to Step 5 Go to Step 2 Go to Step 4

2 3 4

Repair or replace the mode door or the link unit. Is the action complete? Is there continuity between the harness side connector terminal No.B699 and No.I3311? Repair an open circuit between terminal No.B699 and No.I3311. Is the action complete? Go to Step 3 Go to Step 7 Go to Step 6 Is there continuity between the harness side connector terminal No.B693 and No.I3310? Repair an open circuit between terminal No.B693 and No.I3310. Is the action complete? Go to Step 5 Go to Step 9 Go to Step 8 Is there continuity between harness side connector terminal No.B694 and No.I338? Repair an open circuit between terminal No.B694 and No.I338. Is the action complete? Go to Step 7 Is sum of the voltage between the following harness side connector terminal approximately 5V? Voltage between No.I338 and No.I3310 plus voltage between No.I338 and No.I3311 Replace the actuator. Is the action complete? Verify repair Go to Step 13 Verify repair Verify repair Go to Step 12 Dose the mode actuator work normally through manual operation? Replace the sensor. Is the action complete? Replace the auto air conditioner control unit. Is the action complete?

5 6

7 8

5V

Go to Step 11

Go to Step 10

10 11 12 13

1A124 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Inspection of the Fan Motor System

D08R200270

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A125

Condition The fan dose not rotate at all The fan dose not stop

Possible cause

Correction Refer to Chart A Refer to Chart B

Chart A: Fan Does Not Rotate At All

Step Action Value(s) Yes No

1 2 3

Are the fuse No.C19 normal? Are the relay No.B36 normal? Turn on the ignition switch (the engine is run). Is the battery voltage applied between the harness side connector terminal No.B51 and ground? Go to Step 5 Go to Step 3 Go to Step 2

Replace the fuse Replace the relay

Go to Step 4

Repair an open circuit between terminal No.B51 and No.C19 fuse. Is the action complete? Go to Step 3 Go to Step 7 Go to Step 6 Is there continuity between the harness side connector terminal No.B52 and ground (No.B2)? Repair an open circuit between terminal No.B52 and ground. Is the action complete? Go to Step 8 Verify repair Verify repair Go to Step 9 Is the battery voltage applied between the harness side connector terminal No.B52 and No.B51? Replace the blower motor. Is the action complete? Refer to chart B and C. Is the action complete?

5 6

7 8 9

Chart B: Fan Does Not Stop

Step Action Value(s) Yes No

1. Disconnect the power transistor connector I50 and the auto A/C control unit connector I33. 2. Turn on the ignition switch. Does the blower motor stop? Go to Step 3 Go to Step 2 Repair a short circuit between connector, No.B52 and No.I501, or No.B52 and I3317. Is the action complete? Verify repair Replace the power transistor Is the power transistor normal? (Refer to the later section on individual inspection.) Go to Step 4 Replace the auto A/C control unit Reinstall the power transistor. Does the blower motor start operating?

1A126 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Inspection of the Magnetic Clutch System

6VE1 Engine

D08R200272

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A127

Condition Magnetic clutch does not work Possible cause Correction Refer to Chart A

Chart A: Magnetic Clutch Does Not work

Step Action Value(s) Yes No

1 2 3

Is the fuse No.C20 normal? Is the relay No.X7 (compressor relay) No.X5 (A/C thermo relay) and No.B36 (heater relay) normal? Is the pressure switch normal? Go to Step 4 Go to Step 2 Go to Step 3

Replace the fuse Replace the relay Replace the pressure switch

1. Turn the ignition switch on. (the engine is run.) 2. Turn the fun switch and the air conditioner switch on. Is the battery voltage applied between the harness side connector terminal No.E31 and the ground? Go to Step 5 Verify repair Go to Step 8 Go to Step 6 Go to Step 7

5 6 7

Repair or replace the magnetic clutch. Is the action complete? Is there continuity between the harness side connector terminal No.X74 and No.E31? Repair an open circuit between terminal No.X74 and No.E31. Is the action complete? Go to Step 6 Is the battery voltage applied between the harness side connector terminal No.X72 and ground, No.X71 and ground? Repair an open circuit between terminal No.X72 and fuse No.C20, No.X71 and fuse No.C20. Is the action complete? Go to Step 8 Go to Step 12 Go to Step 11 Is the battery voltage applied between the harness side connector terminal No.I3318 and ground? Repair an open circuit between terminal No.I3318 and No.X73. Is the action complete? Go to Step 10 Go to Step 14 Go to Step 13 Is the battery voltage applied between the harness side connector terminal No.C892 and ground? Repair an open circuit between terminal No.C892 and fuse No.C20. Is the action complete? Go to Step 12 Is the battery voltage applied between the harness side connector terminal No.X53 and ground, No.X52 and ground? Repair an open circuit between terminal No.X53 and No.C891, No.X52 and fuse No.C20. Is the action complete? Go to Step 14 Go to Step 18 Go to Step 17 Is the battery voltage applied between the harness side connector terminal No.I3214 and ground?

Go to Step 10

Go to Step 9

10 11

12 13

14

Go to Step 16

Go to Step 15

15

16

1A128 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Chart A: Magnetic Clutch Does Not work (Contd)

Step Action Value(s) Yes No

17

Repair an open circuit between terminal No.X51 and I3214. Is the action complete? Go to Step 16 Go to Step 20 Go to Step 19 Is there continuity between the harness side connector terminal No.I334 and PCM (S47)? Repair an open circuit between terminal No.I334 and PCM (S47). Is the action complete? Go to Step 18 Go to Step 22 Go to Step 21 Is there continuity between the harness side connector terminal No.X51 and No.I3214? Repair an open circuit between terminal No.X51 and No.I3214. Is the action complete? Go to Step 20 Go to Step 24 Go to Step 23 Is there continuity between the harness side connector terminal No.X54 and PCM (F45)? Repair an open circuit between terminal No.X54 and PCM (F45). Is the action complete? Go to Step 22 Go to Step 26 Go to Step 25 Is there continuity between the harness side connector terminal No.X73 and PCM (F4)? Repair an open circuit between terminal No.X73 and PCM (F4). Is the action complete? Go to Step 24 1. Disconnect the auto A/C control unit connectors and connect the PCM connectors. 2. Ground the auto A/C control unit connector terminal No.I3214. Does the magnetic clutch work? Go to Step 28 Verify repair Verify repair Go to Step 27 Replace the PCM. Is the action complete? Replace the auto A/C control unit. Is the action complete?

18 19

20 21

22 23

24 25

26

27 28

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

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A129

Condenser Fan Diagnosis

While the air conditioning is ON, the cycling switch in the triple pressure switch senses the refrigerant pressure, and activates the condenser fan to improve the cooling

capacity of the condenser when the refrigerant pressure exceeds a set pressure value. The condenser fan stops when the air conditioning is turned OFF or when the pressure goes down below the set pressure value.

D08R200271

Condition Condenser fan does not run.

Possible cause

Correction Refer to Chart A Refer to Chart B

1A130 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Chart A Condenser Fan Does Not Run

Step Action Value(s) Yes No

1 2 3

Are 30A fuse normal? Is relay (X-19) normal? Is pressure switch normal?

Go to Step 2 Go to Step 3

Replace Replace Switch defective or insufficient refrigerant. Replace Repair open circuit between Condenser Fan fuse (30A) and No.X19-1. Repair open circuit between fuse (10A) and C89-3.

4 5 Is fan motor normal? 1. Disconnect condenser fan relay (X-19). 2. Check to see if battery voltage is present at the chassis side relay terminal NO. X19-1. Is there a battery voltage? 6 1. Reconnect condenser fan relay (X-19). 2. Check to see if battery voltage is present at chassis side connector terminal No.C89-3. Is there a battery voltage? 7 Check to see if continuity between chassis side relay terminal No.X19-4 and the chassis side connector terminal No.C89-4. Is there a continuity? 8 Check to see if continuity between chassis side connector terminal No. C75-1 and chassis side relay terminal No.X19-3. Is there a continuity?

Go to Step 4 Go to Step 5

Go to Step 6

Go to Step 7

Go to Step 8 Poor ground or open circuit between chassis side connector terminal No.X19-5 (or No.C75-2) and body ground (No.C39).

Repair open circuit.

Repair open circuit.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A131

Chart B Condenser Fan Does Not Stop

Step Action Value(s) Yes No

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

Replace the triple pressure switch.

Replace the condenser fan relay.

1A132 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Individual Inspection
In Car Sensor
1. Disconnect the in car sensor connector (I34). 2. Measure resistance between the in car sensor side terminal No.I343 and No.I344.

Sun Sensor
1. Disconnect the sun sensor connector (I35). 2. Measure the current value on the sun sensor when placed it approximately 15 cm away from 60W incandescent lamp.

D06R200101

Ambient Sensor
1. Disconnect the connector (C86) on the ambient sensor. 2. Measure resistance between the ambient sensor side terminals.

C01R200018

C01R200014

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A133

Power Transistor
1. Remove the power transistor connector (I50) from the evaporator assembly. 2. Check the conduction between the power transistor side terminals.

In Car Sensor
1. Dismount the in car sensor from the automatic heater/air conditioner control unit. Connect (+) end and () end of the battery to the aspirator motor side terminals No.I341 and No.I342, respectively, then check if the motor runs normally.

C01R200017

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

C01RY00005

1A134 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Heater (B36), Thermostat (X5), And Compressor (X7) Relay

1. Disconnect relays and check for continuity and resistance between relay terminals. D For handling of these relays, refer to Heater Relay in this section.

901RY00041

Triple Pressure Switch (V6, A/T)

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

875R200031

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A135

On-Vehicle Service
Power Transistor Automatic Heater/Air Control Unit Conditioner

874RY00010

Legend (1) Evaporator Assembly (2) Power Transistor (3) Power Transistor Connector (4) Instrument Panel Passenger Lower Cover (5) Glove Box (6) Front Console (7) Lower Cluster (8) Passenger Knee Bolster Reinforcement

865RY00012

Legend (1) Connector (2) Set Screw (3) Instrument Panel Cluster (4) Automatic Air Conditioner Control Unit

Removal
1. Disconnect the battery ground cable. 2. Remove instrument panel cluster. D Refer to Instrument Panel Assembly in Body Stractur section. 3. Disconnnect the automatic heater/air conditioner control unit connector. 4. Remove automatic heater/air conditioner control unit.

Removal
1. Remove front console. 2. Remove lower cluster. 3. Remove glove box. 4. Remove instrument panel passenger lower cover. 5. Remove passenger knee bolster reinforcement. 6. Disconnect the power transistor connector. 7. Remove power transistor.

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

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

1A136 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

In Car Sensor

Ambient Sensor

865RY00020

875R200030

Legend (1) In Car Sensor (2) Automatic Air Conditioner Control Unit

Legend (1) Ambient Sensor (2) Sensor Connector (3) Radiator Grille

Removal
1. Disconnect the battery ground cable. 2. Remove the automatic air conditioner control unit. D Refer to the automatic air conditioner control unit section. 3. Remove in car sensor.

Removal
1. Disconnect the battery ground cable. 2. Remove radiator grille. D Refer to Radiator Grille in Body Structure section. 3. Disconnect the ambient sensor connector. 4. Remove the ambient sensor.

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

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

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A137

Sun Sensor

Duct Sensor

826RY00012

Legend (1) Sun Sensor

Removal
1. Disconnect the battery ground cable. 2. Remove the sun sensor. 3. Disconnect the sun sensor connector.
874R200019

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

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

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

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

1A138 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Mode Actuator

Mix Actuator

860R200009

860RY00009

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

Legend (1) Instrument Panel Assembly (2) Actuator Rod (3) Mix Actuator (4) Instrument Panel Center Bracket

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

Removal
1. Disconnect the battery ground cable. 2. Remove the instrument panel assembly. D Refer to the Instrument Panel Assembly in Body and Accessories section. 3. Remove the instrument panel center bracket. 4. Remove the actuator rod. 5. Remove the mix actuator.

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

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

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A139

Intake Actuator

873RY00004

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

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

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

SECTION
POWER ASSISTED SYSTEM
TROOPER

2A1

STEERING
POWER ASSISTED SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Steering System Test . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bleeding The Power Steering System . . . . . . Bleeding Procedure . . . . . . . . . . . . . . . . . . . . . Flushing The Power Steering System . . . . . . Steering Wheel Free Play Adjustment . . . . . . Front End Alignment Inspection and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Steering Gear . . . . . . . . . . . . . . . . . . . . Power Steering Gear and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Gear Disassembled View . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . Power Steering Pump . . . . . . . . . . . . . . . . . . . . Power Steering Pump and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Steering Pump Disassembled View Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1Main Data and Specifications . . . . . . . . . . Center Track Rod Assembly . . . . . . . . . . . . . . Center Track Rod Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outer Track Rod Assembly . . . . . . . . . . . . . . . Outer Track Rod Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A2 2A2 2A5 2A11 2A12 2A12 2A12 2A12 2A12 2A13 2A13 2A18 2A19 2A20 2A20 2A20 2A21 2A22 2A23 2A24 2A25 2A27 2A28 2A28 2A28 2A29 2A30 2A30 2A31 2A32 2A33 2A34 2A34 2A35 2A35 2A35 2A36 2A36 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relay Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relay Lever and Associated Parts . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Linkage and Associated Parts . . . . Main Data and Specifications . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . Supplemental Restraint System Steering Wheel & Column . . . . . . . . . . . . . . . . . . . . . . . Service Precaution . . . . . . . . . . . . . . . . . . . . SRS Connectors . . . . . . . . . . . . . . . . . . . . . . Inflator Module . . . . . . . . . . . . . . . . . . . . . . . . . . Inflator Module and Associated Parts . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . Steering Wheel and Associated Parts . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Combination Switch . . . . . . . . . . . . . . . . . . . . . Combination Switch and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . Lock Cylinder and Associated Parts . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Inspection . . . . . . . . . . . . . . . . . . . . . Steering Column . . . . . . . . . . . . . . . . . . . . . . . . Steering Column and Associated Parts . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Inspection . . . . . . . . . . . . . . . . . . . . . Supplemental Restraint System Steering Wheel & Column and Associated Parts . . . . Main Data and Specifications . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 2A37 2A37 2A38 2A39 2A39 2A39 2A40 2A41 2A41 2A42 2A43 2A43 2A43 2A45 2A45 2A45 2A46 2A46 2A47 2A47 2A47 2A49 2A50 2A50 2A50 2A52 2A54 2A54 2A54 2A56 2A57 2A58 2A58 2A58 2A60 2A62 2A63 2A64 2A64 2A65

2A2

POWER ASSISTED SYSTEM

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

Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.

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

Power Steering Gear

A03RS001

The power steering gear has a recirculating ball system which acts as a rolling thread between the worm shaft and the rack piston. When the worm shaft is turned right, the rack piston moves up in gear. Turning the worm shaft left moves the rack piston down in gear. The rack piston teeth mesh with the sector gear, which is part of the sector shaft. Turning the worm shaft turns the sector shaft, which turns the wheels through the steering linkage.

The control valve in the steering gear directs the power steering fluid to either side of the rack piston. The rack piston converts the hydraulic pressure into a mechanical force. If the steering system becomes damaged and loses hydraulic pressure, the vehicle can be controlled manually.

POWER ASSISTED SYSTEM

2A3

Hydraulic Pump

442RV006

The hydraulic pump is a vane-type design. There are two openings at the rear of the pump housing. The larger opening contains the cam ring, pressure plate, thrust plate, rotor and vane assembly, and end plate. The smaller opening contains the pressure line union, flow control valve and spring.

Pressure Switch
When hydraulic pressure reaches 3650 350 kPa (530 50 psi), the pressure switch of the power steering pump closes causing the Powertrain Control Module (PCM) to actuate the throttle valve, which increases the engine rpm to prevent the overload-induced engine speed slow down. The switch opens when hydraulic pressure drops to 3150 350 kPa (460 50 psi).

2A4

POWER ASSISTED SYSTEM

Steering Linkage

433RS007

Legend (1) Center Track Rod Assembly (2) Outer Track Rod Assembly (3) Pitman Arm

(4) (5) (6) (7)

Relay Lever Rod End,Outer Track Rod Rod End,Inner

The steering linkage consists of a pitman arm, relay lever, center track rod, and two adjustable outer track rods. When the steering wheel is turned, the gear rotates the pitman arm which forces the center track rod to one side. The outer track rods, connected to the center track rod by ball studs, transfers the steering force to the wheels. The outer track rods are adjustable and are used for toe-in adjustments. The center track rod is supported by the pitman arm and relay lever. The relay lever pivots on a support attached to the frame. The overall condition of the steering linkage affects steering performance. If parts are bent, damaged, worn or poorly lubricated, improper and possibly dangerous steering action will result. Whenever any steering linkage components are repaired or replaced, check the steering geometry and front end alignment. Refer to Front End Alignment Inspection and Adjustment in this section.

POWER ASSISTED SYSTEM

2A5

Steering Column
WARNING: TO AVOID DEPLOYMENT WHEN TROUBLE-SHOOTING THE SRS SYSTEM, DO NOT USE ELECTRICAL TEST EQUIPMENT, SUCH AS BATTERY-POWERED OR A/C-POWERED VOLT-METER, OHMMETER, ETC., OR ANY TYPE OF ELECTRICAL EQUIPMENT OTHER THAN SPECIFIED IN THIS MANUAL. DO NOT USE A NON-POWERED PROBE-TYPE TESTER. INSTRUCTION IN THIS MANUAL MUST BE FOLLOWED CAREFULLY, OTHERWISE PERSONAL INJURY MAY RESULT. When servicing a vehicle equipped with Supplemental Restraint System, pay close attention to all WARNINGS and CAUTIONS. For detailed explanation about SRS, refer to Restraints section. The steering column has three important features in addition to the steering function: 1. The column is energy absorbing, designed to compress in a front-end collision to minimize the possibility of injury to the driver of the vehicle. 2. The ignition switch and lock are mounted conveniently on the column.

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

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

General Diagnosis
Condition Vehicle Pulls Possible cause Mismatched or uneven tires. Tires not adequately inflated. Broken or sagging springs. Radial tire lateral force. Improper wheel alignment. Brake dragging in one wheel. Loose, bent or broken front or rear suspension parts. Faulty shock absorbers. Abnormal or Excessive Tire Wear Sagging or broken spring. Tire out of balance. Improper wheel alignment. Faulty shock absorber. Hard driving. Overloaded vehicle. Tires not rotated periodically. Worn or loose road wheel bearings. Wobbly wheel or tires. Tires not adequately inflated. Wheel Hop Blister or bump on tire. Improper shock absorber operation. Correction Replace tire. Adjust tire pressure. Replace spring. Replace tire. Adjust wheel alignment. Repair brake. Tighten or replace the appropriate suspension part(s). Replace shock absorber. Replace spring. Balance or replace tire. Check front end alignment. Replace shock absorber. Replace tire. Replace tire and reduce load. Replace or rotate tire. Replace wheel bearing. Replace wheel or tire. Adjust the pressure. Replace tire. Replace shock absorber.

2A6

POWER ASSISTED SYSTEM

Condition Possible cause Tire or wheel out of balance. Loose wheel bearings. Worn steering linkage ball joints. Worn upper or lower ball joints. Excessive wheel runout. Blister or bump on tire. Excessive loaded radial runout of tire/wheel assembly. Improper wheel alignment. Loose or worn steering linkage. Loose steering gear. Tires not adequately inflated. Loose, bent or broken front or rear suspension parts. Faulty shock absorber. Hub bearing preload misadjustment. Correction Balance wheels or replace tire/or wheel. Replace wheel bearing. Replace ball joints. Replace ball joints Repair or replace wheel and/or tire. Replace tire. Replace tire or wheel. Check wheel alignment. Tighten or replace steering linkage. Tighten housing bolts. Adjust tire pressure. Tighten or replace the appropriate suspension parts. Replace shock absorber. Adjust preload. Replace ball joint. Check wheel alignment. Check and adjust pinion torque. Inflate tires to proper pressure. Repair or replace. Repair or replace. Refer to Power steering system diagnosis Replace wheel bearings. Retighten or repair. Inspect and adjust steering gear preload. shaft Retighten or replace steering shaft. Replace ball joints. Replace ball joints. Replace ball joints. Replace ball joints. Repair or replace. Check and repair steering gear. Adjust wheel alignment. Adjust tire pressure. Retighten. Replace.

Shimmy, Shake or Vibration

Hard Steering

Bind in steering linkage ball studs, upper or lower ball joint. Improper wheel alignment. Steering gear misadjustment. Tire not adequately inflated. Bind in steering column or shaft. Improper power steering system operation.

Too Much Play In Steering

Wheel bearings worn. Loose steering gear or linkage. Steering gear misadjustment. Worn or loose universal joint. steering

Worn steering linkage ball joints. Worn upper or lower ball joints. Poor Steering Wheel Returnability Bind in steering linkage ball joints. Bind in upper or lower ball joints. Bind in steering column and shaft. Bind in steering gear. Improper wheel alignment. Tires not adequately inflated. Loose steering wheel nut. Worn wheel bearing.

POWER ASSISTED SYSTEM

Condition Abnormal Noise Possible cause Worn, sticky or loose upper or lower ball joint, steering linkage ball joints or drive axle joints. Faulty shock absorbers. Worn upper or lower control arm bushing. Loose stabilizer bar. Loose wheel nuts. Replace. Correction

2A7

Replace. Replace. Retighten bolts or replace bushings. Tighten nuts. Check for elongated wheel nut holes. Replace wheel if required.

Loose suspension bolts or nuts. Broken or otherwise damaged wheel bearings. Broken suspension springs. Loose steering gear. Faulty steering gear. Wandering or Poor Steering Stability Mismatched or unevenly worn tires. Loose steering linkage ball joints. Faulty shock absorbers. Loose stabilizer bar. Broken or sagging springs. Steering gear misadjustment. Improper wheel alignment. Erratic Steering When Braking Worn wheel bearings. Broken or sagging springs. Leaking caliper. Warped discs. Badly worn brake pads. Tires are inflated unequally.

Retighten suspension bolts or nuts. Replace wheel bearing. Replace spring. Retighten mounting bolt. Check and adjust steering gear. Replace tire or inflate tires to proper pressure. Replace ball joints. Replace shock absorber. Tighten or replace stabilizer bar or bushings. Replace spring (pairs). Check or adjust steering gear. Adjust wheel alignment. Replace wheel bearings. Replace spring (pairs). Repair or replace caliper. Replace brake disc. Replace brake pads. Inflate tires to proper pressure.

2A8

POWER ASSISTED SYSTEM

between this noise and steering performance. Do not replace the valve unless the hissing noise is extremely objectionable. A replacement valve will also have a slight noise, and is not always a cure for the condition. Correction Adjust hose position. Do not bend tubing by hand. Tighten or replace tie rod end. Tighten steering gear mounting. Check and adjust steering gear preload. Adjust front wheel alignment. Replace front wheel bearing. Replace tie rod end. Replace ball joint. steering shaft Replace steering assembly. Adjust the steering gear. Repair or replace steering gear valve. Bleed the system. Repair steering gear. Replenish fluid. Repair pump assembly. Repair or replace steering gear. Replenish fluid. Bleed hydraulic system. Tighten tie rod end. Replace wheel bearing. Repair or replace steering gear valve. Repair pump assembly. Repair pump assembly. Repair steering gear. Replenish fluid. Repair or replace.

Power Steering System

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

Possible cause Pressure hose touching other parts of vehicle. Tie rod ends loose. Loose steering gear mounting. Steering gear misadjustment.

Poor Return of Steering Wheel to Center

Improper front wheel alignment. Wheel bearing worn. Tie rod end binding. Ball joint binding. Tight or bearing. frozen

Steering gear misadjustment. Sticky or plugged steering gear valve. Entry of air in the power steering system. Momentary Increase In Effort When Turning Wheel Fast To Right or Left Steering Wheel Surges or Jerks When Turning Especially During Parking Excessive Wheel Kick Back or Loose Steering High internal leakage. Power steering fluid level low. Insufficient pump pressure. Sticky steering gear valve. Power steering fluid level low. Air in system. Tie rod end loose. Wheel bearing worn. Hard Steering or Lack of Power Assist Sticky steering gear valve. Insufficient pump pressure. Excessive internal pump leakage. Excessive internal steering gear leakage. Power steering fluid level low. Unstable Engine Idling or Stalling When Turning Pressure switch of the power steering pump or its harness is faulty.

POWER ASSISTED SYSTEM

2A9

Power Steering Pump

Foaming milky power steering fluid, low fluid level, and possible low pressure can be caused by air in the fluid, or loss of fluid due to internal pump leakage. Check for leak and correct. Bleed the system. Extremely cold temperatures will cause air bubbles in the system if the fluid level Condition Low Pressure Due to Steering Pump is low. If the fluid level is correct and the pump still foams, remove the pump from the vehicle and check the housing for cracks. If the housing is cracked, replace the pump housing. Correction Replace relief valve. Replace side plate. Replace cam ring. Replace side plate or rotor. Repair or replace vanes and rotor. Replace side plate. Repair internal leakage. Replace housing. Repair steering unit or pump. Replace side plate or rotor. Replace cam ring. Bleed hydraulic system. Replenish fluid. Tighten mounting bolt. Repair or replace vanes and rotor. Repair rotor and vane. Replace relief valve. Replace side plate and vanes.

Possible cause Relief valve sticking or inoperative. Side plate not flat against cam ring. Extreme wear of cam ring. Scored side plate or rotor. Vanes sticking in rotor slots. Cracked or broken side plate. High internal leakage.

Low Pressure Due to Steering Gear Growling Noise In Steering Pump

Scored housing bore. Excessive back pressure in hoses or steering unit caused by restriction. Scored side plate or rotor. Worn cam ring.

Groaning Noise In Steering Pump

Air in the fluid. Low fluid level. Pump mounting loose.

Rattling Noise In Steering Pump Swishing Noise In Steering Pump Whining Noise In Steering Pump

Vanes sticking in rotor slots. Vane improperly installed. Damaged relief valve. Scored side plate and vanes.

Steering Column Lock System

Condition Will Not Unlock Will Not Lock Possible cause Damaged lock cylinder. Damaged park lock cable. Lock spring broken or worn. Damaged lock cylinder. Ignition switch stuck. Park lock cable damaged. Key Cannot OFF-LOCK be Removed in Ignition switch is not set correctly. Damaged lock cylinder. Faulty shift lock mechanism. Correction Replace lock cylinder. Replace park lock cable. Replace lock cylinder. Replace lock cylinder. Repair or replace ignition switch. Replace park lock cable. Correct ignition switch. Replace lock cylinder. Repair or replace the shift lock mechanism.

Column
Condition Noise in Column Possible cause Universal joint loose. Shaft lock snap ring not seated. Correction Tighten joint. Place snap ring in proper position.

2A10

POWER ASSISTED SYSTEM

Turn Signal Switch

This diagnosis covers mechanical problems only. Refer to Turn Signal Switch in Electrical section for electrical diagnosis. Condition Turn Signal Will Not Stay In Turn Position Possible cause Foreign material or loose parts preventing movement of yoke. Broken or missing canceling spring. Turn Signal Will Not Cancel detent or Correction Repair or replace signal switch. Replace signal switch. Tighten mounting screws. Replace turn signal switch. Replace turn signal switch. Replace turn signal switch. Tighten arm screw. Replace turn signal switch. Replace turn signal switch. Repair turn signal switch. Tighten mounting screws. Replace turn signal switch. Replace turn signal switch. Replace turn signal switch. Repair or replace hazard switch. Refer to Electrical section. Replace flasher unit. Repair loose connector. Replace bulb. Repair bulb socket. Repair loose connector.

Loose switch mounting screws. Switch or anchor bosses broken. Broken, missing or out of position detent, return or canceling spring. Worn canceling cam.

Turn Signal Difficult To Operate

Turn signal switch arm loose. Broken or distorted yoke. Loose or misplaced springs. Foreign parts and/or material. Loose turn signal switch mounting screws.

Turn Signal Will Not Indicate Lane Change

Broken lane change pressure pad or spring hanger. Broken, missing or misplaced lane change spring. Base of wire damaged.

Hazard Switch Cannot Be Turned Off No Turn Signal Lights

Foreign material between hazard switch to turn signal switch body. Electrical failure in chassis harness. Inoperative turn signal flasher unit. Loose chassis harness connector.

Front or Rear Turn Signal Lights Not Flashing

Burned-out or damaged turn signal bulb. High resistance connection ground at bulb socket. Loose chassis harness connector. to

POWER ASSISTED SYSTEM

2A11

Power Steering System Test

Test Procedure

F02RX001

Legend (1) Bolt (M16 1.5) (2) Hose (Vehicle Side)

(3) To Power Steering Gear (4) To Power Steering Pump

Test of fluid pressure in the power steering system is performed to determine whether or not the oil pump and power steering unit are functioning normally. The power steering system test is the method used to identify and isolate hydraulic circuit difficulties. Prior to performing this test, the following inspections and corrections, if necessary, must be made. D Inspect pump reservoir for proper fluid level. D Inspect pump belt for proper tension. D Inspect pump driver pulley condition. 1. Place a container under the pump to catch the fluid when disconnecting or connecting the hoses. 2. With the engine NOT running,disconnect the pressure hose at the power steering pump and install power steering tester J-29877-A. The gauge must be between the shutoff valve and pump. Open the shutoff valve. 3. Check the fluid level. Fill the reservoir with power steering fluid, to the Full mark. Start the engine, then turn the steering wheel and momentarily hold it against a stop (right or left). Turn the engine off and check the connections at tester for leakage. 4. Bleed the system. Refer to Bleeding the Power Steering System in this section. 5. Start the engine and check the pump fluid level. Add power steering fluid if required. When the engine is at normal operating temperature, increase engine speed to 1500 rpm. CAUTION: Do not leave shutoff valve fully closed for more than 5 seconds, as the pump could become damaged internally.

6. Fully close the shutoff valve. Record the highest pressures. D If the pressure recorded is within 93009800 kPa (13501420 psi), the pump is functioning within its specifications. D If the pressure recorded is higher than 9800 kPa (1420 psi), the valve in the pump is defective. D If the pressure recorded is lower than 9300 kPa (1350 psi), the valve or the rotating group in the pump is defective. 7. If the pump pressures are within specifications, leave the valve open and turn (or have someone else turn) the steering wheel fully in both directions. Record the highest pressures and compare with the maximum pump pressure recorded in step 6. If this pressure cannot be built in either side of the power steering gear, the power steering gear is leaking internally and must be disassembled and repaired. 8. Shut the engine off, remove the testing gauge. 9. Reconnect the pressure hose, check the fluid level and make the needed repairs. 10. If the problem still exists, the steering and front suspension must be thoroughly examined.

2A12

POWER ASSISTED SYSTEM

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

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

Flushing The Power Steering System

1. Raise and support the front end of the vehicle off the ground until the wheels are free to turn. 2. Remove the fluid return line at the pump inlet connector and plug the connector port on the pump. Position the line toward a large container to catch the draining fluid. 3. While running the engine at idle, fill the reservoir with new power steering fluid. Turn the steering wheel in both directions. Do not contact or hold the steering wheel to the wheel stops. This will cause the pump to go to pressure relief mode, which may cause a sudden fluid overflow at the reservoir. 4. Install all the lines and hoses. Fill the system with new power steering fluid and bleed the system as described in Bleeding The Power Steering System. Operate the engine for about 15 minutes. Remove the pump return line at the pump inlet and plug the connection on the pump. While refilling the reservoir, check the draining fluid for contamination. If foreign material is still evident, replace all lines, disassemble and clean or replace the power steering system components. Do not re-use any drained power steering fluid.

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

Bleeding The Power Steering System

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

POWER ASSISTED SYSTEM

2A13

Steering Wheel Free Play Adjustment

Inspection

1. Align the front wheels properly in the straight ahead position. 2. Loosen the lock nut on the adjusting screw of the steering gear. 3. Turn the adjust screw clockwise to decrease free play or counter-clockwise to increase. 4. After check of specified free play, tighten the lock nut to specified torque. Torque: 41 Nm (30 lb ft)

Front End Alignment Inspection and Adjustment

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

430RS015

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

Adjustment

480RS004

Camber is the vertical tilting inward or outward of the front wheels. When the wheels tilt outward at the top, the camber is positive (+). When the wheels tilt inward at the top, the camber is negative (). The amount of tilt measured in degrees from the vertical is called the camber angle (1). If camber is extreme or unequal between the wheels, improper steering and excessive tire wear will result. Negative camber causes wear on the inside of the tire, while positive camber causes wear to the outside.
431RS001

2A14

POWER ASSISTED SYSTEM

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

Caster: This illustration is viewed from the side of the vehicle.

Inspection
Before making any adjustments affecting caster, camber or toe-in, the following front end inspection should be made. 1. Inspect the tires for proper inflation pressure. Refer to Main Data and Specifications in Wheel and Tire System section. 2. Make sure that the vehicle is unladen condition (With no passenger or loading). 3. Make sure that the spare tire is installed at the normal position. 4. Inspect the front wheel bearings for proper adjustment. Refer to Front Hub and Disc Overhaul in Suspension section. 5. Inspect the ball joints, tie rod ends and relay rods. If excessive looseness is noted, correct before adjusting. Refer to Steering Linkage in this section. 6. Inspect the wheels and tires for run-out. Refer to Wheel Replacement in Wheel and Tire System section. 7. Inspect the trim height. If not within specifications, the correction must be made before adjusting caster. 8. Inspect the steering gear for looseness at the frame. 9. Inspect the shock absorbers for leaks or any noticeable noise. Refer to Shock Absorber Replacement in Suspension section. 10. Inspect the control arms or stabilizer bar attachment for looseness. Refer to Suspension section. 11. Inspect the front end alignment using alignment equipment. Follow the manufacturer s instructions. 12. Park the vehicle must be on a level surface.

480RS005

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

480RS003

POWER ASSISTED SYSTEM

2A15

Trim Height Adjustment

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

Caster Adjustment
The caster angle can be adjusted by means of the caster shims(1) installed between the chassis frame(2) and fulcrum pins. Caster angle: 210 45 CAUTION: Left and right side must be equal within 30.

450RS003

450RS001

410RS001

1. Check and adjust the tire inflation pressures. 2. Park the vehicle on a level ground and move the front of the vehicle up and down several times to settle the suspension. 3. Make necessary adjustment with the adjusting bolt on the height control arms. Trim height: 129 mm (5.08 in)

450RS002

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

2A16

POWER ASSISTED SYSTEM

Camber Adjustment
The camber angle can be adjusted by means of the camber shims(2) installed in position between the chassis frame(1) and fulcrum pins Camber angle: 0 30 King pin inclination: 1230 30 CAUTION: Left and right side must be equal within 30.

450RS005

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

450RS004

Position of shims Front side When added Caster shim When removed Camber shim Rear side When removed When added When removed When added When added When removed

Camber angle Decreases Increases Unchanged Unchanged Decreases Increases

Caster angle Decreases Increases Decreases Increases Unchanged Unchanged

POWER ASSISTED SYSTEM

2A17

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

3. Adjust the inside wheel angle of each side with the stop bolts. NOTE: The maximum protruding length(1) of stop bolt(3) from the lock nut(2) should be 10 mm or less

433RS003

4. Similarly adjust the inside wheel angle of the other side with stop bolt.
433RS001

2. Tighten the lock nut to the specified torque. Torque: 118 Nm (87 lb ft)

Inside wheel: 34 (+0 to 2) Outside wheel: 32 NOTE: Maximum steering angles should be set after adjusting front wheel alignment. 5. If the stop between the lower link end and the knuckle comes ahead of the stop bolt, adjust the stop bolt so that inner stop bolt touches the drop arm (relay lever).

Maximum Steering Angle Adjustment

The maximum steering angle of the front wheels can be adjusted with the stop bolts under the frame side members.

433RS002

1. Position each front wheel on the turning radius gauge in a straight-ahead position. 2. Set the parking brake firmly.

433RS004

6. Tighten the lock nut to the specified torque. Torque: 23 Nm (17 lb ft)

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POWER ASSISTED SYSTEM

Main Data and Specifications

General Specification
Caster Camber King pin inclination Toe-in Max. steering angle inside outside 210 45 0 30 1230 30 0 2 mm (0 0.08 in) 34 (+0 to 2) 32

Torque Specification

E03RS001

POWER ASSISTED SYSTEM

2A19

Special Tools
ILLUSTRATION TOOL NO. TOOL NAME

J29877A Tester: Power steering

J39213 Adapter: Power steering tester

J29107 Remover: Pitman arm

J26508 Installer: Extension housing oil seal

2A20

POWER ASSISTED SYSTEM

Power Steering Gear

Power Steering Gear and Associated Parts

431RS002

Legend (1) Pipe (2) Universal Joint Bolt (3) Pitman Arm

(4) Nut (5) Gear Box Mounting Bolt and Nut (6) Gear Box

Removal
1. Remove the stone guard. 2. Remove the lower fan shroud. Refer to Radiator in Engine section. 3. Disconnect stabilizer bar at the stabilizer links. Loosen stabilizer bracket fixing nuts. 4. Remove pipe. 5. Remove nut. 6. Use Pitman arm remover J29107 to remove pitman arm.

433RS005

POWER ASSISTED SYSTEM

7. Make a setting mark(1) across the coupling flange and worm shaft to ensure reassembly of the parts in the original position, then remove universal joint bolt.

2A21

Installation
1. Align the setting marks(1) made at removal, then install gear box.

431RW004

8. Push the stabilizer bar aside and remove the gear box mounting bolts and nuts.

431RW004

2. Tighten gear box mounting bolt and nut to specified torque. Torque: 44 Nm (33 lb ft) 3. Tighten gear universal joint bolt to specified torque. Torque: 25 Nm (18 lb ft) 4. Align the notched tooth and install pitman arm.

431RS004

9. Remove gear box.

433RS006

5. Install nut and tighten Nut to specified torque. Torque: 216 Nm (159 lb ft) 6. Install Pipe and tighten to specified torque. Torque: 44 Nm (33 lb ft)

2A22

POWER ASSISTED SYSTEM

Steering Gear Disassembled View

440RS001

Legend (1) Dust Cover (2) Retaining Ring (3) Back Up Ring (4) Oil Seal (5) Ball-nut and Valve Housing Assembly (6) O-ring

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

Seal Ring O-ring Gear Box Sector Shaft Top Cover Assembly Lock Nut

POWER ASSISTED SYSTEM

2A23

Disassembly
CAUTION: Do not clamp the steering gear assembly in a vise by the power cylinder housing. 1. Remove dust cover. 2. Remove retaining ring. 3. Remove back up ring. 4. Remove oil seal. D Clean the faces of the extended stub shaft. D Plug the hose fitting on the inlet side. D Remove the oil seal by blowing compressed air through the hole in the outlet side.

D Holding the top cover stationary, turn the adjusting screw clockwise to raise and free to cover, then remove the cover with O-ring. 7. Bring the stub shaft into straight-ahead position. Do not force the sector shaft off the gear box with a hammer or other impact tools then remove sector shaft.

440RS004

8. Remove ball-nut and valve housing assembly.

440RS002

5. Remove lock nut. D Remove the adjusting screw lock nut and turn the adjusting screw counter-clockwise to remove the preload between the sector gear and the rack piston. 6. Remove the top cover bolts and the top cover assembly.

440RS005

D Always keep the ball nut and valve housing assembly in a horizontal position to prevent them from traveling to the end of the worm shaft and damaging the ball tubes. 9. Remove O-ring. 10. Remove seal ring. 11. Remove O-ring. 12. Remove gear box.

440RS003

2A24

POWER ASSISTED SYSTEM

D Check sector shaft outside diameter. Limit: 31.7 mm (1.25 in)

Inspection and Repair

Inspect the following parts for wear, damage or any other abnormal conditions. D Bearing D Ball-nut and valve housing D Sector shaft D Top cover D Gear box D Needle bearing D Dust seal D Seal ring D Gasket

Ball-nut Rotation

440RS007

Dust Seal and Seal Ring Setting

440RS006

Hold the ball nut and valve housing assembly vertically and see if the ball-nut lowers by turning smoothly. If the ball-nut does not lower smoothly, check the worm shaft for bending and foreign matter. NOTE: When testing the ball nut and valve housing assembly, do not let it travel all the way to the end of worm shaft, or damage to the ball tubes will result.
440RW001

D Note the dust seal (1) and the seal ring(2) installation direction. Always install a new part. D Apply a thin coat of power steering fluid to lip of each part.

POWER ASSISTED SYSTEM

2A25

Gasket Setting

5. Install ball-nut and valve housing assembly. D Always keep the ball screw and valve housing assembly in a horizontal position (avoid holding it vertically), or the rack piston will fall off onto the end of the worm, causing the rack piston to slip out of the worm shaft and ball to fall out.

440RW002

D Note the gasket(1) installation direction. D Apply a thin coat of power steering fluid to lip of each part.
440RS005

Reassembly
1. Install gear box. 2. Apply a thin coat of power steering fluid to the new O-ring(2) and be sure to discard used part, then install o-ring. 3. Apply a thin coat of power steering fluid to the new seal ring(1) and be sure to discard used part, then install seal ring. 4. Apply a thin coat of power steering fluid to the new O-ring and be sure to discard used part, then install o-ring.

D Be careful not to drop the O-ring into the valve housing. D Tighten the valve housing bolts to the specified torque. Torque: 47 Nm (35 lb ft) 6. Install sector shaft. D Tape the sector shaft serrations to protect the seal ring from damage. D Align the center tooth of ball nut with that of the sector shaft.

440RS010

440RS004

7. Install O-ring.

2A26

POWER ASSISTED SYSTEM

11. Install back up ring and position the chamfered face (outer circumference) towards the oil seal. 12. Install retaining ring and position the chamfered face (outer circumference) towards the oil seal. 13. Install dust cover.

8. Install top cover assembly and tighten the fixing bolts to specified torque. Torque: 47 Nm (35 lb ft) 9. Adjust the backlash between the worm gear and the ball nut.

440RS011

D With the worm gear rotating, set it to the straight ahead position. D Set the worm shaft preload to below 10kgcm with the sector shaft adjusting screw. D Measure the worm shaft preload with the worm gear turned 450 both to the right and to the left. The worm gear preload in these positions should be 0.40.6 Nm (46 kgcm) lower than in the straight ahead position. D Lock the sector shaft adjusting screw with the lock nut. Lock nut torque: 41 Nm (30 lb ft) 10. Apply a thin coat of power steering fluid to oil seal lip of each part, then use installer J26508 to install oil seal.

440RS012

POWER ASSISTED SYSTEM

2A27

Main Data and Specifications

General Specifications
Steering unit Type Gear ratio Integral, ball screw 16.3 : 1

Torque Specifications

E03RS003

2A28

POWER ASSISTED SYSTEM

Power Steering Pump

Power Steering Pump and Associated Parts

436R200001

Legend (1) Hose, Suction (2) Hose, Flexible (3) Bolt

(4) Belt (5) Pulley (6) Pump Assembly

Removal
1. Drain the engine coolant. 2. Place a drain pan below the pump. 3. Remove the air cleaner duct (1) and the radiator upper hose (2).

436RW004

POWER ASSISTED SYSTEM

4. Remove the drive belt. 5. Remove the pulley from the power steering pump. 6. Disconnect the suction hose. 7. Disconnect the flexible hose. 8. Remove the power steering pump fixing bolt. 9. Remove the pump assembly. CAUTION: When removing the prmp assembly, be careful not to damage the wiring harnessunder the pump housing.

2A29

Installation
1. Install the adjust plate and tighten the mounting bolts to the specified torque. Torque: 56 Nm (41 lb ft) 2. Install the pump assembly. Connect the harness under the pump housing. 3. Tighten the fixing bolt to the specified torque. Torque: 46 Nm (34 lb ft) 4. Connect the flexible hose, then tighten the eye bolt to specified torque. Torque: 54 Nm (40 lb ft) 5. Connect the suction hose. 6. Install the pulley onto the power steering pump and tighten the nut to the specified torque. Torque: 78 Nm (58 lb ft) 7. Install the air cleaner duct and the radiator upper hose. 8. Refill the engine coolant. 9. Fill and bleed the power steering system. Refer to Bleeding the Power Steering System in this section.

2A30

POWER ASSISTED SYSTEM

Power Steering Pump Disassembled View

442R200001

Legend (1) Bolt (2) Suction Pipe (3) O-ring (4) Front Housing (5) Snap Ring (6) Shaft Assembly (7) Bearing (8) Shaft (9) Retaining Ring (10) Oil Seal (11) O-ring (12) O-ring (13) Gasket

(14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27)

Rear Housing Assembly and Pump Cartridge Side Plate Rotor and Vane Pin Cam Rear Housing Bolt Spring Retaining Ring Filter Valve O-ring Connector Pressure Switch

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

7. Remove the valve. 8. Remove the retaining ring. 9. Remove the filter. 10. Remove the spring. 11. Remove the snap ring. 12. Remove the shaft assembly. 13. Remove the retaining ring. 14. Remove the oil seal. CAUTION: When removing the oil seal, be careful not to damage the housing.

POWER ASSISTED SYSTEM

15. Remove the bolt. 16. Remove the rear housing assembly and the pump cartridge. 17. Remove the gasket. 18. Remove the O-ring. 19. Remove the O-ring. 20. Remove the front housing. 21. Remove the side plate. 22. Remove the rotor and vane. 23. Remove the cam. 24. Remove the pin. 25. Remove the rear housing. 26. Remove the pressure switch.

2A31

Vane

Inspection and Repair

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

442RS003

Rotor

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

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

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

Valve
442RS002

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

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

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

O-ring, Oil Seal, Retaining Ring

Be sure to discard used parts, and always use new parts for installation. Prior to installation, lubricate all seals and rings with power steering fluid.

2A32

POWER ASSISTED SYSTEM

6. Install side plate. CAUTION: When installing side plate, be careful not to damage its inner surface. Damaged side plate may cause poor pump performance, pump seizure or oil leakage. 7. Install front housing. 8. Install a new o-ring and be sure to discard used parts. 9. Install a new o-ring and be sure to discard used parts. 10. Install a new gasket and be sure to discard used parts. 11. Install rear housing and pump cartridge. 12. Install bolt and tighten it to the specified torque. Torque: 17.6 Nm (12.8 lb ft) 13. Install a new oil seal and be sure to discard used parts. CAUTION: When installing the oil seal, be careful not to damage the oil seal contacting surface of the housing. 14. Install shaft assembly. 15. Install snap ring. 16. Install spring. 17. Install retaining ring. 18. Install filter. 19. Install valve. 20. Install retaining ring. 21. Install a new o-ring and be sure to discard used parts. 22. Install connector and tighten it to the specified torque. Torque: 19.6 Nm (14.3 lb ft) 23. Install a new o-ring and be sure to discard used parts. 24. Install suction pipe. 25. Install bolt and tighten it to the specified torque.
442RS004

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

Reassembly
1. Install rear housing. 2. Install pin. 3. Install cam. 4. Install the rotor with punch mark facing the front housing.

Torque: 15.7 Nm (11.5 lb ft) 26. Install pressure switch and tighten it to the specified torque. Torque: 20 Nm (14 lb ft)

5. Install the vanes with curved face in contact with the inner wall of the cam.

442RS005

POWER ASSISTED SYSTEM

2A33

1Main Data and Specifications

General Specifications
Oil pump Type Operating fluid Vane ATF DEXRONIII

Torque Specifications

E02R200002

2A-34 POWER ASSISTED SYSTEM

Center Track Rod Assembly

Center Track Rod Assembly and Associated Parts

433RW001

Legend (1) Nut and Cotter Pin (2) Nut and Cotter Pin, Pitman Arm

(3) Nut and Cotter Pin, Relay Lever (4) Center Track Rod Assembly

POWER ASSISTED SYSTEM

2A35

Removal
1. Raise the vehicle and support the frame with suitable safety stands. 2. Remove nut and cotter pin, then use remover J36831 to disconnect outer track rod assembly from the center track rod. CAUTION: Be careful not to damage the ball joint boot.

4. Remove nut and cotter pin then use remover J36831 to remove relay lever from the center track rod. CAUTION: Be careful not to damage the ball joint boot.

433RS011

5. Remove center track rod assembly.

Inspection and Repair

433RS009

3. Remove nut and cotter pin then use remover J36831 to remove pitman arm from the center track rod. CAUTION: Be careful not to damage the ball joint boot.

Make necessary correction or parts replacement if wear, damage, corrosion, bending, deteriorations or any other abnormal condition are found through inspection. Check the ball joint (Boot, screws and tapered surfaces).

Installation
1. Install center track rod assembly. 2. Install nut, cotter pin and relay lever, then tighten the nut to the specified torque, with just enough additional torque to align cotter pin holes. Install new cotter pin. Torque: 59 Nm (43 lb ft) 3. Install nut, cotter pins and pitman arm, then tighten the nut to the specified torque, with just enough additional torque to align cotter pin holes. Install new cotter pin. Torque: 98 Nm (72 lb ft) 4. Install nut and cotter pins, then tighten the nut to the specified torgue, with fust enough additional torgue to align cotter pen holes. Install new cotter pin. Torque: 98 Nm (72 lb ft)

433RS010

2A-36 POWER ASSISTED SYSTEM

Outer Track Rod Assembly

Outer Track Rod Assembly and Associated Parts

433RS012

Legend (1) Rod End Assembly, Inner (2) Lock Nut, Inner (Left-hand threads) (3) Lock Nut, Outer

(4) Rod End Assembly, Outer (5) Nut and Cotter Pin, Knuckle Arm (6) Nut and Cotter Pin, Center Track Rod

POWER ASSISTED SYSTEM

2A37

Removal
1. Remove wheel and tire assembly. Refer to Wheel Replacement in Suspension section. 2. Remove nut and cotter pin, then use remover J36831 to disconnect outer track rod assembly at the center track rod. CAUTION: Be careful not to damage the ball joint boot.

5. Apply setting marks (1) to ensure reassembly of the parts in their original position, then remove outer rod end assembly.

433RS014

6. Remove inner lock nut. NOTE: For either outer rod, the screw on the right side of the vehicle is threaded counterclockwise. 7. Apply setting marks (1) to ensure reassembly of the parts in their original position, then remove inner rod end.

433RS009

3. Remove nut and cotter pin then use remover J36831 to remove outer track rod assembly from the knuckle arm. CAUTION: Be careful not to damage the ball joint boot.

433RS015

Inspection and Repair

433RS013

4. Remove outer lock nut.

Make necessary correction or parts replacement if wear, damage, corrosion, bending, deteriorations or any other abnormal condition are found through inspection. Check the following parts: D Rod end assembly D Ball joint (Boot, screws and tapered surfaces)

2A-38 POWER ASSISTED SYSTEM

Installation
1. Install inner rod end and align the setting marks applied during disassembly. 2. Tighten the inner lock nut to specified torque. Torque: 118 Nm (87 lb ft) NOTE: For either outer rod, the screw on the right side of the vehicle is threaded counterclockwise. 3. Install outer rod end assembly and align the setting marks applied during disassembly. 4. Tighten the outer lock nut to specified torque. Torque: 118 Nm (87 lb ft) 5. Install knuckle arm nut and cotter pin then tighten the nut to the specified torque, with just enough additional torque to align cotter pin holes. Install new cotter pin. Torque: 98 Nm (72 lb ft) 6. Install center track rod and nut and cotter pin then tighten the nut to the specified torque, with just enough additional torque to align cotter pin holes. Install new cotter pin. Torque: 98 Nm (72 lb ft) NOTE: If replacing the track rod, adjust the new track rod length. Rod length: 328.3 mm (12.93 in)

433RS016

NOTE: Adjust the toe-in. Refer to Front End Alignment Inspection and Adjustment in this section.

POWER ASSISTED SYSTEM

2A39

Relay Lever
Relay Lever and Associated Parts

433RS017

Legend (1) Bolt and Nut (2) Relay Lever and Bracket (3) Bracket

(4) Relay Lever (5) Nut and Washer (6) Nut and Cotter Pin

Removal
1. Raise the vehicle and support the frame with suitable safety stands. 2. Remove nut and cotter pin then use remover J36831 to disconnect relay lever at the center track rod.

433RS011

2A-40 POWER ASSISTED SYSTEM

3. Remove stabilizer bar bolt and nut and push the stabilizer bar aside, then remove the relay lever bolts and nuts.

Installation
1. Install bracket. 2. Install relay lever. 3. Install nut and washer and tighten the nut to the specified torque. Torque: 118 Nm (87 lb ft) 4. Install relay lever and bracket. 5. Install bolt and nut and tighten it to the specified torque. Torque: 44 Nm (33 lb ft) 6. Install nut and cotter pin and tighten the nut to the specified torque, with just enough additional torque to align cotter pin holes. Install new cotter pin. Torque: 59 Nm (43 lb ft)

433RS018

4. Remove relay lever and bracket. 5. Remove relay lever nut and washer. 6. Remove relay lever, use remover J2291201 to remove relay lever from the bracket.

433RS019

7. Remove bracket.

POWER ASSISTED SYSTEM

2A41

Steering Linkage and Associated Parts

Main Data and Specifications
Torque Specifications

E03RS004

2A-42 POWER ASSISTED SYSTEM

Special Tools
ILLUSTRATION TOOL NO. TOOL NAME

J36831 Tie rod end remover

J2291201 Relay lever remover

POWER ASSISTED SYSTEM

2A43

Supplemental Restraint System Steering Wheel & Column

Service Precaution
This steering wheel and column repair section covers the Supplemental Restraint System (SRS) steering column. The following repair procedures are specific to SRS components. When servicing a vehicle equipped with Supplemental Restraint System, pay close attention to all WARNINGS and CAUTIONS. For detailed explanation about SRS, refer to Restraints section. WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. SAFE HANDLING OF INFLATOR MODULES REQUIRES FOLLOWING THE PROCEDURES DESCRIBED BELOW FOR BOTH LIVE AND DEPLOYED MODULES. SAFETY PRECAUTIONS MUST BE FOLLOWED WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY (AIR BAG). AFTER DEPLOYMENT, THE AIR BAG ASSEMBLY (AIR BAG) SURFACE MAY CONTAIN A SMALL AMOUNT OF SODIUM HYDROXIDE, A BY-PRODUCT OF THE DEPLOYMENT REACTION, THAT IS IRRITATING TO THE SKIN AND EYES. MOST OF THE POWDER ON THE AIR BAG ASSEMBLY (AIR BAG) IS HARMLESS. AS A PRECAUTION, WEAR GLOVES AND SAFETY GLASSES WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY, AND WASH YOUR HANDS WITH MILD SOAP AND WATER AFTERWARDS. WHEN CARRYING A LIVE AIR BAG ASSEMBLY, MAKE SURE THE BAG AND TRIM COVER ARE POINTED AWAY FROM YOU. NEVER CARRY AN AIR BAG ASSEMBLY BY THE WIRES OR CONNECTOR ON THE UNDERSIDE OF MODULE. IN THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE BAG WILL THEN DEPLOY WITH MINIMAL CHANCE OF INJURY. WHEN PLACING A LIVE AIR BAG ASSEMBLY ON A BENCH OR OTHER SURFACE, ALWAYS FACE THE BAG AND TRIM COVER UP, AWAY FROM THE SURFACE. NEVER REST A STEERING COLUMN ASSEMBLY ON THE STEERING WHEEL WITH THE AIR BAG ASSEMBLY FACE DOWN AND COLUMN VERTICAL. THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG ASSEMBLY TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY COULD RESULT. TO AVOID DEPLOYMENT WHEN TROUBLE SHOOTING THE SRS SYSTEM, DO NOT USE ELECTRICAL TEST EQUIPMENT, SUCH AS BATTERY-POWERED OR A/C-POWERED VOLT-METER, OHMMETER, ETC., OR ANY TYPE OF ELECTRICAL EQUIPMENT OTHER THAN SPECIFIED IN THIS MANUAL. DO NOT USE A NON-POWERED PROBE-TYPE TESTER. INSTRUCTIONS IN THIS MANUAL MUST BE FOLLOWED CAREFULLY, OTHERWISE PERSONAL INJURY MAY RESULT. CAUTION: D Never use the air bag assembly from another vehicle. Use only the air bag assembly for UX. D The driver s air bag assembly (Inflator module) for 1999 model has different characteristic to the parts for 1998 model.When replace the driver s air bag assembly, confirm the parts number and use only the parts for 1999 model. (The driver s air bag assembly for 1999 model has yellow bar codes label. 1998 model has white bar codes label.)

827RX003

SRS Connectors
CAUTION: The special tellow color connectors are used for supplemental restraint system-air bag circuit. When removing the cable harness, do not pull the cables. Otherwise, cable disconnection may occur.

2A-44 POWER ASSISTED SYSTEM

When connect the SRS connector, insert the connector completely. Imperfect locking may cause malfunction of SRS circuit.

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

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

827RW027

827RW028

POWER ASSISTED SYSTEM

2A45

Inflator Module
Inflator Module and Associated Parts

827RS048

Legend (1) Module Connector

(2) Inflator Module (3) Steering Wheel

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

827RT008

2A-46 POWER ASSISTED SYSTEM

6. Disconnect the yellow 2-way SRS connector located behind the inflator module. D Check for defects such as damage and breakage in the lead wire for the igniter. If an abnormality is found as the result of the inspection, replace the inflator module with a new one.

Installation
1. Install inflator module. CAUTION: D Never use the air bag assembly from another vehicle. Use only the air bag assembly for UX. D The driver s air bag assembly (Inflator module) for 1999 model has different characteristic to the parts for 1998 model.When replace the driver s air bag assembly, confirm the parts number and use only the parts for 1999 model. (The driver s air bag assembly for 1999 model has yellow bar codes label. 1998 model has white bar codes label.) 2. Support the module and carefully connect the module connector. NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of inflator to prevent lead wire from being pinched. 3. Secure the module with one bolt to relieve weight on the wire connector and tighten bolts to specified sequence as illustrated. Torque: 8 Nm (69 lb in)

827RW002

7. Remove inflator module.

Inspection and Repair

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

827RW003

827RS016

The inflator module consists of a cover, air bag, inflator, and retainer. Inspect the inflator module mainly for the following: D Check for holes, cracks, severe blemishes and deformation on the cover. D Check that the retainer is not deformed.

4. Connect the yellow 2-way SRS connector located under the steering column. 5. Connect the battery terminal cable. 6. Set ignition to ON while watching warning light. Light should flash 7 times and then go off. If lamp does not operate correctly, refer to Restraints section.

POWER ASSISTED SYSTEM

2A47

Steering Wheel
Steering Wheel and Associated Parts

827RT022

Legend (1) Horn Lead (2) Steering Wheel Fixing Nut

(3) Inflator Module (4) Steering Wheel

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

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

2A-48 POWER ASSISTED SYSTEM

5. Loosen the inflator module fixing bolt from behind the steering wheel assembly using a TORX driver or equivalent until the inflator module can be released from steering assembly. 9. Apply a setting mark (1) across the steering wheel and shaft so parts can be reassembled in their original position, then remove steering wheel.

430RW001 827RT008

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

10. Move the front wheels to the straight ahead position, then use steering wheel remover J29752 to remove the steering wheel. CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit.

430RT009

827RS016

7. Disconnect horn lead. 8. Remove steering wheel fixing nut.

POWER ASSISTED SYSTEM

2A49

Installation
1. Install steering wheel by aligning the setting marks made when removing. CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. 2. Tighten the steering wheel fixing nut to the specified torque. Torque: 34 Nm (25 lb ft) 3. Connect horn lead. 4. Support the module and carefully connect the module connector. CAUTION: D Never use the air bag assembly from another vehicle. Use only the air bag assembly for UX. D The driver s air bag assembly (Inflator module) for 1999 model has different characteristic to the parts for 1998 model.When replace the driver s air bag assembly, confirm the parts number and use only the parts for 1999 model. (The driver s air bag assembly for 1999 model has yellow bar codes label. 1998 model has white bar codes label.) NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of inflator to prevent lead wire from being pinches. D Secure the module with one bolt to relieve weight on the wire connector. D Tighten bolts to specified sequence as illustrated. Torque: 8 Nm (69 lb in)

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

827RW003

5. Connect the yellow 2-way SRS connector located under the steering column. 6. Connect the battery terminal cable.

2A-50 POWER ASSISTED SYSTEM

Combination Switch
Combination Switch and Associated Parts

431RW001

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

(4) (5) (6) (7)

Combination Switch and SRS Coil Assembly Front Console Assembly Steering Lower Cover Lower Cluster Assembly

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

CAUTION: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering wheel. Failure to do so will cause the coil assembly to become uncentered which will cause damage to the coil assembly. 5. Remove the transmission (for M/T) and transfer control lever knob. Disconnect the wiring harness connectors then remove front console assembly. 6. Remove lower cluster assembly. 7. Remove the engine hood opening lever, then remove steering lower cover.

POWER ASSISTED SYSTEM

8. Loosen the inflator module fixing bolt from behind the steering wheel assembly using a TORX driver or equivalent until the inflator module can be released from steering assembly. Disconnect the yellow 2-way SRS connector located behind the inflator module, then remove inflator module.

2A51

827RS016

9. Apply a setting mark (1) across the steering wheel and shaft so parts can be reassembled in their original position. Move the front wheels to the straight ahead posision, then use steering wheel remover J29752 to remove the steering wheel.
827RT008

430RW001 827RW002

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

CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit.

2A-52 POWER ASSISTED SYSTEM

CAUTION: When turning the SRS coil counterclockwise to full, stop turning if resistance is felt. Forced further turning may damage to the cable in the SRS coil.

430RT009

10. Remove steering column cover. 11. Disconnect the wiring harness connectors located under the steering column, then remove combination switch and SRS coil assembly. NOTE: The SRS coil is a part of the combination switch assembly, which can not be replaced separately. Therefore, be sure not to remove the SRS coil from the combination switch assembly.

826RW014

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

825RW017

825RW030

Installation
1. Install combination switch and SRS coil assembly. After installation of combination switch assembly, connect the combination switch wiring harness connector and the SRS 2-way connector located under the steering column. Then turn the SRS coil counterclockwise to full, return about 3 turns and align the neutral mark.

Legend (1) Steering Column Cover (2) Starter Switch Harness (3) Combination Switch Harness (4) Inflator Module Harness 3. Align the setting marks made when removing then install steering wheel. CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit.

POWER ASSISTED SYSTEM

4. Tighten the steering wheel fixing nut to the specified torque. Torque: 34 Nm (25 lb ft) 5. Support the inflator module and carefully connect the module connector. CAUTION: D Never use the air bag assembly from another vehicle. Use only the air bag assembly for UX. D The driver s air bag assembly (Inflator module) for 1999 model has different characteristic to the parts for 1998 model.When replace the driver s air bag assembly, confirm the parts number and use only the parts for 1999 model. (The driver s air bag assembly for 1999 model has yellow bar codes label. 1998 model has white bar codes label.) NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of inflator to prevent lead wire from being pinched. 6. Secure the module with one bolt to relieve weight on the wire connector. 7. Tighten bolts to specified sequence as illustrated. Torque: 8 Nm (69 lb in)

2A53

827RW003

8. Install steering lower cover then Install the engine hood opening lever. 9. Install lower cluster assembly 10. Install the transmission (for M/T) and transfer control lever knob, then install front console assembly. 11. Connect the wiring harness connectors. 12. Connect the battery terminal cable. 13. Turn the ignition switch to ON while watching warning light and check the light should flash 7 times and then go off. If lamp does not operate correctly, refer to Restraints section.

2A-54 POWER ASSISTED SYSTEM

Lock Cylinder
Lock Cylinder and Associated Parts

431RW003

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

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

Cushion Rubber Lock Cylinder Assembly Front Console Assembly Lower Cluster Assembly Steering Lower Cover Shift Lock Cable (for A/T)

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

CAUTION: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering wheel. Failure to do so will cause the coil assembly to become uncentered which will cause damage to the coil assembly. 5. Remove the transmission (for M/T) and transfer control lever knob and disconnect the wiring harness connectors, then remove front console assembly. 6. Remove lower cluster assembly. 7. Remove the engine hood opening lever and steering lower cover.

POWER ASSISTED SYSTEM

8. Loosen the inflator module fixing bolt from behind the steering wheel assembly using a TORX driver or equivalent until the inflator module can be released from steering assembly.

2A55

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

430RW001 827RT008

9. Disconnect the yellow 2-way SRS connector located behind the inflator module.

11. Move the front wheels to the straight ahead position, then use steering wheel remover J29752 to remove the steering wheel. CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit.

827RW002

430RT009

2A-56 POWER ASSISTED SYSTEM

WARNING: THE INFLATOR MODULE SHOULD ALWAYS BE CARRIED WITH THE URETHANE COVER AWAY FROM YOUR BODY AND SHOULD ALWAYS BE LAID ON A FLAT SURFACE WITH THE URETHANE SIDE UP. THIS IS NECESSARY BECAUSE A FREE SPACE IS PROVIDED TO ALLOW THE AIR CUSHION TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY MAY RESULT. 15. Remove snap ring. 16. Remove cushion rubber. 17. Remove shift lock cable (for A/T). 18. Disconnect the starter switch harness connector located under the steering column, then remove lock cylinder assembly.

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

827RS016

12. Remove steering column cover. 13. Disconnect the wiring harness connectors located under the steering column. 14. Remove the combination switch assembly with SRS coil. NOTE: The SRS coil is a part of the combination switch assembly, which can not be replaced separately. Therefore, be sure not to remove the SRS coil from the combination switch assembly.

826RW014

825RW030

POWER ASSISTED SYSTEM

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

2A57

12. Tighten fixing bolts to specified sequence as illustrated. Torque: 8 Nm (69 lb in)

825RW017 827RW003

Legend (1) Steering Column Cover (2) Starter Switch Harness (3) Combination Switch Harness (4) Inflator Module Harness 8. Install steering wheel by aligning the setting marks made during removal. CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. 9. Tighten the steering wheel fixing nut to the specified torque. Torque: 34 Nm (25 lb ft) 10. Support inflator module and carefully connect the module connector, then install inflator module. CAUTION: D Never use the air bag assembly from another vehicle. Use only the air bag assembly for UX. D The driver s air bag assembly (Inflator module) for 1999 model has different characteristic to the parts for 1998 model.When replace the driver s air bag assembly, confirm the parts number and use only the parts for 1999 model. (The driver s air bag assembly for 1999 model has yellow bar codes label. 1998 model has white bar codes label.) NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of inflator to prevent lead wire from being pinched. 11. Secure the inflator module with one bolt to relieve weight on the wire connector.

13. Install steering lower cover, then install the engine hood opening lever. 14. Install lower cluster assembly. 15. Connect the wiring harness connectors, then install front console assembly and install the transmission (for M/T) and transfer control lever knob. 16. Connect the yellow 2-way SRS connector located under the steering column. 17. Connect the battery terminal cable.

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

2A-58 POWER ASSISTED SYSTEM

Steering Column
Steering Column and Associated Parts

431RW002

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

(7) (8) (9) (10) (11) (12) (13)

Lock Cylinder Assembly Shift Lock Cable (For A/T) Steering Column Assembly Front Console Assembly Lower Cluster Assembly Steering Lower Cover Driver Knee Bolster (reinforcement)

Removal
1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Turn the ignition switch to LOCK. 3. Disconnect the battery terminal cable, and wait at least 5 minutes.

4. Disconnect the yellow 2-way SRS connector located under the steering column.

POWER ASSISTED SYSTEM

CAUTION: The wheel of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column from the steering gear. Failure to do so will cause the SRS coil assembly to become uncentered which will cause damage to the SRS coil assembly. 5. Disconnect the transmission (for M/T) and transfer control lever knob. 6. Disconnect the wiring harness connectors. 7. Remove front console assembly. 8. Remove lower cluster assembly. 9. Remove the engine hood opening lever, then remove steering lower cover. 10. Remove driver knee bolster (reinforcement). 11. Loosen the inflator module fixing bolt from behind the steering wheel assembly using a TORX driver or equivalent until the inflator module can be released from steering assembly.

2A59

827RS016

14. Apply a setting mark (1) across the steering wheel and shaft so parts can be reassembled in their original position. Move the front wheels to the straight ahead position, then use steering wheel remover J29752 to remove the steering wheel.

827RT008

12. Disconnect the yellow 2-way SRS connector located behind the inflator module. 13. Remove inflator module. WARNING: THE INFLATOR MODULE SHOULD ALWAYS BE CARRIED WITH THE URETHANE COVER AWAY FROM YOUR BODY AND SHOULD ALWAYS BE LAID ON A FLAT SURFACE WITH THE URETHANE SIDE UP. THIS IS NECESSARY BECAUSE A FREE SPACE IS PROVIDED TO ALLOW THE AIR CUSHION TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY MAY RESULT.
430RW001

2A-60 POWER ASSISTED SYSTEM

22. Apply a setting mark (1) across the universal joint and steering shaft to reassemble the parts in their original position, then remove steering column assembly. NOTE: A setting mark can be easily made if the shaft is withdrawn a little by loosening the steering shaft universal joint.

430RT009

15. Remove steering column cover. 16. Disconnect the wiring harness connectors located under the steering column. 17. Remove the combination switch assembly with SRS coil. NOTE: SRS coil is a part of combination switch assembly, which can not be replaced singly. Therefore, be sure not to remove the SRS coil from the combination switch assembly.
431RW004

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

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

825RW030

18. Remove snap ring. 19. Remove cushion rubber. 20. Remove shift lock cable (For A/T). 21. Disconnect the starter switch harness connector located under the steering column, then remove lock cylinder assembly.

431RW030

POWER ASSISTED SYSTEM

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

2A61

Sheared Injected Plastic Pin

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

431RW031

Column Tube
Check for collapse by measuring the distance as shown in the figure. Standard distance: 162.2165.8 mm (6.3866.528 in)

431RW033

Shaft Length
Check the shaft length from the upper end of the slide joint to the end of the shaft. If column length is not in specifications, steering column should be replaced. Standard length: 308310 mm (12.12612.205 in)

431RW032

Column Universal Joint for Tilt Mechanism

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

431RX003

Shaft Universal Joint (Lower End)

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

Shaft Bellows Pipe

Check the shaft bellows pipe for bend by using straight edge. Measure the clearance between the bellows pipe and the straight edge (at center of the bellows pipe). Standard: Less than 1 mm (0.039 in)

2A-62 POWER ASSISTED SYSTEM

431RW035

826RW014

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

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

Installation
1. Install steering column assembly. 2. Align the setting marks on the universal joint and steering shaft made during removal. 3. Tighten the steering column fixing bolt (dash panel) to the specified torque. Torque: 19 Nm (14 lb ft) 4. Tighten the steering column fixing bolt bracket) to the specified torque. Torque: 17 Nm (13 lb ft) 5. Tighten the universal joint to the specified torque. Torque: 25 Nm (18 lb ft) 6. Install lock cylinder assembly. 7. Install shift lock cable (For A/T). 8. Install cushion rubber. 9. Install snap ring. 10. Install Combination switch and SRS coil assembly. After installation of combination switch assembly, connect the combination switch wiring harness connector and the SRS 2-way connector located under the steering column. 11. Turn the SRS coil counterclockwise to full, return about 3 turns and align the neutral mark. CAUTION: When turning the SRS coil counterclockwise to full, stop turning if resistance is felt. Forced further turning may damage to the cable in the SRS coil.
825RW017

(pedal

Legend (1) Steering Column Cover (2) Starter Switch Harness (3) Combination Switch Harness (4) Inflator Module Harness 13. Install steering wheel and align the setting marks made when removing. CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. 14. Tighten the steering wheel fixing nut to the specified torque. Torque: 34 Nm (25 lb ft) 15. Support the module and carefully connect the module connector then install inflator module.

POWER ASSISTED SYSTEM

CAUTION: D Never use the air bag assembly from another vehicle. Use only the air bag assembly for UX. D The driver s air bag assembly (Inflator module) for 1999 model has different characteristic to the parts for 1998 model.When replace the driver s air bag assembly, confirm the parts number and use only the parts for 1999 model. (The driver s air bag assembly for 1999 model has yellow bar codes label. 1998 model has white bar codes label.) NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of inflator to prevent lead wire from being pinched. 16. Secure the module with one bolt to relieve weight on the wire connector. 17. Tighten bolts to specified sequence as illustrated. Torque: 8 Nm (69 lb in)

2A63

827RW003

18. Install driver knee bolster (reinforcement). 19. Install steering lower cover. 20. Install the engine hood opening lever. 21. Install lower cluster assembly. 22. Connect the wiring harness connectors then install front console assembly. 23. Install the transmission (for M/T) and transfer control lever knob. 24. Connect the yellow 2-way SRS connector located under the steering column. 25. Connect the battery terminal cable.

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

2A-64 POWER ASSISTED SYSTEM

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

E03R200007

POWER ASSISTED SYSTEM

2A65

Special Tools
ILLUSTRATION TOOL NO. TOOL NAME

J29752 Steering wheel remover

SECTION
FRONT SUSPENSION
TROOPER

3C1

SUSPENSION
CONTENTS
Front Suspension . . . . . . . . . . . . . . . . . . . . . . . Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . Wheel and Tire System . . . . . . . . . . . . . . . . . . 3C1 3D1 3E1

FRONT SUSPENSION
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . General Diagnosis . . . . . . . . . . . . . . . . . . . . . . . Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . Shock Absorber and Associated Parts . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . Stabilizer Bar and Associated Parts . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torsion Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torsion Bar and Associated Parts . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Knuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Knuckle and Associated Parts . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C1 3C2 3C3 3C6 3C6 3C6 3C6 3C6 3C7 3C7 3C7 3C7 3C7 3C8 3C8 3C8 3C9 3C9 3C11 3C11 3C11 3C12 3C12 Upper Control Arm . . . . . . . . . . . . . . . . . . . . . . Upper Control Arm and Associated Parts . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lower Control Arm . . . . . . . . . . . . . . . . . . . . . . Lower Control Arm and Associated Parts . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upper Ball Joint . . . . . . . . . . . . . . . . . . . . . . . . . Upper Ball Joint and Associated Parts . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lower Ball Joint . . . . . . . . . . . . . . . . . . . . . . . . . Lower Ball Joint and Associated Parts . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C14 3C14 3C14 3C15 3C16 3C18 3C18 3C18 3C19 3C20 3C21 3C21 3C21 3C22 3C22 3C23 3C23 3C23 3C24 3C24 3C25 3C26

Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.

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

3C2

FRONT SUSPENSION

General Description

C03RW001

Legend (1) Shock Absorber (2) Upper Control Arm (3) Height Control Arm

(4) (5) (6) (7)

Torsion Bar Link Lower Control Arm Stabilizer Bar

The front suspension is designed to allow each wheel to compensate for changes in the road surface level without greatly affecting the opposite wheel. Each wheel is independently connected to the frame by a steering knuckle, ball joint assemblies, and upper and lower control arms. The front wheels are held in proper relationship to each other by two outer track rods which are connected to steering arms on the knuckles, and to a center track rod. All models have a front suspension system consisting of control arms, stabilizer bar, shock absorber and a torsion bar. The front end of the torsion bar is attached to the lower control arm. The rear of the torsion bar is mounted

into a height control arm at the crossmember. Vehicle trim height is controlled by adjusting this arm. Shock absorbers are mounted between the brackets on the frame and the lower control arms. The lower portion of each shock absorber is attached to the lower control arm. The upper portion of each shock absorber extends through a frame bracket and is secured with two rubber bushings, three retainers and a nut. Ball joint assemblies are bolted to the outer end of the upper and lower control arm and are attached to the steering knuckle. The inner ends of the upper control arm have pressed in bushings. Bolts, passing through the bushing, attach the control arm to the frame. The inner ends of the lower

FRONT SUSPENSION
control arm are attached to the frame by bolts passing through the bushings, which are pressed in the frame. Side roll of the front suspension is controlled by a spring steel stabilizer bar. It is mounted in rubber bushings,

3C3

which are held to the crossmember by brackets. The ends of the stabilizer bar are connected to the lower control arms by links.

General Diagnosis
Condition Vehicle Pulls Possible cause Mismatched or uneven tires. Tires not adequately inflated. Broken or sagging springs. Radial tire lateral force. Improper wheel alignment. Brake dragging in one wheel. Loose, bent or broken front or rear suspension parts. Faulty shock absorbers. Abnormal or Excessive Tire Wear Sagging or broken spring. Tire out of balance. Improper wheel alignment. Faulty shock absorber. Hard driving. Overloaded vehicle. Tires not rotated periodically. Worn or loose road wheel bearings. Wobbly wheel or tires. Tires not adequately inflated. Wheel Hop Shimmy, Shake or Vibration Blister or bump on tire. Improper shock absorber operation. Tire or wheel out of balance. Loose wheel bearings. Worn steering linkage ball joints. Worn upper or lower ball joints. Excessive wheel runout. Blister or bump on tire. Excessive loaded radial runout of tire/wheel assembly. Improper wheel alignment. Loose or worn steering linkage. Loose steering gear. Tires not adequately inflated. Loose, bent or broken front or rear suspension parts. Faulty shock absorber. Hub bearing preload misadjustment. Correction Replace tire. Adjust tire pressure. Replace spring. Replace tire. Adjust wheel alignment. Repair brake. Tighten or replace the appropriate suspension part(s). Replace shock absorber. Replace spring. Balance or replace tire. Check front end alignment. Replace shock absorber. Replace tire. Replace tire and reduce load. Replace or rotate tire. Replace wheel bearing. Replace wheel or tire. Adjust the pressure. Replace tire. Replace shock absorber. Balance wheels or replace tire/or wheel. Replace wheel bearing. Replace ball joints. Replace ball joints. Repair or replace wheel and/or tire. Replace tire. Replace tire or wheel. Check wheel alignment. Tighten or replace steering linkage. Tighten housing bolts. Adjust tire pressure. Tighten or replace the appropriate suspension parts. Replace shock absorber. Adjust preload.

3C4

FRONT SUSPENSION
Condition Possible cause Bind in steering linkage ball studs, upper or lower ball joint. Improper wheel alignment. Steering gear misadjustment. Tire not adequately inflated. Bind in steering column or shaft. Improper power steering system operation. Correction Replace ball joint. Check wheel alignment. Check and adjust pinion torque. Inflate tires to proper pressure. Repair or replace. Repair or replace. Refer to Steering section. Replace wheel bearings. Retighten or repair. Inspect and adjust steering gear preload. shaft Retighten or replace steering shaft. Replace ball joints. Replace ball joints. Replace ball joints. Replace ball joints. Repair or replace. Check and repair steering gear. Adjust wheel alignment. Adjust tire pressure. Retighten. Replace. Replace.

Hard Steering

Too Much Play In Steering

Wheel bearings worn. Loose steering gear or linkage. Steering gear misadjustment. Worn or loose universal joint. steering

Worn steering linkage ball joints. Worn upper or lower end ball joints. Poor Steering Wheel Returnability Bind in steering linkage ball joints. Bind in upper or lower ball joints. Bind in steering column and shaft. Bind in steering gear. Improper wheel alignment. Tires not adequately inflated. Loose steering wheel nut. Worn wheel bearing. Abnormal Noise Worn, sticky or loose upper or lower ball joint, steering linkage ball joints or drive axle joints. Faulty shock absorbers. Worn upper or lower control arm bushing. Loose stabilizer bar. Loose wheel nuts.

Replace. Replace. Retighten bolts or replace bushings. Tighten nuts. Check for elongated wheel nut holes. Replace wheel if required. Retighten suspension bolts or nuts. Replace wheel bearing. Replace spring. Retighten mounting bolt. Check and adjust steering gear.

Loose suspension bolts or nuts. Broken or otherwise damaged wheel bearings. Broken suspension springs. Loose steering gear. Faulty steering gear.

FRONT SUSPENSION
Condition Wandering or Poor Steering Stability Possible cause Mismatched or unevenly worn tires. Loose steering linkage ball joints. Faulty shock absorbers. Loose stabilizer bar. Broken or sagging springs. Steering gear misadjustment. Improper wheel alignment. Erratic Steering When Braking Worn wheel bearings. Broken or sagging springs. Leaking caliper. Warped discs. Badly worn brake pads. Tires are inflated unequally. Low or Uneven Trim Height Broken or sagging springs. Vehicle overloaded. Incorrect springs. Suspension Bottoms Vehicle overloaded. Faulty shock absorber. Incorrect, broken or sagging springs. Body Leans Loose stabilizer bar. Faulty shock absorber, struts or mounting. Broken or sagging springs. Vehicle overloaded. Cupped Tires Worn wheel bearings. Excessive tire or wheel run out. Worn ball joints. Tire out of balance. Correction

3C5

Replace tire or inflate tires to proper pressure. Replace ball joints. Replace shock absorber. Tighten or replace stabilizer bar or bushings. Replace spring (pairs). Check or adjust steering gear. Adjust wheel alignment. Replace wheel bearings. Replace spring (pairs). Repair or replace caliper. Replace brake disc. Replace brake pads. Inflate tires to proper pressure. Replace springs (In pairs). Reduce load. Adjust or replace torsion bar. Reduce load. Replace shock absorber. Replace springs. Tighten stabilizer bar bolts or replace bushings. Replace shock absorber. Replace springs (In pairs). Reduce load. Replace wheel bearing. Replace tire or wheel. Replace ball joints. Adjust tire balance.

3C6

FRONT SUSPENSION

Shock Absorber
Shock Absorber and Associated Parts

450RS006

Legend (1) Nut (2) Rubber Bushing and Washer

(3) Bolt, Nut and Washer (4) Shock Absorber (5) Rubber Bushing and Washer

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

Installation
1. Install rubber bushing and washer. 2. Install shock absorber. 3. Install rubber bushing and washer. 4. Install nut, then tighten it to the specified torque. Torque: 20 Nm (14 lb ft) 5. Install bolt, nut and washer, then tighten to the specified torque. Torque: 82 Nm (61 lb ft)

Inspection and Repair

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: D Shock absorber D Rubber bushing

FRONT SUSPENSION

3C7

Stabilizer Bar
Stabilizer Bar and Associated Parts

410RS002

Legend (1) Nut and Washer (2) Link

(3) Bracket, Nut and Washer (4) Rubber Bushing (5) Stabilizer Bar

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

Inspection and Repair

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: D Stabilizer bar D Rubber bushing D Link ball joint

Installation
1. Install rubber bushing. 2. Install stabilizer bar. 3. Install bracket, then tighten it to the specified torque. Torque: 22 Nm (16 lb ft) 4. Install link. 5. Install nut and washer, then tighten the nut to the specified torque. Torque: 50 Nm (37 lb ft)

3C8

FRONT SUSPENSION

Torsion Bar
Torsion Bar and Associated Parts

410RS003

Legend (1) Adjust Bolt, End Piece and Seat

(2) Height Control Arm (3) Torsion Bar

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

410RS004

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

3C9

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

410RS005

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

410RS006 410RS006

Inspection and Repair

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: D Torsion bar D Height control arm D Adjust bolt D Rubber seat

3C10

FRONT SUSPENSION
5. Install adjust bolt and seat, then turn the adjust bolt to the setting mark(1) applied during disassembly. NOTE: Adjust the trim height. Refer to Front End Alignment Inspection and Adjustment in Steering section.

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

410RS005

3. Apply grease to the bolt portion of the end piece(4). Apply grease to the portion of the seat(5) that fits into the bracket.

410RS004

410RS008

4. Apply grease to the serrated portions.

FRONT SUSPENSION

3C11

Knuckle
Knuckle and Associated Parts

410RW001

Legend (1) Torsion Bar (2) Lower Ball Joint, Nut and Cotter Pin (3) Back Plate (4) Knuckle Assembly (5) Knuckle

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

Needle Bearing Thrust Washer Oil Seal Upper Ball Joint, Nut and Cotter Pin Wheel Speed Sensor

Removal
1. Raise the vehicle and support the frame with suitable safety stands. 2. Remove wheel and tire assembly. Refer to Wheel Replacement in this section. 3. Remove the brake caliper. Refer to Disc Brakes in Brake section.

4. Remove the hub assembly. Refer to Front Hub and Disk in Driveline/Axle section. 5. Remove outer track rod from the knuckle. Refer to Outer Track Rod Assembly Replacement in Steering section. 6. Remove the speed sensor from the knuckle. 7. Loosen torsion bar by height control arm adjust bolt, then remove torsion bar. Refer to Torsion Bar Replacement in this section.

3C12

FRONT SUSPENSION
14. Remove needle bearing by using remover J23907.

8. Remove back plate. 9. Remove lower ball joint by using remover J29107. CAUTION: Be careful not to damage the ball joint boot.

901RW044

Inspection and Repair

901RW042

10. Remove upper ball joint by using remover J36831. CAUTION: Be careful not to damage the ball joint boot.

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: D Knuckle D Knuckle arm D Needle bearing D Thrust washer

Installation
1. Apply appropriate amount of multipurpose type grease to the new bearing (Approx. 5 g)and install needle bearing by using installer J36838 and J8092.

901RW043

11. Remove knuckle assembly. 12. Remove oil seal. 13. Remove washer.

901RW045

FRONT SUSPENSION
2. Apply multipurpose type grease to the thrust washer, and install washer with chamfered side facing knuckle. 3. Use a new oil seal, and apply multipurpose type grease to the area surrounded by the lip (approx. 2 g). Then use installer J41468 and J8092 to install oil seal. After fitting the oil seal to the installer, drive it to the knuckle using a hammer or bench press until the tool front face contacts with the thrust washer.

3C13

901RW046

4. Install knuckle assembly. 5. Install upper ball joint and tighten the nut to the specified torque, with just enough additional torque to align cotter pin holes. Install new cotter pin. Torque: 98 Nm (72 lb ft) 6. Install lower ball joint and tighten the nut to the specified torque, with just enough additional torque to align cotter pin holes. Install new cotter pin. Torque: 147 Nm (108 lb ft) 7. Install back plate. 8. Install wheel speed sensor. 9. Install torsion bar, refer to Torsion Bar Replacement in this section. NOTE: Adjust the trim height. Refer to Front End Alignment Inspection and Adjustment in Steering section.

3C14

FRONT SUSPENSION

Upper Control Arm

Upper Control Arm and Associated Parts

450RS007

Legend (1) Bolt and Plate (2) Camber Shims (3) Caster Shims (4) Nut Assembly (5) Upper Control Arm Assembly (6) Fulcrum Pin

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

Bushing Plate Nut Speed Sensor Cable Nut and Cotter Pin Upper Ball Joint, Bolt Washer and Nut

Removal
1. Raise the vehicle and support the frame with suitable safety stands. 2. Remove wheel and tire assembly. Refer to Wheel Replacement in this section.

3. Remove the brake caliper and disconnect brake pipe. Refer to Disc Brakes in Brake section. 4. Support lower control arm with a jack. 5. Remove speed sensor cable. 6. Remove nut and cotter pin then use remover J36831.

FRONT SUSPENSION
CAUTION: Be careful not to break the ball joint boot.

3C15

901RW048

901RW043

16. Remove fulcrum pin.

7. Remove upper ball joint. 8. Remove bolt and plate. 9. Remove nut assembly. 10. Remove camber shims and note the positions and number of shims. 11. Remove caster shims and note the positions and number of shims. 12. Remove upper control arm assembly. 13. Remove nut. 14. Remove plate. 15. Remove bushing by using remover J29755.

Inspection and Repair

Make necessary parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: D Upper control arm D Bushing D Fulcrum pin

901RW047

3C16

FRONT SUSPENSION
4. Install nut and tighten fulcrum pin nut fingertight. NOTE: Torque fulcrum pin nut after adjusting buffer clearance. Buffer clearance: 20 mm (0.79 in) Torque: 108 Nm (80 lb ft)

Installation
1. Install fulcrum pin. 2. Install bushing by using installer J29755 and J39376.

901RW049 450RS012

5. Install upper control arm assembly with the fulcrum pin projections turned inward.

901RW050

3. Install plate.
450RS013

Legend (1) Projection (2) Outward

FRONT SUSPENSION
6. Install the caster shims(2) between the chassis frame and fulcrum pin. 7. Install the camber shims(1) between the chassis frame and fulcrum pin.

3C17

450RS014

8. Install nut assembly. 9. Install bolt and plate, then tighten the bolt to the specified torque. Torque: 152 Nm (112 lb ft) 10. Install upper ball joint and tighten it to the specified torque. Torque: 57 Nm (42 lb ft) 11. Install nut and cotter pin then tighten the nut to the specified torque, with just enough additional torque to align cotter pin holes. Install new cotter pin. Torque: 98 Nm (72 lb ft) 12. Install speed sensor cable.

3C18

FRONT SUSPENSION

Lower Control Arm

Lower Control Arm and Associated Parts

450R200010

Legend (1) Nut and Washer, Front (2) Bush, Front (3) Bolt, Front (4) Nut and Washer, Rear (5) Bush, Rear (6) Bolt, Rear (7) Bolt, Lower Ball Joint

(8) (9) (10) (11) (12) (13) (14)

Bolt, Torsion Bar Arm Torsion Bar Arm and Nut Torsion Bar Lower Control Arm Lower Ball Joint and Nut Shock Absorber, Bolt Washer and Nut Stabilizer Link, Washer and Nut

Removal
1. Raise the vehicle and support the frame with suitable safety stands. 2. Remove wheel and tire assembly. Refer to Wheel Replacement in this section.

3. Remove the outer track rod from the knuckle. Refer to Steering Linkage in Steering section. 4. Remove the retaining ring from the front axle driving shaft to release the shaft from hub. Refer to Front Hub and Disc in Driveline/Axle section. 5. Support lower control arm with a jack. 6. Remove front nut and washer.

FRONT SUSPENSION
7. Remove rear nut and washer. 8. Remove torsion bar, refer to Torsion Bar Replacement in this section. 9. Remove torsion bar arm. 10. Disconnect the stabilizer link at the lower control arm. 11. Remove the shock absorber lower end from the lower control arm. 12. Remove the lower ball joint from the lower control arm. 13. Remove front bolt. 14. Remove rear bolt. 15. Remove lower control arm. 16. Remove torsion bar arm bolt. 17. Remove lower ball joint bolt. 18. Remove front bushing by using remover J36833.

3C19

19. Remove rear bushing by using remover J36834.

901RW051

901RW034

901RW052

Inspection and Repair

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: D Lower control arm D Bushing

901RW035

3C20

FRONT SUSPENSION
11. Install torsion bar arm bracket and tighten it to the specified torque. Torque: 116 Nm (85 lb ft) 12. Install Torsion bar, refer to Torsion Bar Replacement in this section. 13. Install rear nut and washer and tighten lower link nut fingertight. NOTE: Torque lower control arm nut after adjusting buffer clearance. Buffer clearance: 20 mm (0.79 in) Torque: 196 Nm (145 lb ft)

Installation
1. Install rear bushing by using installer J36834.

901RW053

2. Install front bushing by using installer J36833.

450RS012

14. Install front nut and washer then tighten lower link nut finger-tight. NOTE: Torque lower control arm nut after adjusting buffer clearance . Buffer clearance: 20 mm (0.79 in) Torque: 157 Nm (116 lb ft) NOTE: Adjust the trim height. Refer to Front End Alignment Inspection and Adjustment in Steering section.
901RW036

3. Install lower ball joint bolt. 4. Install torsion bar arm bolt. 5. Install lower control arm. 6. Install rear bolt. 7. Install front bolt. 8. Install lower ball joint and tighten it to the specified torque. Torque: 103 Nm (76 lb ft) 9. Install shock absorber and tighten it to the specified torque. Torque: 82 Nm (61 lb ft) 10. Install stabilizer link and tighten it to the specified torque. Torque: 50 Nm (37 lb ft)
450RS012

FRONT SUSPENSION

3C21

Upper Ball Joint

Upper Ball Joint and Associated Parts

450RS022

Legend (1) Bolt, Nut and Washer

(2) Upper Ball Joint (3) Nut and Cotter Pin

Removal
1. Raise the vehicle and support the frame with suitable safety stands. 2. Remove the speed sensor from the knuckle.

3C22

FRONT SUSPENSION
D After moving the ball joint 4 or 5 times, attach nut then measure the preload. Starting torque: 0.5 3.2 Nm (0.42.4 lb ft)

3. Remove upper ball joint nut and cotter pin, then use remover J36831 to remove the upper ball joint from the knuckle. CAUTION: Be careful not to break the ball joint boot.

450RS024 901RW043

4. Remove bolt and washer. 5. Remove upper ball joint.

If the above limits specified are exceeded, replace the ball joint assembly.

Installation Inspection and Repair

Make necessary parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. D Inspect the lower end boot for damage or grease leak. Move the ball joint as shown in the figure to confirm its normal movement. D Inspect screw/taper area of ball for damage. D If any defects are found by the above inspections, replace the ball joint assembly with new one. 1. Install upper ball joint. 2. Install bolt and nut, then tighten them to the specified torque. Torque: 57 Nm (42 lb ft) 3. Install nut and cotter pin, then tighten the nut to the specified torque with just enough additional torque to align cotter pin holes. Install new cotter pin. Torque: 98 Nm (72 lb ft)

450RS023

FRONT SUSPENSION

3C23

Lower Ball Joint

Lower Ball Joint and Associated Parts

450RS025

Legend (1) Bolt (2) Lower Ball Joint

(3) Nut (4) Nut and Cotter Pin

Removal
1. Raise the vehicle and support the frame with suitable safety stands. 2. Remove wheel and tire assembly. Refer to Wheel Replacement in this section. 3. Remove the outer track rod from the knuckle. Refer to Steering Linkage in Steering section. 4. Remove the retaining ring from the front axle driving shaft to release the shaft from hub. Refer to Front Hub and Disc in Driveline/Axle section. 5. Support lower control arm with a jack. 6. Remove lower ball joint nut and cotter pin, then use remover J29107 to remove the lower ball joint from the knuckle. CAUTION: Be careful not to damage the ball joint boot.
901RW042

3C24

FRONT SUSPENSION

7. Remove nut. 8. Remove lower ball joint. 9. Remove bolt.

Installation
1. Install bolt. 2. Install lower ball joint. 3. Install nut and tighten it to the specified torque. Torque: 103 Nm (76 lb ft) 4. Install nut, then tighten it to the specified torque with just enough additional torque to align cotter pin holes. Install new cotter pin. Torque: 147 Nm (108 lb ft)

Inspection and Repair

Make necessary parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. D Inspect the lower end boot for damage or grease leak. Move the ball joint as shown in the figure to confirm its normal movement . D Inspect screw/taper area of ball for damage. D If any defects are found by the above inspections, replace the ball joint assembly with new one.

450RS026

D After moving the ball joint 4 or 5 times, attach nut the measure the preload. Starting torque: 0.56.4 Nm (0.44.7 lb ft)

450RS024

D If the above limits specified are exceeded, replace the ball joint assembly.

FRONT SUSPENSION

3C25

Main Data and Specifications

General Specifications
Front suspension Torsion bar spring Front shock absorber Type Length Diameter Type Piston diameter Stroke Compressed length Extended length Stabilizer bar Diameter Independent wishbone arms, torsion bar spring with stabilizer bar. 1217 mm (47.9 in) 26.6 mm (1.05 in) Hydraulic, double acting, telescopic 30.0 mm (1.18 in) 130.0 mm (5.12 in) 390.0 mm (15.35 in) 260.0 mm (10.24 in) 26.0 mm (1.02 in)

Torque Specifications

E03R200008

3C26

FRONT SUSPENSION

Special Tools
ILLUSTRATION TOOL NO. TOOL NAME ILLUSTRATION TOOL NO. TOOL NAME

J23907 Remover; Needle bearing

J36833 Remover and Installer kit; Lower arm front bushing

J36838 Installer; Needle bearing

J36834 Remover and Installer kit; Lower arm rear bushing

J8092 Grip

J36831 Tie rod end remover

J41468 Installer; Oil seal

J29107 Lower end remover

J39376 Installer; Upper arm bushing

J29755 Remover and Installer Upper arm bushing

SECTION
REAR SUSPENSION
TROOPER

3D1

SUSPENSION
REAR SUSPENSION
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Coil Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coil Spring and Associated Parts . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . Shock Absorber and Associated Parts . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trailing Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trailing Link and Associated Parts . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D1 3D2 3D3 3D3 3D3 3D4 3D4 3D5 3D5 3D5 3D5 3D5 3D6 3D6 3D6 3D6 3D7 Center Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Center Link and Associated Parts . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lateral Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lateral Rod and Associated Parts . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . Stabilizer Bar and Associated Parts . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D8 3D8 3D8 3D8 3D9 3D10 3D10 3D10 3D10 3D11 3D12 3D12 3D12 3D12 3D13 3D14 3D16

Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.

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

3D2

REAR SUSPENSION

General Description

C03RS003

Legend (1) Stabilizer Bar (2) Lateral Rod

(3) Shock Absorber (4) Trailing Link (5) Center Link

The rear suspension is a 4-link, coil spring type suspension with a stabilizer bar, consisting of two trailing links, center link, lateral rod, shock absorber, and stabilizer. In this suspension, the links are specially arranged to enable the rear axle to move freely, thereby expanding suspension stroke, reducing friction, and improving lateral rigidity and roll control. All these result in improved stability, riding comfort, and rough road maneuverability. Each link connects the axle housing with the frame through a runner bushing. The axle housing is supported by the trailing links and center link longitudinally and by the lateral rod latitudinally.

REAR SUSPENSION

3D3

Coil Spring
Coil Spring and Associated Parts

460RS001

Legend (1) Parking Brake Cable Bracket (2) Shock Absorber

(3) Coil Spring (4) Insulator (5) Stabilizer Bar, Link and Nut

Removal
1. Raise the vehicle and support the frame with suitable safety stands. 2. Support the rear axle case with a jack. 3. Remove the parking brake cable bracket from the trailing link. 4. Disconnect the stabilizer bar at the stabilizer link. 5. Remove the shock absorber from the axle case. 6. Remove spring insulator. 7. Remove coil spring while lowering the rear axle case.

CAUTION: Be sure not to let the brake hose, parking brake cable, and breather hose extend to their full length.

3D4

REAR SUSPENSION
3. Install the insulator on the coil spring. Jack up the axle case gently with the top of the coil spring set to the spring seat on the frame side.

Inspection and Repair

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: D Coil spring D Insulator

Installation
1. Install coil spring and make sure that the coil spring is installed in the proper position. Paint mark(1) should be downward.

460RS004

4. Install shock absorber and tighten the nut lightly,then retighten it to the specified torque after the vehicle is at curb height. NOTE: When mounting shock absorber, be sure not to use grease on bushings or any other nearby part. Torque: 78 Nm (58 lb ft) 5. Install stabilizer bar. Torque: 50 Nm (37 lb ft)
460RW001

6. Install parking brake cable bracket.

2. Fit the end of the coil spring to the coil spring seat and mount the coil spring on the rear axle case.

460RS003

REAR SUSPENSION

3D5

Shock Absorber
Shock Absorber and Associated Parts

461RW002

Legend (1) Bolt and Nut

(2) Shock Absorber (3) Nut and Washer

Removal
1. Remove shock absorber fixing nut and washer. 2. Remove shock absorber fixing bolt and nut. 3. Remove shock absorber.

Installation
1. Install shock absorber. When mounting shock absorber, be sure not to use grease on bushings or any other nearby part. 2. Install bolt and nut, then tighten the bolt and nut lightly. Retighten to the bolt and nut specified torque after the vehicle is at curb height. Torque: 95 Nm (70 lb ft) 3. Install nut and washer, then tighten the nut lightly. Retighten to the nut specified torque after the vehicle is at curb height. Torque: 78 Nm (58 lb ft)

Inspection and Repair

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: D Shock absorber D Rubber bushing (Axle side) NOTE: When mounting rubber bushings, be sure not to use grease on bushings or any other nearby part.

3D6

REAR SUSPENSION

Trailing Link
Trailing Link and Associated Parts

460RW017

Legend (1) Parking Brake Cable

(2) Bolt and Nut (3) Trailing Link

Removal
1. Remove the parking brake cable from the trailing link. 2. Remove the trailing link fixing bolt and nut. 3. Remove trailing link.

Inspection and Repair

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. 1. Trailing link 2. Rubber bushing D Remove the rubber bushing by using remover J39214.

901RW058

REAR SUSPENSION
D Install the rubber bushing by using installer J39214. NOTE: When mounting rubber bushings, be sure not to use grease on bushings or any other nearby part.

3D7

901RW059

Installation
1. Install trailing link. Make sure that the trailing link is in its correct position. NOTE: When mounting trailing link, be sure not to use grease on bushings or any other nearby part.

460RS008

2. Install bolt and nut. Tighten the bolts and nuts lightly, then retighten them to the specified torque after the vehicle is at curb height. Torque: 137 Nm (101 lb ft) 3. Install parking brake cable. CAUTION: The parking brake cable should not be overstrained or slackened.

3D8

REAR SUSPENSION

Center Link
Center Link and Associated Parts

460RX001

Legend (1) Center Link (2) Bolt and Nut

(3) Speed Sensor Cable Bracket (4) Speed Sensor Cable

Removal
1. Remove the speed sensor cable from the center link. 2. Remove the speed sensor cable bracket from the frame. 3. Remove bolt and nut. 4. Remove center link.

Inspection and Repair

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. 1. Center link 2. Rubber bushing D Remove the rubber bushing by using remover J39214.
901RW058

REAR SUSPENSION
D Install the rubber bushing by using to installer J39214. NOTE: When mounting rubber bushings, be sure not to use grease on bushings or any other nearby part.

3D9

901RW059

Installation
1. Install center link. Make sure that the center link is in its correct position. NOTE: When mounting center link, be sure not to use grease bushings or any other nearby part.

460RS010

2. Install bolt and nut. Tighten the bolts and nuts lightly, then retighten them to the specified torque after the vehicle is at curb height. Torque: 137 Nm (101 lb ft) 3. Install speed sensor cable bracket. 4. Install speed sensor cable.

3D10

REAR SUSPENSION

Lateral Rod
Lateral Rod and Associated Parts

460RW019

Legend (1) Bolt and Nut

(2) Nut and Washer (3) Lateral Rod

Removal
1. Remove nut and washer. 2. Remove bolt and nut. 3. Remove lateral rod.

Inspection and Repair

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. 1. Lateral rod 2. Rubber bushing (Frame side) D Remove the rubber bushing (Frame side) by using remover J39214.

901RW060

REAR SUSPENSION
D Install the rubber bushing (Frame side) by using Installer J39215. NOTE: When mounting rubber bushings, do not use grease on bushings or any other nearby parts.

3D11

901RW063

Installation
901RW061

1. Install lateral rod and make sure that the lateral rod is in its correct position. NOTE: When mounting lateral rod, be sure not to use grease on bushings or any other nearby part.

3. Rubber bushing (Axle side) D Remove the rubber bushing (Axle side) by using remover J39792.

460RS016 901RW062

D Install the rubber bushing (Axle side) by using installer J39792.

Legend (1) Frame Side (2) Axle Side 2. Install bolt and nut. Tighten the bolt and nut lightly, then retighten them to the specified torque after the vehicle is at curb height. Torque: 137 Nm (101 lb ft) 3. Install nut and washer. Tighten the nut lightly, then retighten the nut to the specified torque after the vehicle is at curb height. Torque: 78 Nm (58 lb ft)

3D12

REAR SUSPENSION

Stabilizer Bar
Stabilizer Bar and Associated Parts

460RW020

Legend (1) Nut and Washer (2) Link

(3) Bracket and Bolt (4) Rubber Bushing (5) Stabilizer Bar

Removal
1. Raise the vehicle and support the frame with suitable safety stands. 2. Remove wheel and tire assembly. Refer to Wheel Replacement in this section. 3. Remove nut and washer. 4. Remove link. CAUTION: Be careful not to damage the ball joint boot. 5. Remove bracket.

6. Remove stabilizer bar. 7. Remove rubber bushing.

Inspection and Repair

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: D Stabilizer bar D Rubber bushing D Link ball joint

REAR SUSPENSION

3D13

Installation
1. Install rubber bushing. 2. Install stabilizer bar. 3. Install bracket and tighten to the specified torque. Torque: 22 Nm (16 lb ft) 4. Install link. 5. Install nut and washer, then tighten the nut to the specified torque. Torque: 50 Nm (37 lb ft)

460RS018

3D14

REAR SUSPENSION

Main Data and Specifications

General Specifications
Rear suspension Coil spring Type Free length Spring diameter Coil diameter (inner) Effective No. of turns Total No. of turns Shock absorber Type Piston diameter Stroke Extended length Compressed length Stabilizer bar Diameter 4Link, coil spring type with stabilizer bar. 402mm (15.83in) 12.7mm (0.5in) 105mm (4.13in) 5.32 6.82 Hydraulic, double acting, telescopic 25.0mm (0.98in) 175mm (6.89in) 489mm (19.25in) 314mm (12.36in) 19.0mm (0.75in)

REAR SUSPENSION

3D15

Torque Specifications

E03RW006

3D16

REAR SUSPENSION

Special Tools
ILLUSTRATION TOOL NO. TOOL NAME

J39214 Remover and Installer; Trailing center link bushing

J39792 Remover and Installer; Lateral rod bushing (axle side)

J39215 Remover and Installer; Lateral rod bushing (frame side)

SECTION
WHEEL AND TIRE SYSTEM
TROOPER

3E1

SUSPENSION
WHEEL AND TIRE SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel and Associated Parts . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E1 3E2 3E3 3E9 3E9 3E9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tire Replacement . . . . . . . . . . . . . . . . . . . . . . General Balance Procedure . . . . . . . . . . . . . . Balancing Wheel and Tire . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . 3E9 3E10 3E10 3E10 3E11 3E12

Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.

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

3E2

WHEEL AND TIRE SYSTEM

General Description

480R200012

Replacement wheels or tires must be equivalent to the originals in load capacity, specified dimension and mounting configuration. Improper size or type may affect bearing life, brake performance, speedometer/odometer calibration, vehicle ground clearance and tire clearance to the body and chassis. All model are equipped with metric sized tubeless steel belted radial tires. Correct tire pressures and driving habits have an important influence on tire life. Heavy cornering, excessively rapid acceleration and unnecessary sharp braking increase premature and uneven wear.

WHEEL AND TIRE SYSTEM

3E3

Diagnosis

480RS001

Irregular and Premature Wear

Irregular and/or premature wear has many causes. Some of them are incorrect inflation pressures, lack of tire rotation, poor driving habits or improper wheel alignment. Incorrect inflation is common cause of tire premature wear. NOTE: Due to their design, radial tires tend to wear faster in the shoulder area, particularly on the front tires. This makes regular rotation especially necessary. After rotation, be sure to check wheel nut torque, and set tire pressures.

If the following conditions are noted, rotate the tires: D Front tire wear is different from rear. D Uneven wear exists across the tread of any tire. D Left and right front tire wear is unequal. D Left and right rear tire wear is unequal. Check wheel alignment if the following conditions are noted: D Left and right front tire wear is unequal. D Wear is uneven across the tread of any front tire. D Front tire treads have a scuffed appearance with feather edges on one side of the tread ribs or blocks.

Tire Rotation
Tire rotation is recommended to equalize wear for longer tire life.

Tread Wear Indicators

480RS006

480RS002

Legend (1) Spare Tire

The original equipment tires have built-in tread wear indicators(1) to show when tires need replacement. These indicators may appear as wide bands. When the indicators appear in two or more grooves at three locations, tire replacement is recommended.

3E4

WHEEL AND TIRE SYSTEM

6. High tire temperatures. 7. Reduced handling. 8. Reduced fuel economy. Unequal pressure on same axle can cause: 1. Uneven braking. 2. Steering lead. 3. Reduced handling. 4. Swerve on acceleration.

Inflation of Tires

Radial Tire Waddle

710RS003

Tire pressure, in cold condition (after vehicle has set for three hours or more, and driven less than one mile), should be checked monthly or before any extended trip. Tire pressure increases approximately 15% when the tires become hot during driving. Tire pressure specification is shown on the label located on the left door lock pillar. NOTE: Check the tire pressure whenever irregular wear is found. Tire inflation greatly affects tire wear. If the alignment check does not reveal any alignment problems, check the condition of the shock absorbers and wheel/tire balance.

480RS007

Diagnosis List
If the following conditions are noted, rotation is required. 1. Front tire wear is different from rear. 2. Uneven wear exists across the tread of any tire. 3. Left and right front tire wear is unequal. 4. Left and right rear tire wear is unequal. If the following conditions are noted, check the wheel alignment. 1. Left and right front tire wear is unequal. 2. Uneven wear exists across the tread of any tire. 3. Front tire treads have scuffed appearance with feather edges on one side of tread ribs or blocks. 4. There is cupping, flat spotting etc. Higher than recommended pressure can cause: 1. Hard ride. 2. Poor steering stability. 3. Rapid and uneven wear at center of the tread. Lower than recommended pressure can cause: 1. Tire squeal on turns. 2. Hard steering. 3. Rapid and uneven wear on the edges of the tread. 4. Tire rim bruises and rupture. 5. Tire cord breakage.

Waddle is side-to-side movement at the front and/or rear of the car. It can be caused by the steel belt not being straight within the tire, or by excessive lateral runout of the tire or wheel. It is most noticeable at low speed, about 8 to 48 km/h (5 to 30 mph). It may also cause rough ride at 80 to 113 km/h (50 to 70 mph). The car can be road tested to see which end of the car has the faulty tire. If the tire causing the waddle is on the rear, the rear end of the car will waddle. From the driver s seat, it feels as if someone is pushing on the side of the car. If the faulty tire is on the front, the waddle is more easily seen. The front sheet metal appears to be moving back and forth. It feels as if the driver s seat is the pivot point in the car. Another more time-consuming method of determining the faulty tire is substituting tire and wheel assemblies that are known to be good. Follow these steps: 1. Drive the car to determine if the waddle is coming from the front or rear. 2. Install tire and wheel assemblies known to be good (from a similar car) in place of those on the end of the car which is waddling. If the waddle cannot be isolated to front or rear, start with the rear tires. 3. Road test again. If improvement is noted, install the original tire and wheel assemblies one at a time until the faulty tire is found. If no improvement is noted, install tires known to be good in place of all four. Then, install the originals one at a time until the faulty tire is found.

WHEEL AND TIRE SYSTEM

3E5

Radial Tire Lead/Pull

Lead/Pull is vehicle deviation from a straight path, on a level road with no pressure on the steering wheel. Lead is usually caused by: 1. Poorly manufactured radial tires. 2. Uneven brake adjustment. 3. Wheel alignment. The way in which a tire is built can produce lead in a car. An example of this is placement of the belt. Off-center belts on radial tires can cause the tire to develop a side force while rolling straight down the road and the tire will tend to roll like a cone. The Radial Tire Lead/Pull Correction chart should be used to make sure that front wheel alignment is not mistaken for tire lead. Rear tires will not cause lead/pull.

3E6

WHEEL AND TIRE SYSTEM

Radial Tire Lead/Pull Correction Chart

Step 1 Action 1. Inflate tires to recommended pressure. 2. Road test vehicle on level uncrowned road. Was a problem corrected? 2 Switch front tires side to side and road test again. Was a problem corrected? 3 4 5 Did the vehicle lead in same direction? Put tires back in original position and check alignment. Was a problem corrected? Install known good tire on one front side. Was a problem corrected? Replace tire Typical examples of abnormal tire ahead wear and major causes: CAUTION: Similar wear patterns can be caused by worn suspension parts, misalignment of wheels and tires, and other suspension related problems. Spotty wear wear localized on shoulder sections, and in an extreme cases, the tire becomes polygonal in shape. Tread wear one-sided. End Go to Step 5 Install a known good tire in place of other front tire If lead corrected, replace tire End If roughness results,replace tires Go to Step 4 Go to Step 2 Yes No

Go to Step 3 Go to Step 5

480RW003

1. Rotating parts out of balance. 2. Tire or wheel out of round. 3. Hub or knuckle out of round or distorted.

480RW002

1. Tire or wheel out of round or distorted. 2. Hub or knuckle out of round or distorted. 3. Play in hub bearings or ball joint. 4. Rotating parts out of balance.

WHEEL AND TIRE SYSTEM

Localized tread wear.

3E7

Wear in shoulders at points opposed to each other.

480RW004

480RW006

1. Once spotty wear develops in tread due to hard braking or abrupt starting, localized wear tends to be promoted. Shoulder wear (generally wear develops in outer shoulder):

1. Tire or wheel out of round or distorted. 2. Play in bearings or ball joint. Premature wear in shoulders.

480RW007

1. Flexing of tire excessive due to under-inflation.

480RW005

1. Camber or toe-in incorrect. 2. Shoulder wear caused by repeated hard-cornering.

3E8

WHEEL AND TIRE SYSTEM

One sided feather edging.

480RW008

1. Wear caused by repeated hard-cornering. 2. Camber or toe-in incorrect.

WHEEL AND TIRE SYSTEM

3E9

Wheel
Wheel and Associated Parts

480RW001

Legend (1) Wheel Lug Nut (2) Wheel and Tire

Removal
1. Loosen wheel lug nut by approximately 180 g (half a rotation), then raise the vehicle and remove the nuts. 2. Remove wheel and tire. NOTE: Never use heat to loosen a tight wheel lug nut. The application of heat to the hub can shorten the life of the wheel and may cause damage to wheel bearings.

Installation
1. Install wheel and tire. 2. Install wheel lug nut, and lower the vehicle. Tighten the wheel lug nuts to the specified torque in numerical order. Torque: 118 Nm (87 lb ft) CAUTION: Before installing wheels, remove any build-up of corrosion on the wheel mounting surface and brake disc mounting surface by scraping and wire brushing. Installing wheels without good metal-to-metal contact at mounting surfaces can cause wheel nuts to loosen, which can later allow a wheel to come off while the vehicle is moving. NOTE: Valve caps should be on the valve stems to keep dust and water out.

480RS020

3E10

WHEEL AND TIRE SYSTEM

Tire
Tire Replacement
When replacement is necessary, the original metric the size should be used. Most metric tire sizes do not have exact corresponding alphanumeric tire sizes. It is recommended that new tires be installed in pairs on the same axle. If necessary to replace only one tire, it should be paired with tire having the most tread, to equalize braking traction. CAUTION: Do not mix different types of tires such as radial, bias and bias-belted tires except in emergencies, because vehicle handling may be seriously affected and may result in loss of control. Steel 1 Vertical play: Less than 1.5 mm (0.059 in) 2 Horizontal play: Less than 1.5 mm (0.059 in) Aluminum 1 Vertical play: Less than 0.7 mm (0.028 in) 2 Horizontal play: Less than 0.7 mm (0.028 in)

Tire Dismounting
Remove valve cap on valve step and deflate the tire. Then use a tire changing machine to mount or dismount tires. Follow the equipment manufacturer s instruction. Do not use hand tools or tire lever alone to change tires as they may damage the tire beads or wheel rim.

Tire Mounting
Rim bead seats should be cleaned with a wire brush or coarse steel wool to remove lubricants, and light rust. Before mounting a tire, the bead area should be well lubricated with an approved tire lubricant. After mounting, inflate the tire to 196kPa (28 psi) so that beads are completely seated. Inflate the air to specified pressure and install valve cap to the stem. WARNING: NEVER STAND OVER TIRE WHEN INFLATING. BEAD MAY BREAK WHEN BEAD SNAPS OVER RIMS SAFETY HUMP AND CAUSE SERIOUS PERSONAL INJURY. NEVER EXCEED 240 KPA (35 PSI) PRESSURE WHEN INFLATING. IF 240 KPA (35 PSI) PRESSURE WILL NOT SEAT BEADS, DEFLATE, RE-LUBRICATE AND RE-INFLATE. OVER INFLATION MAY CAUSE THE BEAD TO BREAK AND CAUSE SERIOUS PERSONAL INJURY.
480RS012

General Balance Procedure

Deposits of mud, etc. must be cleaned from the inside of the rim. The tire should be inspected for the following: match mount paint marks, bent rims, bulges, irregular tire wear, proper wheel size and inflation pressure. Then balance according to the equipment manufacturer s recommendations. There are two types of wheel and tire balance. Static balance is the equal distribution of weight around the wheel. Assemblies that are statically unbalanced cause a bouncing action called tramp. This condition will eventually cause uneven tire wear.

Tire Repair
There are many different materials on the market used to repair tires. Manufacturers have published detailed instructions on how and when to repair tires. These instructions can be obtained from the tire manufacturer if they are not included with the repair kit.

Wheel Inspection
Damaged wheels and wheels with excessive run-out must be replaced. Wheel run out at rim (Base on hub Bore):

WHEEL AND TIRE SYSTEM

3E11

Balancing Wheel and Tire

On-vehicle Balancing
On-Vehicle balancing methods vary with equipment and tool manufacturers. Be sure to follow each manufacturer s instructions during balancing operation.

Off-vehicle Balancing
Most electronic off-vehicle balancers are more accurate than the on-vehicle spin balancers. They are easy to use and give a dynamic balance. Although they do not correct for drum or disc unbalance (as on- vehicle spin balancing does), they are very accurate.

480RS013

Legend (1) Heavy Spot Wheel Shimmy (2) Add Balance Weights Here Dynamic balance is the equal distribution of weight on each side of the wheel center-line so that when the tire spins there is no tendency for the assembly to move from side to side. Assemblies that are dynamically unbalanced may cause shimmy.

480RS015

480RS014

Legend (1) Heavy Spot Wheel Hop (2) Add Balance Weights Here WARNING: STONES SHOULD BE REMOVED FROM THE TREAD TO AVOID OPERATOR INJURY DURING SPIN BALANCING AND TO OBTAIN A GOOD BALANCE.

3E12

WHEEL AND TIRE SYSTEM

Main Data and Specifications

General Specifications
Wheels Size Offset P.C.D., wheel studs Standard tire Size Pressure(Front) Pressure(Rear) 16 x 7JJ 38.0 mm (1.50 in) 139.7 mm (5.50 in) P245/70R16 210 kPa (30 psi) 240 kPa (35 psi)

Torque Specifications

E03RW002

SECTION
DIFFERENTIAL (FRONT)
TROOPER

4A11

DRIVELINE/AXLE
CONTENTS
Differential (Front) . . . . . . . . . . . . . . . . . . . . . . . Differential (Rear) . . . . . . . . . . . . . . . . . . . . . . . Driveline Control System (Shift on the fly) . . Driveline Control System (TOD) . . . . . . . . . . . Drive Shaft System . . . . . . . . . . . . . . . . . . . . . . Transfer Case (Standard Type) . . . . . . . . . . . Transfer Case (TOD) . . . . . . . . . . . . . . . . . . . . 4A1 4A2 4B1 4B2 4C 4D1 4D2

DIFFERENTIAL (FRONT)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . Front Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pinion Shaft Oil Seal . . . . . . . . . . . . . . . . . . . . . Pinion Shaft Oil Seal and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Drive Axle Assembly . . . . . . . . . . . . . . . Front Drive Axle Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A11 4A12 4A12 4A13 4A13 4A13 4A14 4A14 4A15 4A15 4A15 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential Assembly . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Differential Cage Assembly . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 4A17 4A19 4A19 4A110 4A112 4A121 4A121 4A121 4A122 4A123 4A125 4A127

Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM(SRS). REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE REFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.

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

4A12

DIFFERENTIAL (FRONT)

Front Drive Axle

Diagnosis
Condition Oil Leak At Front Axle Oil Leak At Pinion Shaft Possible cause Worn or defective oil seal. Front axle housing cracked. Too much gear oil. Oil seal worn or defective. Pinion flange loose or damaged. Noises In Front Axle Drive Shaft Joint Clank When Accelerating From Coast Shudder or Acceleration Vibration During Broken or worn drive shaft joints and bellows (BJ and DOJ). Loose drive shaft joint to output shaft bolts. Damaged inner drive shaft joint. Excessive drive shaft joint angle. Worn or damaged drive shaft joints. Sticking spider assembly (inner drive shaft joint). Sticking joint assembly (outer drive shaft joint). Vibration At Highway Speeds Noises in Front Axle Out of balance or out of round tires. Front end out of alignment. Insufficient gear oil. Wrong or poor grade gear oil. Drive pinion to ring gear backlash incorrect. Worn or chipped ring gear, pinion gear or side gear. Pinion shaft bearing worn. Wheel bearing worn. Differential bearing loose or worn. Wanders and Pulls Wheel bearing preload too tight. Incorrect front alignment. Steering linkage loose or worn. Steering gear out of adjustment. Tire worn or improperly inflated. Front or rear suspension parts loose or broken. Front Wheel Shimmy Wheel bearing worn or improperly adjusted. Incorrect front alignment. Worn ball joint or bush. Steering linkage loose or worn. Steering gear out of adjustment. Tire worn or improperly inflated. Shock absorber worn. Correction Replace the oil seal. Repair or replace. Correct the oil level. Replace the oil seal. Tighten or replace. Replace the drive shaft joints and bellows. Tighten. Replace. Repair. Replace. Lubricate or replace. Lubricate or replace. Balance or replace. Align. Replenish the gear oil. Replace the gear oil. Adjust the backlash. Replace the ring gear, pinion gear or side gear. Replace the pinion shaft bearing. Replace the wheel bearing. Tighten or replace. Adjust the wheel bearing preload. Adjust the front alignment. Tighten or replace. Adjust or replace the steering gear. Adjust the inflation or replace. Tighten or replace. Adjust or replace. Adjust the front alignment. Replace the ball joint or bush. Tighten or replace. Tighten or replace. Replace or adjust the inflation. Replace the shock absorber.

DIFFERENTIAL (FRONT)

4A13

Pinion Shaft Oil Seal

Pinion Shaft Oil Seal and Associated Parts

415RW015

Legend (1) Flange Nut (2) Flange

(3) Oil Seal (4) Outer Bearing (5) Collapsible Spacer

Removal
1. Raise the vehicle and support it at the frame. The hoist must remain under the front axle housing. 2. Drain the front axle oil by loosening the drain plug(1).

412RS001

4A14

DIFFERENTIAL (FRONT)

3. Remove the front propeller shaft. Refer to Front Propeller Shaft in this section. 4. Remove flange nut by using pinion flange holder J37221.

Inspection and Repair

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: 1. Seal surface of the pinion. 2. Cage bore for burns.

Installation
1. Install collapsible spacer. Discard the collapsible spacer and install a new one. 2. Install outer bearing. used

NOTE: Do not drive in, but just temporarily set in the outer bearing by hand, which should be indirectly pressed in finally by tightening the flange nut. 3. Install oil seal, use oil seal installer J24250 to install a new oil seal that has been soaked in axle lubricant.

425RW039

5. Remove flange. 6. Remove oil seal. 7. Remove outer bearing by using remover J39602.

415RS002

4. Install flange. 5. Install flange nut, refer to Differential Assembly Overhaul for flange nut reassembly in this section. NOTE: Discard the used nut and install a new one.

415RW016

8. Remove collapsible spacer.

DIFFERENTIAL (FRONT)

4A15

Front Drive Axle Assembly

Front Drive Axle Assembly and Associated Parts

412RW001

Legend (1) Mounting Bolt and Nut (2) Washer and Spacer (3) Breather Hose (4) Shift Switch Connector (5) Protector

(6) Front Axle Case Assembly and Front Drive Shaft Assembly (LH side) (7) Hub Assembly (Disc, Back Plate and Knuckle) (8) Front Drive Shaft Assembly (RH side) (9) Propeller Shaft (with TOD) (10) Propeller Shaft (11) Bolt

Removal
1. Jack up the vehicle and support it using jack stands. 2. Remove the tire and wheel.

4A16

DIFFERENTIAL (FRONT)
14. Disconnect shift switch connector.

3. Remove the drain bolt to drain differential oil. NOTE: a. During the work, be sure that the diff case is supported by the jack.

412RS031

15. Remove VSV assembly (1). NOTE: Be sure not to remove hose and connector from VSV asm.

412RS003

b. Remove the brake caliper fixing bolt and hang the caliper. Refer to Disc Brakes in Brake section. c. Remove the antilock brake system speed sensor. Refer to Front Wheel Speed in Brake section. 4. Remove the hub assembly (Disc, back plate and knuckle), refer to Front Hub and Disc in this section. 5. Disconnect the knuckle and the suspension arm. Refer to Suspension section. 6. Remove steering link and arm assembly, refer to Steering Linkage in Steering section. 7. Remove suspension crossmember. 8. Remove propeller shaft, refer to Front Propeller Shaft in this section. 9. Remove protector. 10. Remove breather hose. 11. Remove the hose clip. 12. Disconnect breather hose from front drive axle tube and disconnect housing. 13. Disconnect vacuum hose from actuator.

412RW002

DIFFERENTIAL (FRONT)
16. Remove mounting bolt and nut.

4A17

19. Lower the vehicle and disconnect the RH front drive shaft assembly, then remove the front axle case assembly and front drive shaft assembly (LH).

412RS004

17. Remove washer and spacer. 18. Remove the mounting bracket fixing bolt.

412RS006

20. Remove front drive shaft assembly (RH).

Installation
1. Install front drive shaft assembly (RH) and lay the assembly on the lower arm. 2. Install front axle case assembly and front drive shaft assembly (LH) and place the axle case on the jack, connect to the front drive shaft assembly (RH) before installing to the vehicle. 3. Install bolt and tighten the mounting bracket fixing bolt to the specified torque. Torque: 116 Nm (85lb ft) 4. Install washer and spacer.

412RS005

4A18

DIFFERENTIAL (FRONT)

5. Tighten the mounting bolt and nut to the specified torque. Torque: 152 Nm (112lb ft)

412RW005

Legend (1) Frame (2) Spacer (3) Washer (4) Bolt (5) Nut 6. Install VSV assembly and tighten nuts to specified torque. Torque: 8 Nm (69lb in) 7. Install the shift switch connector. NOTE: Be careful not to permit the entry of dust into the connector. 8. Install the actuator side of vacuum hose. NOTE: Be careful not to permit the entry of dust into the hose. 9. Connect breather hose and install the hose clip. 10. Install protector and tighten bolts to specified torque. Torque: 26 Nm (20lb ft) 11. Install propeller shaft, refer to Front Propeller Shaft in this section. 12. Install suspension crossmember. 13. Steering link and arm assembly, refer to Steering Linkage in Steering section. 14. Install hub assembly (Disc, back plate and knuckle), refer to Front Hub and Disc in this section.

DIFFERENTIAL (FRONT)

4A19

Differential Assembly
Disassembled View

415RW001

Legend (1) Differential Assembly (2) Flange Nut (3) Flange (4) Dust Cover (5) Oil Seal (6) Outer Bearing (7) Outer Bearing Outer Race (8) Damper (9) Bracket (10) Differential Carrier (11) Bearing Cap

(12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23)

Bolt Inner Bearing Outer Race Collapsible Spacer Pinion Gear Inner Bearing Adjust Shim Diff Cage Assembly Side Bearing Outer Race Side Bearing Adjust Shim Bolt Axle Case

4A110 DIFFERENTIAL (FRONT)

Disassembly
1. Remove differential carrier fixing bolt. 2. Remove differential assembly. 3. Using holding fixture J37264 and holding fixture base J328920, fix the differential assembly to the bench.

7. Remove side bearing outer race, after removal, keep the right and left hand side bearing assemblies separate to maintain inner and outer race combinations. 8. Remove side bearing, using remover J22888 and adapter J81072.

415RS005 425RS008

4. Remove bearing cap bolt. 5. Apply a setting mark to the side bearing cap and the differential carrier then remove bearing cap.

9. Remove adjust shim, note the thickness and position of the shims removed. 10. Remove the flange nut using holding wrench J37221 after raising up its staked parts completely.

425RS009

425RW040

6. Remove differential cage assembly.

11. Remove flange. 12. Remove dust cover.

DIFFERENTIAL (FRONT)
13. Remove the drive pinion assembly using a soft metal rod and a hammer.

4A111

20. Remove the inner bearing outer race (1) and the outer bearing outer race (2) by using a brass bar and a hammer.

425RW041

14. Remove collapsible spacer. 15. Remove the inner bearing using a separator J2291201 and a press.

425RS014

425RS015

415RS006

16. Remove adjust shim. 17. Remove inner bearing outer race. 18. Remove oil seal. 19. Remove outer bearing.

4A112 DIFFERENTIAL (FRONT)

21. Remove damper and bracket. 2. Using installer J24252 and grip J8092, install Inner bearing outer race.

425RW042 415RS008

Reassembly
1. Using installer J24256 and grip J8092, install outer bearing outer race.

3. Install adjust shim and adjust drive pinion mounting distance 1. Apply gear oil to the inner and outer drive pinion bearing. Clean the pinion setting gauge set. Then install the gauge set together with the inner and outer bearings. 2. Tighten the nut to the specified torque. Torque: 2.3 Nm (20 lb in)

415RS007

415RS009

Legend (1) Pilot : J2177742 (2) Nut and Bolt : J235979 (3) Gauge Plate : J235977

DIFFERENTIAL (FRONT)
3. Clean the side bearing bores. Install the dial indicator with the discs and arbor. Install and tighten the bearing caps to the specified torque. Torque: 98 Nm (72 lb ft) Legend (1) Dial Indicator (2) Ganging Arbor (3) Plunger (4) Gauge Plate

4A113

5. Position the plunger on the gauge plate. Move the gauging arbor slowly back and forth and locate the position at which the dial indicator shows the greatest defection. At this point, once again set the dial indicator to 0. Repeat the procedure to verify the 0 setting.

415RS010

Legend (1) Dial Indicator: J8001 (2) Disc (2 pcs.): J235978 (3) Arbor: J235971 (4) Gauge Plate: J2359742 4. Set the dial indicator to 0. Place it on the mounting post of the gauging arbor with the contact button touching the indicator pad. Force the dial indicator downward until the needle has made a half turn clockwise. Tighten down the dial indicator in this position.
425RS021

6. After the ZERO setting is obtained, rotate the gauging arbor until the dial indicator rod does not touch the gauging plate. Record the number the dial indicator needle points to.

425RS020 425RS022

Legend (1) Example=Dial indicator reading of 0.085

4A114 DIFFERENTIAL (FRONT)

7. Record the pinion depth code on the head of the drive pinion. The number indicates a necessary change in the pinion mounting distance. A plus number indicates the need for a greater mounting distance (which can be achieved by decreasing the shim thickness). A minus number indicates the need for a smaller mounting distance (which can be achieved by increasing the shim thickness). If examination reveals pinion depth code 0, the pinion is nominal.

425RS023

DIFFERENTIAL (FRONT)
8. Select the shim using the chart;
Pinion marking Dial indicator reading (Inches) 0.081 0.082 0.083 0.084 0.085 0.086 0.087 0.088 0.089 0.090 0.091 0.092 0.093 0.094 0.095 0.096 0.097 0.098 0.099 0 0.001 0.002 0.003 0.004 0.005 0.006 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) +10 mm (Inches) +8 mm (Inches) +6 mm (Inches) +4 mm (Inches) +2 mm (Inches) 0 mm (Inches) 2 mm (Inches) 4 mm (Inches) 6 mm (Inches) 8 mm (Inches)

4A115

10 mm (Inches) 2.18 (0.0858) 2.20 (0.0866) 2.23 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008)

NOTE: When ordering shims, find the part number in the parts catalog by using the thickness of shims listed in the above table.

4. Place the shim on the drive pinion, with the chamfered side turned towards the pinion head then install the inner bearing onto the pinion using an installer J613301 and a press.

4A116 DIFFERENTIAL (FRONT)

NOTE: Do not apply pressure to the roller cage and apply pressure only to the inner race. 2. Tighten the nut to the specified torque using the pinion flange holder J37221. Torque: 177275Nm (130203 lb ft) NOTE: Discard used flange nut and install new one and do not over tighten the flange nut.

425RS024

5. Discard the used collapsible spacer and install a new one. 6. Install pinion gear. 7. Install outer bearing. 8. Use oil seal installer J24250 to install a new oil seal that has been soaked in rear axle lubricant. NOTE: Take care to use a front differential oil seal, NOT the rear differential oil seal.

425RW040

3. Adjust pinion bearing preload. a. Measure the bearing preload by using a torque meter. Note the scale reading required to rotate the flange. b. Continue tightening flange nut until the specified starting torque is obtained. Starting torque: New bearing 0.71.1 Nm(5.649.98 lb in) Used bearing 0.40.5Nm(2.864.94Ib in)

415RS011

9. Install dust cover. 10. Install flange. 11. Install flange nut. 1. Apply lubricant to the pinion threads.
425RS027

4. Using punch J39209, stake the flange nut at two points.

DIFFERENTIAL (FRONT)
NOTE: When staking, be sure to turn the nut to insure that there is no change in bearing preload. Make sure of preload again as instructed in 3).

4A117

2. Insert the differential cage assembly with bearing outer races into the side bearing bores of the carrier.

415RS012

425RS030

Legend (1) 1.3mm or less 12. Install adjust shim. 1. Attach the side bearing to the differential assembly without shims. Support the opposite side using a pilot to prevent bearing damage.

3. Using two sets of feeler gauges, insert a feeler stock of sufficient thickness between each bearing outer race and the carrier to remove all end play. Make certain the feeler stock is pushed to the bottom of the bearing bores. Mount the dial indicator J8001 on the carrier so that the indicator stem is at right angles to a tooth on the ring gear.

425RS029 425RS031

Legend (1) Drive handle:J8092 (2) Installer:J24244 (3) Pilot:J81072

4A118 DIFFERENTIAL (FRONT)

4. Adjust feeler gauge thickness from side to side until ring gear backlash is in the specified range. Backlash: 0.130.18 mm(0.005 0.007 in) 13. Install the side bearings together with the selected shims.

425RS029

425RS032

With zero end play and correct backlash established, remove the feeler gauge packs, determine the thickness of the shims required and add 0.05 mm (0.002 in) to each shim pack to provide side bearing preload. Always use new shims. 5. Use bearing remover J22888 and pilot J81072 to remove side bearing.

Legend (1) Drive Handle:J8092 (2) Installer: J24244 (3) Pilot: J81072 14. Install side bearing outer race. 15. Install differential cage assembly. 16. Install bearing cap then align the setting marks(1) applied at disassembly.

415RS013

425RS035

DIFFERENTIAL (FRONT)
17. Tighten the cap bolt to the specified torque. Torque: 98 Nm (72 lb ft)

4A119

Gear Tooth Contact Pattern Check and Adjustment 1. Apply a thin coat of prussian blue or equivalent to the faces of the 78 teeth of the ring gear. Check the impression of contact on the ring gear teeth and make necessary adjustment as described in illustration if the contact is abnormal.

425RS036

1. Measure the amount of runout of the ring gear at its rear face. Standard: 0.02 mm ( 0.001 in) Limit: 0.05 mm ( 0.002 in) Legend (1) Heel (2) Toe (3) Concave Side(Coast) (4) Convex Side(Drive)
425RS038

425RS037

4A120 DIFFERENTIAL (FRONT)

425RS039

18. Install differential assembly. 1. Clean the faces of the front axle case and differential carrier. Apply Three Bond TB1215 or equivalent to the sealing side of the axle case and the carrier. 2. Attach the differential case and the carrier assembly to the front axle case and tighten the nuts and bolts. Torque: 25 Nm (19 lb ft)

3. Fill the axle case with hypoid gear lubricant, to just below the filler hole. Lubricant capacity: 1.4 liter(1.5 US qt) 19. Install damper. 1. Clean the faces and bolt thread hole of differential carrier. 2. Install the bracket with new bolts. 3. Install the damper to the bracket with new bolts. Torque: 22 Nm (16 lb ft)

415RS014

425RW042

DIFFERENTIAL (FRONT)

4A121

Differential Cage Assembly

Disassembled View

415RS015

Legend (1) Pinion Gear (2) Thrust Washer (3) Side Gear (4) Cross Pin

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

Ring Gear Bolt Differential Cage Lock Pin

Disassembly
1. Remove bolt. 2. Remove ring gear. 3. Remove lock pin, break staking on the lock pin, using a 5 mm (0.20 in) diameter drill.

425RS042

4A122 DIFFERENTIAL (FRONT)

4. Remove the cross pin, using a soft metal rod and a hammer. 5. Tighten the fixing bolts in a diagonal sequence as illustrated.

425RS043

415RS016

5. Remove pinion gear. 6. Remove side gear. 7. Remove thrust washer.

Clearance between the differential pinion and the cross pin measurement:
Standard: 0.06 0.12 mm (0.0020.005 in) Limit: 0.2 mm (0.008 in)

Inspection and Repair

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: 1. Ring gear, pinion gear 2. Bearing 3. Side gear, pinion gear, cross pin 4. Differential cage, carrier 5. Thrust washer 6. Oil seal

Ring gear replacement:

1. The ring gear should always be replaced with the drive pinion as a set. 2. Clean the ring gear threaded holes to remove the locking agent. 3. When installing the ring gear, apply LOCTITE 271 or equivalent to all the threaded area and half of the unthreaded area of the bolt. 4. Discard used bolts and install new ones. Torque: 108 Nm (80 lb ft)

425RS045

DIFFERENTIAL (FRONT)

4A123

Clearance between the side gear and the differential box:

Standard: 0.030.10 mm (0.0010.004 in) Limit: 0.15 mm(0.006 in)

Reassembly
1. Install thrust washer. 2. Install side gear. 3. Install the pinion gear by engaging it with the side gears while turning both pinion gears simultaneously in the same direction.

425RS046

Legend (1) Side Gear (2) Differential Box

425RS048

Play in splines between the side gear and the axle shaft:
Standard: 0.080.36 mm(0.003 0.014 in) Limit:0.5m (0.02 in)

4. Install cross pin. 1. Be sure to install the cross pin so that it is in alignment with the lock pin hole in the differential cage.

425RS049

2. Adjust the backlash between the side gear and the pinion gear. Backlash:0.03 0.08 mm (0.001 0.003 in)
425RS047

4A124 DIFFERENTIAL (FRONT)

Thickness of thrust washers available: 1.00 mm, 1.05 mm, 1.10 mm (0.039 in, 0.041 in, 0.043 in) 7. Tighten the bolts in diagonal sequence as illustrated. Torque: 108 Nm (80 lb ft) NOTE: Discard used bolts and install new ones.

425RS050

5. Install lock pin. After lock pin installation, stake the cage to secure the lock pin.

415RS016

425RS051

Legend (1) Staked Portion (2) Lock Pin 6. Clean the ring gear threaded holes to remove the locking agent. When installing the ring gear, apply LOCTITE 271 or equivalent to all the threaded area and half of the unthreaded area of the bolt.

DIFFERENTIAL (FRONT)

4A125

Main Data and Specifications

General Specifications
Axle tube Type Gear type Gear ratio Differential type Oil capacity Type of lubricant Axle shaft type Hub locking Type liter (US qt) (to 1) It consists of the duct, a cast iron housing and the axle tube. Hypoid 4.300 Two pinion 1.4 (1.5) (Differential) 0.12 (0.13) (Actuator Housing: Shift on the fly) 75W90 GL5 (Multi grade type) Refer to General Information Constant velocity joint (Birfield joint type and double offset joint) Rigid

Torque Specifications

E04RW002

4A126 DIFFERENTIAL (FRONT)

E04R200005

DIFFERENTIAL (FRONT)

4A127

Special Tools
ILLUSTRATION TOOL NO. TOOL NAME ILLUSTRATION TOOL NO. TOOL NAME

J37221 Holder; Pinion flange

J2291201 Separator

J24250 Installer; Oil seal

J24256 Installer; Outer bearing outer race

J37264 Differential holding fixture (Use with J328920 base)

J8092 Driver handle

J328920 Holding fixture base

J24252 Installer; Inner bearing outer race

J22888 Puller; Side bearing

J2177742 Pilot

J81072 Adapter; Side bearing plug

J235979 Nut and bolt

4A128 DIFFERENTIAL (FRONT)

ILLUSTRATION TOOL NO. TOOL NAME ILLUSTRATION TOOL NO. TOOL NAME

J235977 Gauge plate

J24244 Installer; Side bearing

J8001 Dial indicator

J39602 Remover; Outer bearing

J235978 Disc

J235971 Arbor

J613301 Installer; Pinion bearing

J39209 Punch; End nut lock

SECTION
DIFFERENTIAL (REAR)
TROOPER

4A21

DRIVELINE/AXLE
DIFFERENTIAL (REAR)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Housing and Associated Parts . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Seal Replacement . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Shaft and Associated Parts . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Oil Seal Replacement . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pinion Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . Pinion Oil Seal and Associated Parts . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A21 4A23 4A24 4A25 4A25 4A25 4A26 4A26 4A27 4A27 4A27 4A28 4A29 4A29 4A210 4A210 4A210 4A211 4A211 Differential Assembly . . . . . . . . . . . . . . . . . . . . Differential Assembly and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Differential Cage Assembly . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Limited Slip Differential . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A212 4A212 4A212 4A213 4A214 4A215 4A217 4A224 4A224 4A225 4A225 4A226 4A228 4A228 4A229 4A229 4A231 4A235 4A236

Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM(SRS). REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE REFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.

CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED , do not use supplemental coatings (Paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally,such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specification. Following these instructions can help you avoid damage to parts and systems. The f244 differential has two N types A-type and Btype. A-type: the sticker with bar code is attached. B-type: the sticker with no bar code on the lower part of carrier is attached.

4A22

DIFFERENTIAL (REAR)

In case of Work Shop Manual;

A-type: Refer to 98 UBS Work Shop Manual. B-type: Described in This Work Shop Manual.

425RY00018

DIFFERENTIAL (REAR)

4A23

General Description
The rear axle assembly is of the semifloating type in which the vehicle weight is carried on the axle housing . The center line of the pinion gear is below the center line of the ring gear (hypoid drive). All parts necessary to transmit power from the propeller shaft to the rear wheels are enclosed in a banjo type axle housing. The 9.61 inch ring gear rear axle uses a conventional ring and pinion gear set to transmit the driving force of the engine to the rear wheels. This gear set transfers this driving force at a 90 degree angle from the propeller shaft to the drive shafts. The axle shafts are supported at the wheel end of the shaft by a roller bearing. The pinion gear is supported by two tapered roller bearings. The pinion depth is set by a shim pack located between the gear end of the pinion and the roller bearing that is pressed onto the pinion. The pinion bearing preload is set by crushing a collapsible spacer between the bearings in the axle housing.

420RY00003

The ring gear is bolted onto the differential cage with 12 bolts. The differential cage is supported in the axle housing by two tapered roller bearings. The differential and ring gear are located in relationship to the pinion by using selective shims and spacers between the bearing and the axle housing. To move the ring gear, shims are deleted from one side and an equal amount are added to the other side. These shims are also used to preload the bearings which

are pressed onto the differential cage. Two bearing caps are used to hold the differential into the rear axle housing. The differential is used to allow the wheels to turn at different rates of speed while the rear axle continues to transmit the driving force. This prevents tire scuffing when going around corners and prevents premature wear on internal axle parts. The rear axle is sealed with a pinion seal, a seal at each axle shaft end, and by a liquid gasket between the differential carrier and the axle housing.

4A24

DIFFERENTIAL (REAR)

Diagnosis
Many noises that seem to come from the rear axle actually originate from other sources such as tires, road surface, wheel bearings, engine, transmission, muffler, or body drumming. Investigate to find the source of the noise before disassembling the rear axle. Rear axles, like any other mechanical device, are not absolutely quiet but should be considered quiet unless some abnormal noise is present. To make a systematic check for axle noise, observe the following: 1. Select a level asphalt road to reduce tire noise and body drumming. 2. Check rear axle lubricant level to assure correct level, and then drive the vehicle far enough to thoroughly warm up the rear axle lubricant. 3. Note the speed at which noise occurs. Stop the vehicle and put the transmission in neutral. Run the engine speed slowly up and down to determine if the noise is caused by exhaust, muffler noise, or other engine conditions. 4. Tire noise changes with different road surfaces; axle noises do not. Temporarily inflate all tires to 344 kPa (50 psi) (for test purposes only). This will change noise caused by tires but will not affect noise caused by the rear axle. Rear axle noise usually stops when coasting at speeds under 48 km/h (30 mph); however, tire noise continues with a lower tone. Rear axle noise usually changes when comparing pull and coast, but tire noise stays about the same. Distinguish between tire noise and rear axle noise by noting if the noise changes with various speeds or sudden acceleration and deceleration. Exhaust and axle noise vary under these conditions, while tire noise remains constant and is more pronounced at speeds of 32 to 48 km/h (20 to 30 mph). Further check for tire noise by driving the vehicle over smooth pavements or dirt roads (not gravel) with the tires at normal pressure. If the noise is caused by tires, it will change noticeably with changes in road surface. 5. Loose or rough front wheel bearings will cause noise which may be confused with rear axle noise; however, front wheel bearing noise does not change when comparing drive and coast. Light application of the brake while holding vehicle speed steady will often cause wheel bearing noise to diminish. Front wheel bearings may be checked for noise by jacking up the wheels and spinning them or by shaking the wheels to determine if bearings are loose. 6. Rear suspension rubber bushings and spring insulators dampen out rear axle noise when correctly installed. Check to see that there is no link or rod loosened or metaltometal contact. 7. Make sure that there is no metaltometal contact between the floor and the frame. After the noise has been determined to be in the axle, the type of axle noise should be determined, in order to make any necessary repairs.

Gear Noise
Gear noise (whine) is audible from 32 to 89 km/h (20 to 55 mph) under four driving conditions. 1. Driving under acceleration or heavy pull. 2. Driving under load or under constant speed. 3. When using enough throttle to keep the vehicle from driving the engine while the vehicle slows down gradually (engine still pulls slightly). 4. When coasting with the vehicle in gear and the throttle closed. The gear noise is usually more noticeable between 48 and 64 km/h (30 and 40 mph) and 80 and 89 km/h (50 and 55 mph).

Bearing Noise
Bad bearings generally produce a rough growl or grating sound, rather than the whine typical of gear noise. Bearing noise frequently wowwows at bearing rpm, indicating a bad pinion or rear axle side bearing. This noise can be confused with rear wheel bearing noise.

Rear Wheel Bearing Noise

Rear wheel bearing noise continues to be heard while coasting at low speed with transmission in neutral. Noise may diminish by gentle braking. Jack up the rear wheels, spin them by hand and listen for noise at the hubs. Replace any faulty wheel bearings.

Knock At Low Speeds

Low speed knock can be caused by worn universal joints or a side gear hub counter bore in the cage that is worn oversize. Inspect and replace universal joints or cage and side gears as required.

Backlash Clunk
Excessive clunk on acceleration and deceleration can be caused by a worn rear axle pinion shaft, a worn cage, excessive clearance between the axle and the side gear splines, excessive clearance between the side gear hub and the counterbore in the cage, worn pinion and side gear teeth, worn thrust washers, or excessive drive pinion and ring gear backlash. Remove worn parts and replace as required. Select closefitting parts when possible. Adjust pinion and ring gear backlash.

DIFFERENTIAL (REAR)

4A25

Axle Housing
Axle Housing and Associated Parts

420RY00001

Legend (1) Coil Spring and Insulator (2) Axle Housing Assembly (3) ABS Speed Sensor and Harness (4) Nut (5) Parking Brake Cable (6) Bolt and Nut (7) Antilock Brake System (ABS) Connector and Bracket (8) Bolt and Nut

(9) (10) (11) (12) (13) (14) (15) (16) (17)

Nut Differential Assembly Axle Shaft Assembly Brake Disc Brake Pipe Brake Caliper Nut Breather Hose Flare Nut

Removal
1. Raise the vehicle and support it with suitable safety stands. The hoist must remain under the rear axle housing. 2. Remove brake fluid. Refer to Hydraulic Brakes in Brake section. 3. Remove rear wheels and tires. Refer to Wheel in Suspension section.

4. Remove propeller shaft. Refer to Rear Propeller Shaft in this section. 5. Drain the rear axle oil into a proper container. 6. Remove parking brake cable, release the connection between the cable fixing clip equalizer. Refer to Parking Brakes in Brake section. 7. Move the clip aside and pull out the breather hose. 8. Disconnect the ABS connectors (1) and remove the brackets (2) attached to the frame and center link.

4A26

DIFFERENTIAL (REAR)
20. Remove the brake pipe clip and fixing bolt on the axle housing and take out the brake pipe. 21. Remove the bearing holder fixing nut and take out the axle shaft assembly, be sure not to damage the oil seal by the spline of the shaft, Refer to Axle Shaft in this section. 22. Remove differential assembly, refer to Differential Assembly in this section.

Oil Seal Replacement

Remove the oil seal, carefully not to damage the housing, and mount new oil seal using oil seal installer J39210.

350RS001

9. Loosen the brake tube flare nut, remove the clip and take out the brake tube. 10. Remove the shock absorber fixing nut from the axle housing. 11. Remove the stabilizer linkage mounting nut from the axle housing. 12. Remove the lateral rod fixing nut from the axle housing. 13. Remove the center link mounting bolt and nut from the axle housing. 14. Remove the trailing link fixing bolt and nut from the axle housing. 15. Jack down and remove the coil spring and insulator. 16. Axle housing assembly can be separated from the vehicle on completion of steps 1 11. 17. Remove the brake caliper fixing bolt (3), loosen the flare nut (1), release the clip (2) and take out the brake caliper together with the flexible hose.

420RS004

Installation
1. Install differential assembly, refer to Differential Assembly in this section. 2. Install axle shaft assembly then tighten the bearing holder mounting nut to the specified torque. Be sure not to damage the oil seal by the spline of the shaft. Torque: 74Nm (54lb ft) 3. Install brake pipe. 4. Connect antilock brake system (ABS) speed sensor and harness, refer to 4Wheel AntiLock Brake System (ABS) in Brake section. 5. Install brake disc. 6. Install brake caliper. Refer to Disk Brakes in Brake section. 7. Install axle housing assembly. 8. Install coil spring and insulator. 9. Install the trailing link fixing bolt and nut to the axle housing. For the procedures in items 913, refer to Suspension section. 10. Install the center link bolt and nut to the axle housing. 11. Install the lateral rod fixing nut to the axle housing. 12. Install the stabilizer linkage mounting nut to the axle housing. 13. Install the shock absorber fixing nut to the axle housing.

306RS001

18. Remove brake disc. 19. Remove antilock brake system speed sensor fixing bolt and the clip and bracket on the axle housing.

DIFFERENTIAL (REAR)
14. Install brake tube flare nut, Refer to Disk Brakes in Brake section. 15. Install ABS connector and bracket. 16. Connect breather hose.

4A27

17. Install parking brake cable, Refer to Parking Brakes in Brake section. 18. Bleed brakes. Refer to Hydraulic Brakes in Brake section.

Axle Shaft
Axle Shaft and Associated Parts

420RY00005

Legend (1) Brake Caliper (2) Brake Disc (3) Wheel Pin (4) Axle Shaft Assembly (5) Back Plate (6) Parking Brake Assembly

(7) (8) (9) (10) (11) (12) (13)

Bearing Holder Bearing Retainer Snap Ring Bolt Nut Antilock Brake System (ABS) Speed Sensor

Removal
1. Raise the vehicle. 2. Remove tires and wheels. Refer to Wheel in Steering section.

3. Remove brake caliper. Use a wire to attach the brake caliper to the frame. Refer to Disk Brakes in Brake section. 4. Remove brake disc. 5. Remove ABS sensor. 6. Remove Parking brake assembly. Refer to Parking Brakes in Brake section.

4A28

DIFFERENTIAL (REAR)
cable mounting 14. Remove back plate. 15. Remove the wheel pins using a remover J6627A.

7. Remove the parking brake bolts(Behind the back plate)(1).

311RS001

420RS007

8. Remove the bearing holder mounting nuts. 9. Remove axle shaft assembly. NOTE: Be sure not to damage the oil seal. 10. Remove snap ring. 11. Using a bearing remover J39211 and press, remove retainer together with the bearing holder.

Inspection and Repair

Make necessary correction or parts replacement if wear, corrosion or any other abnormal conditions are found through inspection.

Visual Check:
Check the following parts for wear, damage, noise or any other abnormal conditions: 1. Axle shaft 2. Bearing When checking the axle shaft, pay special attention to the splined portions and replace the shaft if distortion or step wear is noticeable. Correct slight step wear with a grinder.

420RS006

12. Remove bearing. 13. Remove bearing holder.

420RS008

DIFFERENTIAL (REAR)

4A29

Axle Shaft Runout

Limit: 1.0 mm (0.039 in)

Oil Seal Replacement

Remove the oil seal carefully not to damage the bearing holder bore . When installing, use oil seal installer J39379.

420RS009

Axle Shaft Flange Runout

Limit: 0.08 mm (0.003 in)

420RS011

Installation
1. Install wheel pin. 2. Install back plate. 3. Install bearing holder. 4. Install bearing. 5. Install retainer by using a bearing installer J39212, press fit together with the bearing.

420RS010

420RS012

4A210 DIFFERENTIAL (REAR)

6. Install snap ring. 7. Install axle shaft assembly. NOTE: Be sure not to damage the oil seal. 8. Tighten the bearing holder mounting nut to the specified torque. Torque: 74Nm (54 Ib ft) 9. Fix the parking brake cable mounting bolt (Behind the back plate). 10. Install parking brake assembly, refer to Parking Brakes in Brake section. 11. Install antilock brake system sensor. 12. Install brake disc. 13. Install brake caliper, refer to Disk Brakes in Brake section.

Pinion Oil Seal

Pinion Oil Seal and Associated Parts

425RY00010

Legend (1) Flange Nut and Washer (2) Flange

(3) Oil Seal (4) Outer Bearing (5) Collapsible Spacer

Removal
1. Remove the rear propeller shaft. Propeller Shaft in this section. 2. Drain the rear axle oil. Refer to Rear

DIFFERENTIAL (REAR)
3. Remove flange nut and washer by using pinion flange holder J861401 after raising up its staked parts completely.

4A211

Inspection and Repair

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: 1. Seal surface of the pinion. 2. Cage bore for burns.

Installation
1. Install collapsible spacer, discard the used collapsible spacer and install a new one. 2. Install outer bearing. NOTE: Do not drive in, but just temporarily set in the outer bearing by hand, which should be indirectly pressed in finally by tightening the flange nut. 3. By using the seal installer J37263, install a new oil seal (1) that has grease on seal lip.

415RS018

4. Remove flange. 5. Remove oil seal. 6. Remove outer bearing by using remover J39602.

425RS004

4. Install flange. 5. Install flange nut and washer. Refer to Differential Assembly in this section for flange nut reassembly. NOTE: Discard the used nut and install a new one.
425RY00003

7. Remove collapsible spacer.

4A212 DIFFERENTIAL (REAR)

Differential Assembly
Differential Assembly and Associated Parts

425RY00004

Legend (1) Bolt and Nut (2) Axle Shaft Assembly

(3) Parking Brake Cable (4) Differential Assembly (5) Nut

Removal
1. Jack up and support the frame with stands. 2. Remove the wheel and tire. Refer to Wheel in Steering section. 3. Drain the differential oil. 4. Remove the propeller shaft. Refer to Rear Propeller Shaft in this section. 5. Remove the ABS speed sensor. Refer to 4Wheel Antilock Brake System (ABS) in Brake section.

6. Remove the parking brake cable fastening clip and disconnect the equalizer section. Refer to Parking Brakes in Brake section. 7. Remove the bearing holder fixing nuts. 8. Remove axle shaft assembly, be sure not to damage the oil seal by axle shaft. 9. Remove differential carrier mounting bolts and nuts. 10. Remove differential assembly.

DIFFERENTIAL (REAR)

4A213

Installation
1. Clean the contact surfaces of the axle and differential carrier. As shown in the drawing, apply Three Bond TB1215 or equivalent then install differential assembly.

425RS006

2. Install bolt and nut. Tighten the differential carrier mounting bolts and nuts to the specified torque. Torque:Nuts 44Nm (33lb ft) Bolts 66Nm (48lb ft) 3. Install axle shaft assembly. Be sure not to damage the oil seal by axle shaft. 4. Install nut, refer to Axle Shaft in this section. 5. Install parking brake cable, refer to Parking Brakes in Brake section. NOTE: After completing the assembling work, fill the prescribed gear oil to the filler hole. Lubricant capacity: 3.0 liter (3.2 US qt) 6. Tighten the oil filler plug to the specified torque. Torque: 78Nm (58lb ft)

4A214 DIFFERENTIAL (REAR)

Disassembled View

415RY00002

Legend (1) Flange Nut and Washer (2) Flange (3) Oil Seal (4) Outer Bearing (5) Outer Bearing Outer Race (6) Diff Carrier (7) Bearing Cap (8) Bolt

(9) (10) (11) (12) (13) (14) (15) (16) (17)

Inner Bearing Outer Race Collapsible Spacer Inner Bearing Adjust Shim (Pinion Position) Drive Pinion Shaft Differential Cage Assembly Adjust Shim (Diff Cage Assembly) Side Bearing Side Bearing Outer Race

DIFFERENTIAL (REAR)

4A215

Disassembly
1. Using holding fixture J42832 and holding fixture base J328920, fix the differential assembly to the bench.

5. Remove side bearing by using remover J42379 and adapter J81073. Select collet halves 44803 in remover kit J42379 for side bearing removal and insert is not required for this operation.

415RW003 425RW035

2. Apply a setting mark to the side bearing cap and the differential carrier then remove bearing cap.

6. Note the thickness and position of the shims then remove adjust shim. 7. Remove the flange nut and washer by using pinion flange holder J861401 after raising up its staked parts completely.

425RS009

3. Remove differential cage assembly. 4. Remove side bearing outer race. After removal, keep the right and left hand side bearing assemblies separate to maintain inner and outer race combinations.

415RS018

8. Removed flange assembly.

4A216 DIFFERENTIAL (REAR)

9. Remove the drive pinion assembly using a soft metal rod and a hammer. 15. Remove the inner bearing outer race (1) and the outer bearing outer race (2) by using a brass bar and a hammer.

425RY005

10. Remove collapsible spacer. 11. Remove the inner bearing by using remover J42379.Select insert 303174 and collet halves 44803 in remover kit J42379 for inner bearing removal.

425RS014

425RS015

415RW004

12. Remove adjust shim. 13. Remove oil seal. 14. Remove outer bearing.

DIFFERENTIAL (REAR)

4A217

Reassembly
1. Install outer bearing outer race by using installer J44461 and grip J8092.

2. Tighten the nut to the specified torque. Torque: 2.3 Nm (20 lb in)

425RW030 425RY00011

2. Install inner bearing outer race by using installer J44462 and grip J8092.

3. Clean the side bearing bores. Place discs and dial indicator on to arbor, and place tool into position in side bearing bores. Install and tighten the bearing caps to the specified torque.

425RY00012

3. Adjust the drive pinion mounting distance as follows: 1. Apply gear oil to the inner and outer drive pinion bearing. Clean the pinion setting gauge set. Then install the gauge set together with the inner and outer bearings. Install gauge plate J42826 (3), inner pilot J42827 (2) ,stud and nut J2177743 (4) and outer pilot J42824 (1) through inner and outer bearings.

425RW031

Legend (1) Dial Indicator: J8001 (2) Gauge Plate: J44451 (3) Disc (2 pcs.): J44452 (4) Arbor: J235971

4A218 DIFFERENTIAL (REAR)

4. Set the dial indicator J8001 to 0. Place it on the mounting post of the gauging arbor with the contact button touching the indicator pad. Force the dial indicator downward until the needle has made a half turn clockwise. Tighten down the dial indicator in this position. 6. After the ZERO setting is obtained, rotate the gauging arbor until the dial indicator rod does not touch the gauging plate. Record the number the dial indicator needle points to.

425RS022

425RS020

Legend (1) Example=Dial indicator reading od 0.085 7. Record the pinion depth code on the head of the drive pinion. The number indicates a necessary change in the pinion mounting distance. A plus number indicates the need for a greater mounting distance (which can be achieved by decreasing the shim thickness). A minus number indicates the need for a smaller mounting distance (which can be achieved by increasing the shim thickness). If examination reveals pinion depth code 0, the pinion is nominal.

Legend (1) Dial Indicator (2) Ganging Arbor (3) Plunger (4) Gauge Plate 5. Position the plunger on the gauge plate. Move the gauging arbor slowly back and forth and locate the position at which the dial indicator shows the greatest defection. At this point, once again set the dial indicator to 0. Repeat the procedure to verify the 0 setting.

425RS023

425RS021

DIFFERENTIAL (REAR)
8. Select the shim thickness using the chart;
Pinion marking Dial indicator reading (inches)

4A219

+10

+9

+8

+7

+6

+5

+4

+3

+2

+1

10

0.080 0.081 0.082 0.083 0.084 0.085 0.086 0.087 0.088 0.089 0.090 0.091 0.092 0.093 0.094 0.095 0.096 0.097 0.098 0.099 0.000 0.001 0.002 0.003 0.004 0.005 0.006 2.14
(0.0843)

2.12
(0.0835)

2.12
(0.0835)

2.12
(0.0835)

2.12
(0.0835)

2.14
(0.0843)

2.14
(0.0843)

2.16
(0.0850)

2.12
(0.0835)

2.12
(0.0835)

2.14
(0.0843)

2.14
(0.0843)

2.16
(0.0850)

2.16
(0.0850)

2.18
(0.0858)

2.18
(0.0858)

2.12
(0.0835)

2.12
(0.0835)

2.14
(0.0843)

2.14
(0.0843)

2.16
(0.0850)

2.16
(0.0850)

2.18
(0.0858)

2.18
(0.0858)

2.20
(0.0866)

2.20
(0.0866)

2.12
(0.0835)

2.12
(0.0835)

2.14
(0.0843)

2.14
(0.0843)

2.16
(0.0850)

2.16
(0.0850)

2.18
(0.0858)

2.18
(0.0858)

2.20
(0.0866)

2.20
(0.0866)

2.22
(0.0874)

2.22
(0.0874)

2.12
(0.0835)

2.12
(0.0835)

2.14
(0.0843)

2.14
(0.0843)

2.16
(0.0850)

2.16
(0.0850)

2.18
(0.0858)

2.18
(0.0858)

2.20
(0.0866)

2.20
(0.0866)

2.22
(0.0874)

2.22
(0.0874)

2.24
(0.0822)

2.24
(0.0822)

2.26
(0.0890)

2.12
(0.0835)

2.12
(0.0835)

2.14
(0.0843)

2.14
(0.0843)

2.16
(0.0850)

2.16
(0.0850)

2.18
(0.0858)

2.18
(0.0858)

2.20
(0.0866)

2.20
(0.0866)

2.22
(0.0874)

2.22
(0.0874)

2.24
(0.0882)

2.24
(0.0882)

2.26
(0.0890)

2.26
(0.0890)

2.28
(0.0898)

2.28
(0.0898)

2.12
(0.0835)

2.12
(0.0835)

2.14
(0.0843)

2.14
(0.0843)

2.16
(0.0850)

2.16
(0.0850)

2.18
(0.0858)

2.18
(0.0858)

2.20
(0.0866)

2.20
(0.0866)

2.22
(0.0874)

2.22
(0.0874)

2.24
(0.0882)

2.24
(0.0882)

2.26
(0.0890)

2.26
(0.0890)

2.28
(0.0898)

2.28
(0.0898)

2.30
(0.0905)

2.30
(0.0905)

2.14
(0.0843)

2.16
(0.0850)

2.16
(0.0850)

2.18
(0.0858)

2.18
(0.0858)

2.20
(0.0866)

2.20
(0.0866)

2.22
(0.0874)

2.22
(0.0874)

2.24
(0.0882)

2.24
(0.0882)

2.26
(0.0890)

2.26
(0.0890)

2.28
(0.0898)

2.28
(0.0898)

2.30
(0.0905)

2.30
(0.0905)

2.32
(0.0914)

2.32
(0.0914)

2.34
(0.0921)

2.16
(0.0850)

2.18
(0.0858)

2.18
(0.0858)

2.20
(0.0866)

2.20
(0.0866)

2.22
(0.0874)

2.22
(0.0874)

2.24
(0.0882)

2.24
(0.0882)

2.26
(0.0890)

2.26
(0.0890)

2.28
(0.0898)

2.28
(0.0898)

2.30
(0.0905)

2.30
(0.0905)

2.32
(0.0914)

2.32
(0.0914)

2.34
(0.0921)

2.34
(0.0921)

2.36
(0.0929)

2.36
(0.0929)

2.18
(0.0858)

2.20
(0.0866)

2.20
(0.0866)

2.22
(0.0874)

2.22
(0.0874)

2.24
(0.0882)

2.24
(0.0882)

2.26
(0.0890)

2.26
(0.0890)

2.28
(0.0898)

2.28
(0.0898)

2.30
(0.0905)

2.30
(0.0905)

2.32
(0.0914)

2.32
(0.0914)

2.34
(0.0921)

2.34
(0.0921)

2.36
(0.0929)

2.36
(0.0929)

2.38
(0.0937)

2.38
(0.0937)

2.20
(0.0866)

2.22
(0.0874)

2.22
(0.0874)

2.24
(0.0882)

2.24
(0.0882)

2.26
(0.0890)

2.26
(0.0890)

2.28
(0.0898)

2.28
(0.0898)

2.30
(0.0905)

2.30
(0.0905)

2.32
(0.0914)

2.32
(0.0914)

2.34
(0.0921)

2.34
(0.0921)

2.36
(0.0929)

2.36
(0.0929)

2.38
(0.0937)

2.38
(0.0937)

2.40
(0.0945)

2.40
(0.0945)

2.24
(0.0882)

2.24
(0.0882)

2.26
(0.0890)

2.26
(0.0890)

2.28
(0.0898)

2.28
(0.0898)

2.30
(0.0905)

2.30
(0.0905)

2.32
(0.0914)

2.32
(0.0914)

2.34
(0.0921)

2.34
(0.0921)

2.36
(0.0929)

2.36
(0.0929)

2.38
(0.0937)

2.38
(0.0937)

2.40
(0.0945)

2.40
(0.0945)

2.42
(0.0953)

2.42
(0.0953)

2.44
(0.0961)

2.26
(0.0890)

2.28
(0.0898)

2.28
(0.0898)

2.30
(0.0905)

2.30
(0.0905)

2.32
(0.0914)

2.32
(0.0914)

2.34
(0.0921)

2.34
(0.0921)

2.36
(0.0929)

2.36
(0.0929)

2.38
(0.0937)

2.38
(0.0937)

2.40
(0.0945)

2.40
(0.0945)

2.42
(0.0953)

2.42
(0.0953)

2.44
(0.0961)

2.44
(0.0961)

2.46
(0.0969)

2.46
(0.0969)

2.28
(0.0898)

2.30
(0.0905)

2.30
(0.0905)

2.32
(0.0914)

2.32
(0.0914)

2.34
(0.0921)

2.34
(0.0921)

2.36
(0.0929)

2.36
(0.0929)

2.38
(0.0937)

2.38
(0.0937)

2.40
(0.0945)

2.40
(0.0945)

2.42
(0.0953)

2.42
(0.0953)

2.44
(0.0961)

2.44
(0.0961)

2.46
(0.0969)

2.46
(0.0969)

2.48
(0.0977)

2.48
(0.0977)

2.30
(0.0905)

2.32
(0.0914)

2.32
(0.0914)

2.34
(0.0921)

2.34
(0.0921)

2.36
(0.0929)

2.36
(0.0929)

2.38
(0.0937)

2.38
(0.0937)

2.40
(0.0945)

2.40
(0.0945)

2.42
(0.0953)

2.42
(0.0953)

2.44
(0.0961)

2.44
(0.0961)

2.46
(0.0969)

2.46
(0.0969)

2.48
(0.0977)

2.48
(0.0977)

2.50
(0.0987)

2.50
(0.0987)

2.34
(0.0921)

2.34
(0.0921)

2.36
(0.0929)

2.36
(0.0929)

2.38
(0.0937)

2.38
(0.0937)

2.40
(0.0945)

2.40
(0.0945)

2.42
(0.0953)

2.42
(0.0953)

2.44
(0.0961)

2.44
(0.0961)

2.46
(0.0969)

2.46
(0.0969)

2.48
(0.0977)

2.48
(0.0977)

2.50
(0.0987)

2.50
(0.0987)

2.52
(0.0992)

2.52
(0.0992)

2.54
(0.1000)

2.36
(0.0929)

2.38
(0.0937)

2.38
(0.0937)

2.40
(0.0945)

2.40
(0.0945)

2.42
(0.0953)

2.42
(0.0953)

2.44
(0.0961)

2.44
(0.0961)

2.46
(0.0969)

2.46
(0.0969)

2.48
(0.0977)

2.48
(0.0977)

2.50
(0.0984)

2.50
(0.0984)

2.52
(0.0992)

2.52
(0.0922)

2.54
(0.1000)

2.54
(0.1000)

2.56
(0.1008)

2.56
(0.1008)

2.38
(0.0937)

2.40
(0.0945)

2.40
(0.0945)

2.42
(0.0953)

2.42
(0.0953)

2.44
(0.0961)

2.44
(0.0961)

2.46
(0.0969)

2.46
(0.0969)

2.48
(0.0977)

2.48
(0.0977)

2.50
(0.0984)

2.50
(0.0984)

2.52
(0.0992)

2.52
(0.0922)

2.54
(0.1000)

2.54
(0.1000)

2.56
(0.1008)

2.56
(0.1008)

2.58
(0.1016)

2.58
(0.1016)

2.42
(0.0953)

2.42
(0.0953)

2.44
(0.0961)

2.44
(0.0961)

2.46
(0.0969)

2.46
(0.0969)

2.48
(0.0977)

2.48
(0.0977)

2.50
(0.0984)

2.50
(0.0984)

2.52
(0.0992)

2.52
(0.0922)

2.54
(0.1000)

2.54
(0.1000)

2.56
(0.1008)

2.56
(0.1008)

2.58
(0.1016)

2.58
(0.1016)

2.44
(0.0961)

2.46
(0.0969)

2.46
(0.0969)

2.48
(0.0977)

2.48
(0.0977)

2.50
(0.0984)

2.50
(0.0984)

2.52
(0.0992)

2.52
(0.0922)

2.54
(0.1000)

2.54
(0.1000)

2.56
(0.1008)

2.56
(0.1008)

2.58
(0.1016)

2.58
(0.1016)

2.46
(0.0969)

2.48
(0.0977)

2.48
(0.0977)

2.50
(0.0984)

2.50
(0.0984)

2.52
(0.0992)

2.52
(0.0922)

2.54
(0.1000)

2.54
(0.1000)

2.56
(0.1008)

2.56
(0.1008)

2.58
(0.1016)

2.58
(0.1016)

2.48
(0.0977)

2.50
(0.0984)

2.50
(0.0984)

2.52
(0.0992)

2.52
(0.0922)

2.54
(0.1000)

2.54
(0.1000)

2.56
(0.1008)

2.56
(0.1008)

2.58
(0.1016)

2.58
(0.1016)

2.52
(0.0992)

2.52
(0.0922)

2.54
(0.1000)

2.54
(0.1000)

2.56
(0.1008)

2.56
(0.1008)

2.58
(0.1016)

2.58
(0.1016)

2.54
(0.1000)

2.56
(0.1008)

2.56
(0.1008)

2.58
(0.1016)

2.58
(0.1016)

2.56
(0.1008)

2.58
(0.1016)

2.58
(0.1016)

2.58
(0.1016)

4A220 DIFFERENTIAL (REAR)

4. Place the shim (1) on the drive pinion, then install the inner bearing (2) onto the pinion by using installer J42828 and a press . NOTE: Do not apply pressure to the roller cage. Apply pressure only to the inner race. 10. Install flange nut and washer. 1. Apply lubricant to the pinion threads. 2. Using the pinion flange holder J861401, tighten the nut only enough to remove the shaft end play. NOTE: Discard used flange nut and install new one.

425RW024

5. Install collapsible spacer. Discard the used collapsible spacer and install a new one. 6. Install drive pinion shaft assembly. 7. Install outer bearing. 8. Use oil seal installer J37263 to install a new oil seal that has grease on seal lip.

415RW006

3. Adjust pinion bearing preload. a. Measure the bearing preload by using a torque meter and note the scale reading required to rotate the flange. b. Continue tightening flange nut until the specified starting torque is obtained. Starting torque: 1.11.6 Nm (1014 lb in) NOTE: a. Do not overtighten or loosen and then retighten the nut. b. Pinion nut torque should be in the range of 298380 Nm (220281 Ib ft).

425RS025

9. Install flange assembly.

425RW018

DIFFERENTIAL (REAR)
4. Using punch J39209, stake the flange nut at two points. NOTE: When staking, be sure to turn the nut to ensure that there is no change in bearing preload. Make sure of preload again as instructed in 3).

4A221

2. Insert the differential cage assembly with bearing outer races into the side bearing bores of the carrier.

425RS030

425RS028

11. Adjust ring gear backlash. 1. Attach the side bearing to the differential assembly without shims by using installer J42829 and grip J8092.

3. Using two sets of feeler gauges, insert a feeler stock of sufficient thickness between each bearing outer race and the carrier to remove all end play. Make certain the feeler stock is pushed to the bottom of the bearing bores. Mount the dial indicator J8001 on the carrier so that the indicator stem is at right angles to a tooth on the ring gear.

425RW003

425RS031

4A222 DIFFERENTIAL (REAR)

4. Adjust feeler gauge thickness from side to side until ring gear backlash is in the specified range. Backlash: 0.13 0.2mm (0.005 0.008in) 12. Install the side bearings together with the selected shims by using installer J42829 (2) and grip J8092 (1).

425RW032 425RS032

With zero end play and correct backlash established, remove the feeler gauge packs, determine the thickness of the shims required and add 0.05 mm (0.002 in) to each shim pack to provide side bearing preload. Always use new shims. 5. Remove side bearing by using remover J42379 and adapter J81073.

13. Install side bearing outer race. 14. Install differential cage assembly. 15. Align the setting marks (1) applied at disassembly then install the bearing cap.

425RS035

415RW003

DIFFERENTIAL (REAR)
16. Tighten the bolt to the specified torque. Torque:108Nm (80lb ft)

4A223

425RS038

425RS036

Gear Tooth Contact Pattern Check and Adjustment 1. Apply a thin coat of Prussian blue or equivalent to the faces of the 78 teeth of the ring gear. Check the impression of contact on the ring gear teeth and make necessary adjustment as described in illustration if the contact is abnormal.

Legend (1) Heel (2) Toe (3) Concave Side(Coast) (4) Convex Side(Drive)

425RS039

4A224 DIFFERENTIAL (REAR)

Differential Cage Assembly

Disassembled View

415RY00001

Legend (1) Pinion Mate Gear (2) Thrust Washer(for Side Gear) (3) Side Gear (4) Differential Shaft

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

Ring Gear Bolt Differention Cage Lock Pin

DIFFERENTIAL (REAR)

4A225

Disassembly
1. Remove bolt. 2. Remove ring gear. 3. Remove lock pin using a small drift.

D D D D

Side gear, pinion mate gear, differential shaft Differential cage, carrier Thrust washer Oil seal

Ring gear replacement: 1. The ring gear should always be replaced with the drive pinion as a set. 2. Clean the ring gear threaded holes to remove the locking agent. 3. Discard used bolts and install new ones. 4. When installing the ring gear, apply LOCTITE 271 or equivalent to all the threaded area and half of the unthreaded area of the bolt. Torque: 127Nm (94 lb ft)

425RY00002

4. Remove the differential shaft by using a soft metal rod and a hammer.

425RW033

Clearance between the differential pinion and the pinion shaft measurement. Standard: 0.07 0.13 mm (0.003 0.005 in) Limit: 0.2 mm (0.008 in)

425RS043

5. Remove pinion mate gear. 6. Remove side gear and thrust washer.

Inspection and Repair

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: D Ring gear, pinion gear D Bearing
425RY00007

4A226 DIFFERENTIAL (REAR)

Clearance between the side gear and the differential box. Standard: 0.032 0.105 mm (0.001 0.004 in) Limit: 0.105 mm (0.004 in)

Reassembly
Differential cage Thrust washer Side gear Pinion gear 1. Install the pinion gear by engaging it with the side gears while turning both pinion gears simultaneously in the same direction. 2. Install the pinion mate gear with thrust washer by engaging it with the side gears while turning both pinion mate gears simultaneously in the same direction.

425RY00005

Legend (1) Side gear (2) Differential box Play in splines between the side gear and the axle shaft. Standard: 0.07 0.38 mm (0.003 0.014 in) Limit: 0.5 mm (0.02 in)

425RS048

3. Install differential shaft. 1. Be sure to install the differential shaft so that it is in alignment with the lock pin hole in the differential cage.

425RY00006

425RS049

DIFFERENTIAL (REAR)
2. Adjust the backlash between the side gear and the pinion gear. Backlash: 0.10 0.20 mm (0.004 0.008 in) Thickness of thrust washers available mm in 0.80 0.031 0.90 0.035 1.00 0.039 1.10 0.043 1.20 0.047 1.30 0.051 Torque: 127Nm (94 lb ft)

4A227

5. Tighten the bolts in diagonal sequence as illustrated. NOTE: Discard used bolts and install new ones.

425RW033

425RY00008

4. Install lock pin. D Install the lock pin using small drift.

425RY00009

4A228 DIFFERENTIAL (REAR)

Limited Slip Differential

Disassembled View

425RY001

Legend (1) Screw (2) Differential cage A (3) Thrust washer (4) Spring disc (5) Friction Plate (6) Friction plate (7) Friction Plate (8) Friction disc (9) Friction Plate (10) Friction disc (11) Friction Plate (12) Pressure ring (13) Side gear

(14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26)

Pinion and Pinion shaft Side gear Pressure ring Friction Plate Friction disc Friction Plate Friction disc Friction Plate Friction Plate Friction Plate Spring disc Thrust washer Differential cage B

DIFFERENTIAL (REAR)

4A229

Disassembly
Differential Cages A and B 1. To ensure installation of the parts in original position apply a setting mark before removing the differential cages A and B. 2. Using special tool, J44450, grip it with a vice, and set the differential.

9. Remove Friction plate. 10. Remove Friction disc. 11. Remove Friction plate. 12. Remove Friction disc. 13. Remove Friction plate. 14. Remove Pressure ring. 15. Remove Side gear. 16. Remove Pinion and pinion shaft. 17. Remove Side gear. 18. Remove Pressure ring. 19. Remove Friction plate. 20. Remove Friction disc. 21. Remove Friction plate. 22. Remove Friction disc. 23. Remove Friction plate. 24. Remove Friction plate. 25. Remove Friction plate. 26. Remove Spring disc. 27. Remove Thrust washer. 28. Remove Differential cage B.

Inspection and Repair

425RS054

3. Gradually and evenly loosen the 3 fixing screws of the differential cages A and B.

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition is found through inspection.

Visual check
Check the following parts for wear, damage, noise or any other abnormal conditions. D Friction disc, friction plate and spring disc

425RS055

4. Remove Differential cage A. 5. Remove Thrust washer. 6. Remove Spring disc. NOTE: When removing the spring disc, friction disc, and friction plate, place them in order for clear distinction of left and right use. 7. Remove Friciton plate. 8. Remove Friction plate.
425RS056

Legend (1) Sliding surfaces (2) Projections

4A230 DIFFERENTIAL (REAR)

D Pressure ring D Case

425RY003

425RS059

Legend (3) Sliding surface with the friction disc. When nicks or scratches are found, polish with an oil stone and repair on a level block using a compound. (4) Sliding spherical surface with the pinion gear. (5) Sliding surface with the side gear. (6) Vshaped groove of the pressure ring and V shaped section of the pinion shaft. (7) Fitting section with the case. (8) Face contacting the inner surface of the differential case. Repair burrs and nicks using an oil stone. D Thrust washer

Legend (11) Contact surface with the spring disc. (12) Inner groove of the differential cage B. Repair light nicks and burrs using an oil stone.

425RS060

Legend (7) Fitting section with the case. (8) Face contacting the inner surface of the differential case. Repair burrs and nicks using an oil stone. (9) Sliding surface with the side gear or case. (11) Contact surface with spring disc.
425RS058

Legend (9) Sliding surface with the side gear or case. (10) Peripheral groove of the side gear. Repair light nicks and burrs using an oil stone.

DIFFERENTIAL (REAR)
Measure the Deformation of the friction disc & plate. Limit: 0.08 mm (0.003 in) Measure the wear of the thrust washer Limit: 1.3 mm (0.05 in)

4A231

425RS061

425RS063

Measure the wear of the friction plate & disc Limit(AB): 0.1 mm (0.004 in) Remarks: A=Inner or outer projections B=Sliding surface subjected to abrasion

Reassembly
Adjust the clearance between the friction disc and plate. 1. Measuring the depth of the differential cage. Standard (AB): (C): 89.13 mm (3.51 in) 9.13 mm (0.36 in)

425RS062

425RS064

4A232 DIFFERENTIAL (REAR)

2. Measuring the overall length of the pressurering, friction disc and friction plate. D Mount the pinion shaft in the pressurering and then install the friction disc & plate. D Measure the length between the plates over the Vgroove. (D)

425RS066

2. Measuring the dimension between the thrust washers at both ends. D Assemble the side gear, pinion, pinion shaft, pressure ring and thrust washer, and pressing the pressure ring tothe pinion shaft in the direction of the shaft to make the clearance 0.
425RS065

3. After measuring dimensions A,B,C and D, make adjustment in the following manner: D Measure the thickness (E) of the spring disc. 1.75mm (0.069in) 2 discs 4. Select the friction disc & plate so as to satisfy the following equation: {(A-B)+C}-(D+E)=0.06-0.20mm (0.002-0.008in) Also, the total size difference of the friction disc & plate and spring disc should be 0.05mm (0.02in) or less. Thickness :1.651.751.85mm(0.0650.0690.073 in)

D Have the side gear contact to the pinion to make the backlash 0. D Measure the dimension washers at both ends. (H) between thrust

Backlash adjustment of the side gear in the direction of the shaft

1. Measuring the depth of the differential cage. (FB): 95.63 mm (3.76 in) (G): 15.63 mm (0.62 in)

425RS067

DIFFERENTIAL (REAR)
3. After measuring dimensions of each of the above sections, proceed with the adjustment in the following manner: Adjust the clearance to satisfy the equation below. {(F B) + G H}=0.05 0.20 mm Also, select the thrust washers so that the dimensional difference between the back surfaces of the left and right pressure rings to the thrust washers is 0.05mm or less. Thickness : 1.5mm (0.059 in) 1.6 mm(0.063 in) 1.7 mm(0.067 in) NOTE: When assembling the parts, apply recommended gear oil sufficiently to each of the parts, especially, to the contact surfaces and sliding surfaces. 1. Install Differential cage B. 2. Install Thrust washer. 3. Install Spring disc. D When assembling the spring disc, make sure the mounting direction is correct as shown in figure.

4A233

6. Install Friction plate. 7. Install Friction disc. 8. Install Friction plate. 9. Install Friction disc. 10. Install Friction plate. 11. Install Pressure ring. 12. Install Side gear. 13. Install Pinion and pinion shaft. 14. Install Side gear. 15. Install Pressure ring. 16. Install Friction plate. 17. Install Friction disc. 18. Install Friction plate. 19. Install Friction disc. 20. Install Friction plate. 21. Install Friction plate. 22. Install Friction plate. 23. Install Spring disc. D When assembling the spring disc, make sure the mounting direction is correct. 24. Install Thrust washer. 25. Install Differential cage A. 26. Install Screw. D Matching the guide marks of the differential cages A and B, tighten the screws evenly in the diagonal order.

425RY004

Legend (1) Friction Plate (2) Spring Disc (3) Friction Disc 4. Install Friction plate. 5. Install Friction plate.
425RS055

4A234 DIFFERENTIAL (REAR)

27. Check the operation. D Measure the starting torque using the side gear holder. Starting torque: 29 45 Nm (3.0 4.6 kgm/ 22 33Ib ft)

425RW065

Legend (1) Side Gear Holder : J44450

DIFFERENTIAL (REAR)

4A235

Main Data and Specifications

General Specifications
Rear axle Type Rear axle Size Gear type Gear ratio (to 1) Differential type Lubricant Grade Locking Differential Lubricant Banjo, Semifloating 244 mm (9.61 in) Hypoid 4.300 Two pinion GL5: (Standard differential) GL5, LSD: (Limited slip differential) 80W90 GL5 (USE Limited Slip Differential Gear Lubricant or Friction Modifier Organic Additive) 3.0 liter (3.2 US qt)

Capacity

Torque Specifications

420RY00002

4A236 DIFFERENTIAL (REAR)

Special Tools
ILLUSTRATION TOOL NO. TOOL NAME ILLUSTRATION TOOL NO. TOOL NAME

J39210 Installer; Axle shaft inner seal

J37263 Installer; Pinion oil seal

J6627A Wheel pin remover

J42832 Holding fixture

J39211 Remover; Axle shaft bearing

J328920 Holding fixture base

J39212 Installer; Axle shaft bearing

J42379 Remover; Bearing

J39379 Installer; Outer axle seal

J81073 Adapter; Side bearing plug

J861401 Pinion flange holder

J44461 Installer; Outer bearing outer race

DIFFERENTIAL (REAR)
ILLUSTRATION TOOL NO. TOOL NAME ILLUSTRATION

4A237

TOOL NO. TOOL NAME

J8092 Grip

J44451 Gage plate

J44462 Installer; Inner bearing outer race

J8001 Dial indicator

J42824 Pilot;Outer

J44452 Disc (2 required)

J2177743 Nut & Stud

J235971 Arbor

J44453 Pilot;Inner

J42828 Installer; Pinion bearing

J44449 Pilot;Outer bearing

J39209 Punch; End nut lock

4A238 DIFFERENTIAL (REAR)

ILLUSTRATION TOOL NO. TOOL NAME

J42829 Installer; Side bearing

J39602 Remover; Outer bearing

J39858 Clutch pack unloading tool kit Includes J341741/J341742 Screw cap and Cap J2234215 Forcing screw

J44450 Side gear holder

SECTION
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
TROOPER

4B11

DRIVELINE/AXLE
DRIVELINE CONTROL SYSTEM (SHIFT ON THE FLY)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . Shift On The Fly System . . . . . . . . . . . . . . . . . Outline of Shift on The Fly System . . . . . . . . . Functions of Indicator Lamp . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Axle Diagnosis . . . . . . . . . . . . . . . . . . . . . Shift On The Fly Vacuum Piping And Electric Equipment . . . . . . . . . . . . . . . . . . . . . . 4B11 4B12 4B12 4B16 4B17 4B117 4B119 Vacuum piping diagram . . . . . . . . . . . . . . . . . . Inspection And Repair . . . . . . . . . . . . . . . . . . . 4WD Control Unit . . . . . . . . . . . . . . . . . . . . . . . 4WD Control Unit Associated Parts . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B119 4B120 4B123 4B123 4B124 4B124

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

4B12

DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)

Shift On The Fly System

Outline of Shift on The Fly System
The shift on the fly system switches between 2 wheel drive (2WD) and 4 wheel drive (4WD) electrically by drivers pressing the 4WD switch (push button type) on instrument panel. This system controls below operations. (Shifting between 4H and 4L must be performed by transfer control lever on the floor.) 1. Shifting the transfer front output gear (Connecting to, and disconnecting from, front propeller shaft by motor actuator). 2. Retrial of shifting the transfer front output gear. 3. Connecting front wheels to, and disconnecting them from, the front axles by vacuum actuator. 4. Indicator on instrument panel. 5. 4WD out signal to other Electronic Hydraulic Control Unit.

System Diagrams

412RX003

DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)

4B13

Normal Operation
The motor actuator mounted on transfer rear case is driven by signal from 4WD switch on instrument panel. After complete the connecting transfer front output gear to, or disconnecting it from, front propeller shaft, condition Time Chart of Shifting Under Normal Condition of the transfer position switch changes. The vacuum solenoid valve (VSV) is driven by the signal from transfer position switch and the vacuum actuator connects front wheels to, or disconnect them from, front axles.

F04RW002

4B14

DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)

gear. This procedure is repeated 3 times in maximum. While this procedure, 4WD indicator lamp blinks by 2 Hz. If the transfer position switch does not turn on after aforementioned procedure has been repeated 3 times, the gear shifting is stopped and 4WD indicator lamps blinking changes from 2Hz to 4Hz to notify driver that the gear shifting is stopped. This blinking of indicator lamp continues until 4WD switch is returned from 4WD to 2WD.

Retrial
The motor actuator starts transfer gear shifting after signal from 4WD switch on instrument panel has been received. But the shifting may be impossible in cold weather or under high speed condition. When 2 seconds have passed since transfer gear shifting started and the transfer position switch dose not turn on (the gear engagement is not completed), the motor reverses its rotation for 1.2 seconds and tries again to shift transfer Time Chart of Shifting Under Severe Condition (retrial)

F04RX001

DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)

Warning at 4L position :In view of the shifting mechanism of transfer, the gear shifting from 4WD to 2WD at 4L condition is impossible. Therefore, the transfer position switch can not be turned off by 4WD

4B15

switch when vehicle is in 4L condition. In the case this condition continues for 2 seconds, the shifting to 2WD is stopped and the indicator lamps blinking changes from 2Hz to 4Hz to notify driver of wrong operation.

Time Chart of Shifting from 4WD to 2WD at 4L Condition

F04RX002

4WD out signal to other Electronic Hydraulic Control Unit : 4WDcontrol unit sends 4WD out signal to other Electronic Hydraulic Control Unit as below. 4WD out signal (Period) 120 ms 240 ms Vehicle Condition 2WD 4WD Transfer position switch 2WD (Open) 4WD (Close) Front axle switch 2WD (Open) 4WD (Close)

4B16

DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)

Functions of Indicator Lamp

Indication of vehicle condition : Indicator lamp is controlled by 4WD control unit and shows vehicle conditions as below. Indicator Off On Blink (2Hz) Blink (4Hz) Vehicle condition 2WD 4WD Operating Stop operating 4WD switch Off (Close) On (Open) On (Open) Off (Close) On (Open) Off (Close) Bulb check : Transfer position switch 2WD (Open) 4WD (Close) 4WD (Close) 2WD (Open) 2WD (Open) 4WD (Close) Front axle switch 2WD (Open) 4WD (Close) 2WD (Open) 4WD (Close) 2WD (Open) 4WD (Close)

F04RX003

Retrials from 2WD to 4WD :In cold weather or under high speed condition, the gear shifting (engagement) sometimes does not complete by 3 trials. In such case, the indicator lamp inform driver of this incident as aforementioned chart (shown at Retrial in Outline of shift on the fly system).

DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)

4B17

Diagnosis
Before Judging That Troubles Occur (Unfaulty mode)
When Switching from 2WD to 4WD 1. In case that blinking frequency of the 4WD indicator changes from 2Hz to 4Hz. When heavy synchronization load is needed, the motor actuator tries the shifting transfer gear three times including the activation shifting. While the motor actuator tries shifting, the indicator blinks by 2Hz. If the third shifting fails, the indicators blinking changes from 2Hz to 4Hz at the same time that the motor actuator shifted back to 2WD. Heavy synchronization load occurs by: D extremely lower temperature. D higher speed, rotation difference of wheels during cornering. Solution 1: Operate again after stop the vehicle or slow down. 2. In case that the 4WD indicator continues blinking by 2Hz for more than 11.5 seconds. When there is rotation difference of wheels or there is phase difference between front wheels and axles, it is difficult to connect front wheels to front axles. The blinking by 2Hz shows that shifting the transfer gear or connecting the front wheels is in the middle of operating. In above case, the indicators blinking by 2Hz shows that connecting the front wheels is not completed (because the indicators blinking changes to 4Hz when the shifting transfer gear is impossible.). And removal of rotation or phase difference make connecting the front wheels possible. Solution 2: When vehicle is running, drive straight ahead while accelerating and decelerating. When vehicle is at a stop, move the vehicle forward and backward from 2 to 3 meters. When switching from 4WD to 2WD 1. In case that the 4WD indicator continues blinking by 2Hz . The 4WD indicator continues blinking by 2Hz until both shifting the transfer gear and disconnecting the front wheels are completed when switching 4WD to 2WD. When driveline is loaded with torsional torque, the shifting transfer gear and disconnecting front wheels are impossible. In this case, removal of torsional torque on driveline make the shifting transfer gear and disconnecting front wheels possible. Solution 3: When vehicle is running, drive straight ahead while accelerating and decelerating. When vehicle is at a stop, move the vehicle forward and backward from 2 to 3 meters. 2. In case that the 4WD indicators blinking changes from 2Hz to 4Hz. Check the position of transfer lever. Is it at 4L position? In view of the shifting mechanism of transfer, the gear shifting from 4WD to 2WD at 4L condition is impossible. Solution 4: Push the 4WD switch to 4WD, shift the transfer lever to High position and reoperate the 4WD switch to 2WD.

4B18

DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)

Parts Location

D08RX005

Legend (1) I12 (2) I9 (3) H7, H24, H25 (4) Fuse Box (5) C16 (6) C94 (7) M11, M12

(8) (9) (10) (11) (12) (13) (14)

M22 M23 M24 H10 M26 Relay & Fuse Box H12, H16

DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)

4B19

Wiring Diagram

D08RW028

4B110

DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)

D08RW029

DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B111

Connector List

D04RW030

4B112

DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)

Diagnosis of The Faults Based on the Status of 4WD Indicator Lamp, 4WD Switch and T/F Change Lever
Diagnosis charts are shown on below. If troubles can not be solved after every chart was traced, troubles may occur in the 4WD control unit. In this case, replace the 4WD control unit and trace every chart again. Fault on switching from 2WD to 4WD 1. In case that 4WD indicators blinking changes from 2Hz to 4Hz after Solution 1 is carried out. Faults occur in the motor actuator or the transfer case assembly. Remove the motor actuator and check function. If problem was found and it was repaired, try Solution 1 again. After that, disassemble the transfer case assembly for check and repair or replace. If incident is not improved after above mentioned actions were taken, replace the 4WD control unit. 2. In case that 4WD indicator does not blink nor light, when switching from 2WD to 4WD. Step 1 Is ignition turned on? Go to Step 2 2 Does the indicator light comes on when the engine is not started? Action Yes No Turn on the ignition and trace this chart from start. Burning out of indicator lamp or disconnection of harness wire. Trace this chart from the start after repair or replace.

Go to Step 3 3 Start the engine. Is the 4WD switch turned from 2WD to 4WD? Short-circuit (body short) on harness of the 4WD switch. Fault of the 4WD switch (holding the closed condition). Trace this chart from the start after repair or replace.

Push the 4WD switch to 4WD.

DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B113

3. Case that the indicator keeps blinking by 2Hz after aforementioned Solution 2 is carried out. Step 1 Were problems found? Action Check the air pressure and wear of all tires. Yes Try Solution 2 after adjust the air pressure and replace worn tires. No

Go to Step 2 Disconnection of the motor actuator harness wiring. Trace this chart from the start after repair or replace. Faults on the motor actuator. Trace this chart from the start after replace. Internal faults of transfer case. Disassemble the transfer case for check. Trace this chart from the start after repair or replace. Faults on the transfer position switch or its harness. Trace this chart from the start after repair or replace. Faults on the VSV main body, its harness or vacuuming system. Trace the front axle diagnosis chart in this section. After that, trace this chart from the start. Disconnection on the axle harness. Trace this chart from the start after repair or replace. Faults on Front Axle ASM. Trace the front axle diagnosis chart in this section. After that, trace this chart from the start.

2 Can the transfer lever be operated from High to 4L or vice versa?

Go to Step 3 3 Pull out the hoses from vacuum actuator and operate 4WD switch. Is there negative pressure on either of hoses?

Go to Step 4 4 Check the axle switch. Were problems found?

Internal faults on axle switch. Trace this chart from the start after replace.

4B114

DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)

Fault on switching from 4WD to 2WD 1. Case that indicator does not blink nor turn out. Step 1 Does the indicator turn out by ignition off? 2 Is the 4WD switch on 2WD position? Go to Step 2 Disconnection on the 4WD switch harness or breakdown of the 4WD switch in open state. Trace this chart from the start after repair or replace. Action Yes No Short circuit of the indicator harness.

Turn the 4WD switch to 2WD position. Trace this chart from the start.

DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B115

2. Case that indicator keeps 2Hz blinking after aforementioned Solution 3 is carried out. Step 1 Were problems found? Action Check the air pressure and wear of all tires. Yes Try Solution 3 after adjust the air pressure and replace worn tires. Faults on the harness wiring of motor actuator. Trace this chart from the start after repair or replace. Internal faults on transfer case. Disassemble the transfer case for check. Trace this chart from the start after repair or replace. Faults on the motor actuator. Trace this chart from the start after or replace. No

Go to Step 2

2 Can the transfer lever be operated from High to 4L or vice versa?

Go to Step 3 Faults on the transfer position switch or its harness. Trace this chart from the start after repair or replace. Faults on the VSV main body, its harness or vacuuming system. Trace the front axle diagnosis chart in this section. After that, trace this chart from the start.

Pull out the hoses from vacuum actuator and operate 4WD switch. Is there negative pressure on either of hoses?

Go to Step 4 4 Check the axle switch. Were problems found? Internal faults on axle switch. Trace this chart from the start after replace. Faults on Front Axle ASM. Trace the front axle diagnosis chart in this section. After that, trace this chart from the start.

Short circuit (body short) or disconnection of the axle harness. Trace this chart from the start after repair or replace.

4B116

DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)

3. Case that indicators blinking changes to 4Hz after aforementioned Solution 4 is carried out. Step 1 Can the transfer lever be operated from High to 4L or vice versa? Action Yes Faults on the harness wiring of motor actuator. Trace this chart from the start after repair or replace. Faults on the motor actuator. Trace this chart from the start after replace. Internal faults on transfer case. Disassemble the transfer case for check. Trace this chart from the start after repair or replace. No

Faults on the 4WD control unit. Trace this chart from the start after replace.

DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B117

Front Axle Diagnosis

D When the 4WD switch is operated from 4WD to 2WD, indicator light does not go out. Step 1 2 Action Drive slow 100 200m after a few minutes idling. Has indicator light gone out? Jack up front tires. Does the right side of front wheel rotate when the left side of front wheel is rotated? 3 1. Check the actuator switch. 2. Check the circuit to indicator. Was a problem found? Trace this chart from the start after repair or replace. Trace this chart from the start after repair or replace. Go to Step 4 Go to Step 3 Disassemble axle ASM for check. Trace this chart from the start after repair or replace. All right. Go to Step 2 Yes No

1. Check the VSV valve. 2. Check the circuit to VSV valve. Was a problem found?

Go to Step 5 Trace this chart from the start after repair or replace. Disassemble axle ASM for check. Trace this chart from the start after repair or replace.

Is vacuum piping all right? (tank, hose, & pipe damage or trouble) Go to Step 6

Does actuator work all right?

Trace this chart from the start.

4B118

DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)

D When the 4WD switch is operated from 2WD to 4WD, indicator light is not actuated. Step 1 2 Action Drive slow 100 200m after a few minutes idling. Has indicator light actuated? Jack up front tires. Does not the right side of front wheel rotate when the left side of front wheel is rotated? 3 1. Check the actuator switch. 2. Check the circuit to indicator. Was a problem found? Trace this chart from the start after repair or replace. Trace this chart from the start after repair or replace. Go to Step 4 Go to Step 3 Disassemble axle ASM for check. Trace this chart from the start after repair or replace. All right. Go to Step 2 Yes No

1. Check the VSV valve. 2. Check the circuit to VSV valve. Was a problem found?

Go to Step 5 Trace this chart from the start after repair or replace. Disassemble axle ASM for check. Trace this chart from the start after repair or replace.

Is vacuum piping all right? (tank, hose, & pipe damage or trouble) Go to Step 6

Does actuator work all right?

Trace this chart from the start.

DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B119

Shift On The Fly Vacuum Piping And Electric Equipment

Vacuum piping diagram

C04RW007

VSV Assembly, Actuator Assembly

Vacuum Tank

412RS032

412RS033

4B120

DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)

Inspection And Repair

Vacuum Piping

C04RW008

1. Pull out the Hose A in figure and install a vacuum gauge. 2. Plug up Hose B in figure to prevent the leak of vacuum. 3. Start the engine and measure vacuum 2 or 3 minutes afterward. 4. Repeat 1) and 2) but with Hose A plugged and Hose B pulled out. 5. If vacuum measures 400mmHg, or if it shows a sudden drop immediately after engine stop, inspect the hose, tank, and pipe for damage. NOTE: Be careful not to permit the entry of dust and water during inspection. 6. Pull out Hose D in above illustration. 7. Plug Hose E in above illustration. 8. Make sure that Hose D in above illustration is under atmospheric pressure. 9. Pull out Hose E and plug Hose D, and make sure that Hose E is under atmospheric pressure. 10. If Check 8) or 9) has revealed stoppage, check and see that there is no bend, foreign matter in the hose or in the filter. If there is trouble, repair or replace.

Check Valve

C04RS004

1. Apply vacuum from the orange colored side(1). Vacuum:400mmHg 2. Check leakage of vacuum. 3. Make sure that vacuum cannot be applied from the black colored side(2). 4. If vacuum is not applicable as much as 400mmHg, and if there is resistance on the intake side, replace with a new check valve.

DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B121

VSV Assembly
Inspect the vehicle side harness as follows:

2. With battery connected A B:There is continuity C:Closed 3. If 1) and 2) fail, replace with a new VSV.

Axle Position Switch

412RS071

Legend (1) Grey (2) Blue

412RS048

1. Remove connector. 2. Shift transfer lever to 2H and start the engine. NOTE: Do not move the vehicle while inspection. 3. Make sure that there is continuity in the vehicle side of harness. If there is no continuity, check transfer shift switch and wiring. Inspect both VSVs as follows:

1. With ball (1) being free A B:There is continuity 2. With ball forced into the switch A B:No continuity 3. If 1) and 2) fail, replace with a new switch.

Motor Actuator Assembly

Inspect the function of the motor actuator assembly as follows:

F04RS004

1. With battery not connected (Usual). AC:There is continuity B:Closed

4B122

DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)

Shift rod of the motor actuator moves and stops at 2WD position.

1. Disassemble the motor actuator from transfer rear case.

412RW037

412RX002

Legend (3) Shift Rod (4) Connector 2. Connect the terminals as shown in figure. Shift rod of the motor actuator moves and stops at 4WD position.

Legend (1) 2WD (2) 4WD (3) Shift Rod (4) Connector 4. If 2) and 3) fail, replace with a new motor actuator.

Transfer Position Switch

412RX001

Legend (1) 2WD (2) 4WD (3) Shift Rod (4) Connector 3. Connect the terminals as shown in figure.

412RW040

Legend (1) Ball 1. With ball being free. AB : There is continuity. 2. With ball forced into the switch. AB : No continuity. 3. If 1) and 2) fail, replace with a new switch.

DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B123

4WD Control Unit

4WD Control Unit Associated Parts

412RW044

Legend (1) Lower Cluster Assembly (2) Front Console Assembly

(3) Harness Connector (4) Nut (5) 4WD Control Unit

4B124

DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)

Removal
1. Remove lower cluster assembly and front console assembly. Refer to Interior Trim in Body and Accessories section. 2. Remove nut. 3. Remove 4WD control unit. 4. Disconnect harness connector (1).

412RW045

Legend (1) Harness Connector

Installation
1. Connect harness connector, then install 4WD control unit. 2. Install lower cluster assembly and front console assembly.

SECTION
DRIVE LINE CONTROL SYSTEM (TOD)
TROOPER

4B21

DRIVELINE/AXLE
DRIVELINE CONTROL SYSTEM (TOD)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . System Components . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Functions of Indicator Lamp . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic Diagnostic Flow Chart . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 4B21 4B22 4B24 4B24 4B28 4B212 4B216 4B217 4B218 Connector List . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Failed Pin . . . . . . . . . . . . . . . . . . . . . Checking Failed TOD Control Unit Pin . . . . . Diagnostic Trouble Codes . . . . . . . . . . . . . . . . Diagnosis from Trouble Codes . . . . . . . . . . . . Trouble Diagnosis Depending on The Status of TOD Indicator . . . . . . . . . . . . . . . . . . . . . . . . Diagnosis from Symptom . . . . . . . . . . . . . . . . . 4B221 4B223 4B226 4B231 4B232 4B256 4B285

Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.

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

4B22 DRIVE LINE CONTROL SYSTEM (TOD)

General Description

C07RY00003

TOD (Torque on Demand) system is traction state control system to vehicle.

Transfer Position and Drive Mode

Three drive modes can be selected through operation of 4WD switch and transfer lever. Transfer Position HIGH 4WD AUTO SWITCH ON OFF 4L ON/OFF Mode 2H TOD 4L Drive mode Rear wheel drive Electronically controlled torque split four wheel drive Low-speed mechanical lock-up four wheel drive

The electronic control unit (ECU) judges the signals from the transfer lever and controls the transfer drive mode and shift-on-the-fly system status.

TOD Control
The TOD position usually drives the rear wheels, and transmits the torque to the front wheels with the help of electronically controlled torque split mechanism according to running conditions encountered. The driving force is directly transmitted to the rear wheels. This force is split by the transfer and delivered to the front wheels. The magnitude of the torque transmitted to the front wheels is controlled by changing the pressing force of the multi plate disk clutch built in the transfer unit. The

pressing force of the clutch is controlled by changing the voltage to the electromagnetic coil mounted to the rear of the clutch. When the clutch is completely disengaged, the rear wheels are driven. When the clutch is completely engaged, a rigid four wheel drive mode is obtained. The torque split status is controlled continuously between the rear wheel and four wheel drive modes. This system includes front and rear speed sensors, and receives throttle position sensor information from the PCM. The control unit receives signals sent from these sensors and changes the pressing force of the multi plate disk clutch to determine the torque distribution on the front and rear wheels. Therefore, when the slip of the rear wheels is increased against the current torque level in the normal

DRIVE LINE CONTROL SYSTEM (TOD)

rear wheel drive mode, the control unit detects the slip condition, determines the optimum torque based on the feedback control logic, and increases the torque to the front wheels. The control unit uses the signal from the throttle position sensor to predict the future vehicle condition and the intention of the driver with respect to acceleration and deceleration, and determines the initial torque distribution using these data and the information from the speed sensors. In case of small circle turning in the parking lot, for example, the control unit minimizes the clutch pressing force to restrict a braking phenomenon. When the ABS becomes active, the control unit optimizes the clutch pressing force to ensure stable braking.

4B23

TOD Indicator Control

The TOD indicator on the instrument panel informs the driver of the current working status of the transfer unit. The information consists of two items: the drive mode (2H, TOD, 4L, transition) and the torque split status of the TOD (torque distribution level). The indicator can display occasional errors and corresponding error codes.

4B24 DRIVE LINE CONTROL SYSTEM (TOD)

System Components
Parts Location

A07RY00002

Legend (1) T/F Connector (2) 4H Switch and 4L Switch (3) High-Low Planetary Gear Set (4) Mechanical Lock

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

Multi Plate Disk Clutch Pack Electromagnetic Coil Rear Speed Sensor Front Speed Sensor

DRIVE LINE CONTROL SYSTEM (TOD)

4B25

Front and Rear Speed Sensors

The sensors are built in the transfer case, and detect the rotation of rotors directly coupled to the propeller shafts. Thirty rectangular pulses are output per one rotation of the propeller shaft.

Multi Plate Disk Clutch Pack

Transmits the torque determined by the clutch pressing force to the front propeller shaft via the front drive chain.

262RW029

261RW045

Mechanical Lock Sleeve

Couples the front and rear propeller shaft mechanically when the transfer shaft is in the 4L position.

Electromagnetic Coil
Receives the duty signals from the TOD control unit and controls the pressing force of the clutch pressure cam.

262RW028

261RW044

4B26 DRIVE LINE CONTROL SYSTEM (TOD)

High-Low Planetary Gear Set

Establishes an auxiliary transmission mechanism. When the transfer shift lever is set to the 2H or TOD position, the reduction gear ratio is 1.000 and the corresponding driving force is generated. When the transfer shift lever is set to the 4L position, the reduction gear ratio is 2.480 and the corresponding driving force is generated.

Transfer Connector
Transmits the input and output signals of the speed sensors, electromagnetic coil, and 4H and 4L switche to the vehicle harness. A waterproof 12-pin type is used.

261RW046

262RW030

TOD Indicator Lamps (on the instrument panel)

Inform the following items. D Bulb check D Drive mode D ABS IN status D BRAKE ON status

4H and 4L Switch
Detects the shift position of the transfer from the movement of the transfer lever and outputs signals to the TOD control unit.

261RW002 821RW049

DRIVE LINE CONTROL SYSTEM (TOD)

4B27

Check Lamp
Inform the following items. D Bulb check D Fail (fail alarm) D Trouble code

821RW078

TOD ECU
This control unit is mounted to the front right hand seat via a special bracket.

F07RW029

4B28 DRIVE LINE CONTROL SYSTEM (TOD)

Functions of Indicator Lamp

TOD Indicator Lamps

C07RY00017

DRIVE LINE CONTROL SYSTEM (TOD)

Indication During Transition of Transfer Lever When the transfer lever is shifted, and the signals from the AXLE switch do not comply with the signal conditions of the 4H and 4L switch, the transfer lever position signals generated by the 4H and 4L switch and the N position signals are repeatedly output at an interval of 0.8 second. NOTE: After the transfer lever is set to the specified position and the AXLE switch generates compliant signals, the normal output status is returned.

4B29

C07RW015

Bulb Check When the starter switch is turned on, the TOD indicator lamps go on as shown below. NOTE: Once the starter switch is turned on, all the TOD indicator lamps are lit for two seconds even if the transfer lever is in any position.

C07RW016

4B210 DRIVE LINE CONTROL SYSTEM (TOD)

Simplified checking method of ABS IN and BRAKE ON signals: In the event that any of the signal inputs listed below are observed while the self-diagnostic code is being displayed (the self-diagnostic connector is short-circuited to GND), you can simply check the ABS IN and BRAKE ON signals as shown in the figures below.

C07RW0171

DRIVE LINE CONTROL SYSTEM (TOD) 4B211

Check Lamp
Check Lamp Bulb Check When the starter switch is turned on in the normal state, the control unit turns on the CHECK lamp to check the bulb.

C07RW019

4B212 DRIVE LINE CONTROL SYSTEM (TOD)

Diagnosis
General Information Diagnosis
The troubles on TOD are classified into the group that can be identified by the lighting status of the TOD indicator lamps and those that can be recognized as abnormal phenomena of the vehicle by the driver. The troubles that can be identified by the lighting status of the TOD indicator lamps are examined by the procedures Diagnosis from Trouble Codes and Trouble Diagnosis Depending on The Status of TOD Indicator. The troubles that can be recognized as abnormal phenomena of the vehicle by the driver are examined by the procedure Diagnosis from symptom.

Self-diagnosis
The control unit has a function of self-diagnosis. If a trouble occurs in the course of system startup, the control unit blinks the CHECK lamp and saves the trouble code.

C07RW021

NOTE: If an intermittent fault occurs, the control unit stops blinking upon removal of the fault. The trouble code is saved to the control unit.

DRIVE LINE CONTROL SYSTEM (TOD) 4B213

Indication Method of Trouble Code D Short-circuit terminal 8 of the self-diagnostic connector to GND to display the trouble code on the CHECK lamp. D If no trouble codes exist, code 12 is displayed continuously. D If trouble codes exist, code 12 is displayed three times, and the trouble codes, starting from the smaller code number, are displayed three times respectively.

821RW021

C07RY00018

4B214 DRIVE LINE CONTROL SYSTEM (TOD)

How to Clear The Trouble Code The trouble codes saved to the control unit can be deleted by the following procedure if the starter switch is being in the OFF position. 1. Shift the transfer lever to the neutral position between HIGH and 4L, and short-circuit the self-diagnostic connector. NOTE: The neutral position between HIGH and 4L refers to the point that turns off the TOD indicator lamps. (However, be sure to check the position before short-circuiting the self-diagnostic connector.) Trouble Intermittently Observed Troubles intermittently observed are mostly attributable to temporary imperfect connection of harnesses and connectors. When such troubles are found, check the associated circuit according to the following procedure. 1. Check whether improper connectors are plugged in or connector terminals are completely engaged. 2. Check whether the terminals are deformed or damaged. If yes, remove the deformation or damage and connect the terminals securely. 3. It is likely that wires in the harness are falsely broken. Therefore, in examination of failed harness circuit, shake the harness for check to such extent that the harness will not be damaged. Test Run of Failed TOD Vehicle If the TOD indicator lamps experienced faulty operation even once in the past, the failed portion can be identified by use of the procedure Diagnosis from Trouble Codes or Trouble Diagnosis Depending on The Status of TOD Indicator. If the troubles that are only recognized as abnormal phenomena of the vehicle by the driver are observed, conduct the test run in the following procedure to reproduce the faulty phenomena and diagnose the fault for each phenomenon. 1. Start the engine, and check that the TOD indicator lamps are turned on for about two seconds for initial check; the CHECK lamp goes off; and the TOD indicator lamps display the specified drive mode. (If the CHECK lamp starts blinking, read the trouble codes and identify the failed portion.) 2. While keeping the vehicle standstill, operate the 4WD switch and shift the transfer lever to change the modes: 2H modeTOD mode4L modeTOD mode2H mode. Check that the TOD indicator lamps correctly display the status whenever the mode is changed. If the transition status is displayed during the shift operation, run the vehicle a little to complete shifting. 3. Slowly start the vehicle in the TOD mode, and add the power to accelerate to at least 40 km/h and maintain the speed for about two minutes. Apply the brake to completely stop the vehicle. Repeat this test pattern at least three times. 4. Turn the steering to the right end (or left end) in the TOD mode, and slowly start the vehicle and make a circle five times. Next, conduct the same test in the 2H mode. 5. Slowly start the vehicle in the TOD mode, and accelerate to at least 40 km/h. Keep the established speed, carefully change the mode in the sequence TOD mode2H mode TOD mode while checking that the shift is complete in each mode change. After the test, apply the brake to completely stop the vehicle. 6. Slowly start the vehicle in the TOD mode, and accelerate to at least 40 km/h. Apply the brake strongly so that the ABS works, and completely stop the vehicle.

C07RW011

2. Turn on the starter switch while maintaining the state of step 1, and step on the brake pedal five times within five seconds from the first step on. (Note that five times includes the first step on). (The TOD indicator lamps display the 4L mode whenever the brake pedal is stepped on.) 3. If the conditions shown in steps 1 and 2 are met, the trouble codes saved to the control unit are cleared. (After the codes are completely deleted, the code 12 that indicates the normal condition is continuously displayed.)

Precautions on Diagnosis
Replacement of Control Unit The control unit itself rarely fails. In most cases, the harnesses have failed (i.e. short-circuit) to cause secondary troubles. Other cases include that the cause has been unknown due to intermittent occurrence of troubles and the troubles are removed accidentally along with replacement of control unit, resulting in misjudgment of cause. Therefore, before replacing the control unit, check the connector joints and whether the unspecified current flows in the control unit due to short-circuit between harnesses.

DRIVE LINE CONTROL SYSTEM (TOD) 4B215

7. Slowly start the vehicle in the 4L mode, and accelerate to at least 20 km/h. Apply the brake to completely stop the vehicle. If the CHECK lamp starts blinking during the test run, read the trouble codes and give appropriate maintenance according to the diagnostic procedure. If the TOD indicator lamps are lit abnormally during the run, check the lighting condition and give appropriate maintenance according to the diagnostic procedure. Even if the phenomena are not observed, try to reproduce the abnormal state reported by the customer to the possible extent. Post-Repair Check As long as the starter is not turned off, the TOD indicator lamps continue blinking even after the failed portion is repaired. Therefore, upon completion of repair, be sure to turn off the starter switch once and then turn on it to conduct the test run sequence specified in steps 1 through 7 above and check that the TOD indicator lamps no longer show any faulty status.

4B216 DRIVE LINE CONTROL SYSTEM (TOD)

Basic Diagnostic Flow Chart

C07RW0231

DRIVE LINE CONTROL SYSTEM (TOD) 4B217

Parts Location

D08RW367

Legend (1) I9 (2) C63 (3) H7, H8, H25 (4) H33 (5) Fuse Box (6) C16 (7) B13 (8) H55, H57 (9) M22 (10) M23

(11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21)

M24 H10 H17 E54 E29 Relay & Fuse Box H12 B48, B49 H33, H36 M27 I12

4B218 DRIVE LINE CONTROL SYSTEM (TOD)

Circuit Diagram

D04RY00003

DRIVE LINE CONTROL SYSTEM (TOD) 4B219

D04RY00002

4B220 DRIVE LINE CONTROL SYSTEM (TOD)

D04RY00010

DRIVE LINE CONTROL SYSTEM (TOD) 4B221

Connector List
No. B-13 Connector face No. H-8 Connector face

B-48

H-10

B-49

H-12

C-16

H-17

C-63

H-25

C-94

H-33

E-29

H-36

E-54

H-55

H-7

H-57

4B222 DRIVE LINE CONTROL SYSTEM (TOD)

No. I-9 Connector face

I-12

M-22

M-23

M-24

M-27

DRIVE LINE CONTROL SYSTEM (TOD) 4B223

Checking Failed Pin

Connector Pin Assignment
D ECU pin assignment

D04RY00011

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

NAME N.C N.C N.C DG MAP N.C IND. b N.C IND. Rr N.C N.C SOL (+) Ref COM () VIG TPS TECH 2 IND. a IND. c IND. AUTO CHECK N.C PGND ADC (+) N.C N.C Not used Not used Not used Gas/Diesel Not used Display FrontB Not used Display RearE Not used Not used EMC Speed Reference Speed Return Ignition TPS (PWM) TECH2 Display FrontA Display FrontC Display AutoD Check T/F Not used Power Ground Axle Disconnect Output Not used Not used

CONTENTS

4B224 DRIVE LINE CONTROL SYSTEM (TOD)

No. 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 NAME N.C N.C N.C DIAG TOD SW 4H SW Frt. Sig ABS IN VIG N.C 4WD OUT BRAKE N.C N.C LIGHTING SW N.C AXLE SW N.C 4L SW Rr. Sig GND GND. 2 N.C Not used Not used Not used Diagnostic Input TOD Switch 4H Switch Input Front Speed Signal ABS In Ignition Not used 4WD Signal Output Brake Switch Input Not used Not used Lighting Switch Input Not used Axle Switch Input Not used 4L Switch Input Rear Speed Signal ECU Ground 1 ECU Ground 2 Not used CONTENTS

DRIVE LINE CONTROL SYSTEM (TOD) 4B225

Reference
D Transfer connector pin assignment (connector on the transfer case) for inspection of transfer pins.

810RW310

No. 1 2 3 4 5 6 7 8 9 10 11 12

NAME Ref. (Rer. ) Ref. (Frt. ) SW GND 4H SW (+) Rer. (+) Frt. (+) POWER GND SOL (+) COM () (Rer. ) COM () (Frt. ) NC 4L SW (+)

CONTENTS Rear speed sensor reference output Front speed sensor reference output SW GND 4H SW plus terminal Rear speed sensor plus Front speed sensor plus Power GND Electromagnetic solenoid Rear speed sensor GND Front speed sensor GND Not used 4L SW plus terminal

4B226 DRIVE LINE CONTROL SYSTEM (TOD)

Checking Failed TOD Control Unit Pin

NOTE: 1. Unplug the ECU connector and the pins, unless otherwise specified. 2. Before removing the ECU, turn off the ignition switch. 3. If the standard values are not observed, check the pins with other testers. Che ck Pin No. 4 22 46 31 Circuit to be tested Ignition Engine Switch State Position OFF OFF OFF OFF STOP STOP STOP STOP Multimeter Scale/ Range W W W W Measure between Pin Number 4, 46 22, 46 46, GND 31, 46 Standard Valve Note

D-G MAP P-GND GND 4H SW

Continuity : OK Continuity : OK Continuity : OK No continuity (high, 4L) and continuity (N) : OK No continuity (high) and continuity (4L, N) : OK Continuity : OK Remove ECU and start the engine. Move the vehicle forth and back to connect axle surely. DLC connector terminal 8

44

4L SW

OFF

STOP

44, 46

42

AXLE SW

ON

RUN

42, 46

29

DIAG

OFF

STOP

29 (TOD), 8 (DLC Connector) 17 (+), 46 () 6 (+), 46 () 18 (+), 46 () 20 (+), 46 () 33 (+), 46 () 12 (+), 46 () 32 (+), 46 ()

Continuity : OK

17 6 18 20 33 12 32

IND.a IND.b IND.c CHECK LAMP ABS IN Ref. Ft.(+)

ON ON ON ON ON ON ON

STOP STOP STOP STOP STOP STOP STOP

DCV DCV DCV DCV DCV DCV DCV

8.0 14.5 V 8.0 14.5 V 8.0 14.5 V 8.0 14.5 V 11.5 14.5 V 5 9 V 0.7 6 V

When the indicator lamp is turned off. When the indicator lamp is turned off. When the indicator lamp is turned off.

Connect ECU Connect ECU and move the vehicle (off one tooth of speed sensor ring) making sure of voltage change. Connect ECU and move the vehicle (off one tooth of speed sensor ring) making sure of voltage change. Connect ECU

45

Rr.(+)

ON

STOP

DCV

45 (+), 46 ()

0.7 6 V

13 14

COM(-) Vig

ON ON

STOP STOP

DCV DCV

13 (+), 46 () 14 (+), 46 ()

0V 8 14.5 V

DRIVE LINE CONTROL SYSTEM (TOD) 4B227

Che ck Pin No. 37 15 Circuit to be tested Ignition Engine Switch State Position OFF ON STOP STOP Multimeter Scale/ Range DCV DCV Measure between Pin Number 37 (+), 46 () 15 (+), 46 () 36, 46 23, 46 11, 46 30 (+), 46 () 40 (+), 46 () 19 (+), 46 () 8 (+), 46 () 34 (+), 46 () Standard Valve Note

BRAKE TPS

8 14.5 V PWM duty cycle 10% 90% 7 12 kW 10 30 W 1.0 5.0 W SW OFF : 0 V SW ON : 8.0 14.5 V SW OFF : 8.0 14.5 V SW ON : 0 V TOD : 0 V 2H&4L : 8.0 14.5 V 0V 8 14.5 V

Press brake pedal Step on the accelerator pedal and make sure that duty cycle changes. Disconnect battery GND terminal Disconnect battery GND terminal Disconnect battery GND terminal SW OFF : Contact point open SW ON : Contact point close

36 23 11 30

4WD OUT ADC(+) SOL(+) 4WD SW

OFF OFF OFF ON

STOP STOP STOP STOP

W W W DCV

40

LIGHTING AUTO INDI RR INDI VIG

ON

STOP

DCV

19

ON

STOP

DCV

Connect ECU.

8 34

ON ON

STOP STOP

DCV DCV

Connect ECU. When the indicator lamp is turned on.

4B228 DRIVE LINE CONTROL SYSTEM (TOD)

Tech 2 Scan Tool

From 98 MY, Isuzu dealer service departments are recommended to use Tech 2. Please refer to Tech 2 scan tool user guide.

901RW257

Legend (1) PCMCIA Card (2) SAE 16/19 Adaptor

(3) DLC Cable (4) Tech 2

DRIVE LINE CONTROL SYSTEM (TOD) 4B229

Getting Started
D Before operating the Isuzu PCMCIA card with the Tech 2, the following steps must be performed: 1. The Isuzu 98 System PCMCIA card (1) inserts into the Tech 2 (4). 2. Connect the SAE 16/19 adapter (2) to the DLC cable (4). 3. Connect the DLC cable to the Tech 2 (4) 4. Mark sure the vehicle ignition is off. 5. Connect the Tech 2 SAE 16/19 adapter to the vehicle DLC connector.

Operating Procedure
The power up screen is displayed when you power up the tester with the Isuzu systems PCMCIA card. Follow the operating procedure below.

821RW021

6. The vehicle ignition turns on. 7. Power up the Tech 2. 8. Verify the Tech 2 power up display.

060RY027

060RW009

4B230 DRIVE LINE CONTROL SYSTEM (TOD)

060RX062

DRIVE LINE CONTROL SYSTEM (TOD) 4B231

Diagnostic Trouble Codes

Code 12 13 14 15 16 21 23 24 26 27 28 31 32 33 36 37 38 Item Start code Ref Front speed sensor Ref Front speed sensor TPS ECU Rear speed sensor EMC (+) Rear speed sensor ADC (+) & AXLE SW EMC (+) ADC (+) ADC (+) ECU ECU ECU Tech 2 code (P code) P1735 P1731 P1736 P1737 P1716 P1733 P1738 P1760 P1721 P1761 P1762 P1712 P1714 Normal Shorted GND Input abnormality (open, sig or com) Shorted VB Input abnormality Shorted or disconnected wiring, abnormality in input CPU abnormality Input abnormality (open, sig or com) Shorted GND Input abnormality Output abnormality Shorted or disconnected coil/wiring Shorted or disconnected coil/wiring Shorted GND CPU abnormality CPU abnormality CPU abnormality Diagnosis Check flow No. 6 2 6 3 7 1 5 10 4 11 9 12 13 1 1 1

TPS : Throttle Position Sensor EMC : Electromagnetic coil ADC : Shift on the fly (Axle Dis Connect)

4B232 DRIVE LINE CONTROL SYSTEM (TOD)

Diagnosis from Trouble Codes

D Diagnose the based on the fault that have been saved to the control unit according to the system self-diagnostic function.

Check flow 1

Trouble code 23, 36, 37(P1712), 38(P1714)

Phenomenon The ECU has failed.

Standard

Step 1 Turn on the starter switch. Is the trouble reproduced?

Action

Yes Replace the ECU and conduct the test run. Go to Step 3

No

Go to Step 2 The trouble is not reproduced. Refer to Troubles intermittently observed. Go to Step 3

1. Clear the trouble codes. 2. Conduct the test run. Is the trouble reproduced during the test run? Replace the ECU and conduct the test run. Go to Step 3 Repeat the Diagnosis Flow.

1. Check that all the parts are mounted. 2. Clear the trouble codes. Is this step complete?

Return to Step 3

DRIVE LINE CONTROL SYSTEM (TOD) 4B233

Check flow 2

Trouble code 14 (P1731)

Phenomenon Front speed sensor signal open or GND short, speed sensor com open.

Standard 0.3 > sensor voltage

NOTE: The following procedure shows the case that the front or rear sensor common grounding line is broken.

D04RY00004

4B234 DRIVE LINE CONTROL SYSTEM (TOD)

Step 1 1. Start the engine. 2. Select TOD mode. Is there the memory except DTC 14(P1731)? 2 1. Turn off the starter switch. 2. Disconnect the ECU connector (B48) and (B49). Is there the continuity between the connector (B48) terminal 10 and 25? 3 1. Disconnect the transfer connector (M27). Is there the continuity between the connector (B48) terminal 10 and the connector (M27) terminal 6, the connector (B49) terminal 12 and connector (M27) terminal 2, and the connector (B49) terminal 13 and connector (M27) terminal 10? 4 Is the memory DTC 24(P1733)? Go to Step 5 5 6 Is there the continuity between harnesses of terminal 32 and 45 (vehicle side terminal of the front and rear speed sensor)? Is there the continuity between harnesses of terminal 12 and 13 (vehicle side terminal of the speed sensor COM() and ref)? Go to Step 6 Replace front and rear speed sensor. Go to Step 7 Replace the front speed sensor. Go to Step 7 Repair the circuit. Go to Step 7 Go to Step 3 Go to Step 4 Go to Step 2 Action Yes No

Repair the circuit. Go to Step 7 Refer to other trouble check flow. Repair the circuit. Go to Step 7

Repair the circuit. Go to Step 7

1. Check that all the parts are mounted. 2. Clear the trouble code. Is the step complete? Verify the repair. Return to Step 7

DRIVE LINE CONTROL SYSTEM (TOD) 4B235

Check flow 3

Trouble code 16 (P1737)

Phenomenon The front speed sensor no pulse.

Standard Hi level : 4.5 6.0 V Lo level : 0.7 2.0 V Frequency (F) = 700 850 Hz (at 30 mile/h)

NOTE: Find the trouble in which the pulse corresponding to the running speed is not input.

D04RY00004

4B236 DRIVE LINE CONTROL SYSTEM (TOD)

Step 1 1. Connect TECH 2. While running in TOD mode, does TECH2s front speed sensor indication change with vehicle speed? Go to Step 2 2 1. Clear the trouble code. While running at 40 km/h or 25 mph in TOD mode for 30 consecutive sec, is the trouble code reissued? Go to Step 3 3 1. Turn off the starter switch. 2. Disconnect the ECU connector (B48) and (B49). Is there the continuity between the connector (B48) terminal 10 and 25? 4 1. Disconnect the transfer connector (M27). Is there the continuity between the connector (B48) terminal 10 and the connector (M27) terminal 6, the connector (B49) terminal 12 and connector (M27) terminal 2, and the connector (B49) terminal 13 and connector (M27) terminal 10? 5 1. Clear the trouble code. While running at 40 km/h or 25 mph in TOD mode for 30 consecutive sec, is the trouble code reissued? 6 1. Check that all the parts are mounted. 2. Clear the trouble code. Is this step complete? Replace ECU. Go to Step 6 Repeat the Diagnosis Flow. Go to Step 6 Replace the front speed sensor. Go to Step 5 Repair the circuit. Go to Step 6 Go to Step 4 Action Yes No Repair and inspection front speed sensor tone wheel. Go to Step 6 The trouble is not reproduced. Refer to Troubles intermittently observed.

Repair the circuit. Go to Step 5

Return to Step 6

DRIVE LINE CONTROL SYSTEM (TOD) 4B237

Check flow 4

Trouble code 27 (P1738)

Phenomenon The front speed sensor no pulse.

Standard Hi level : 4.5 6.0 V Lo level : 0.7 2.0 V Frequency (F) = 700 850 Hz (at 30 mile/h)

NOTE: Find the trouble in which the pulse corresponding to the running speed is not input.

D04RY00004

4B238 DRIVE LINE CONTROL SYSTEM (TOD)

Step 1 1. Connect TECH 2. While running in TOD mode, does TECH2s rear speed sensor indication change with vehicle speed? Go to Step 2 2 1. Clear the trouble code. While running at 40 km/h or 25 mph in TOD mode for 30 consecutive sec, is the trouble code reissued? Go to Step 3 3 1. Turn off the starter switch. 2. Disconnect the ECU connector (B48) and (B49). Is there the continuity between the connector (B48) terminal 23 and 25? 4 1. Disconnect the transfer connector (M27). Is there the continuity between the connector (B48) terminal 23 and the connector (M27) terminal 5, the connector (B49) terminal 12 and connector (M27) terminal 1, and the connector (B49) terminal 13 and connector (M27) terminal 9? 5 1. Clear the trouble code. While running at 40 km/h or 25 mph in TOD mode for 30 consecutive sec, is the trouble code reissued? 6 1. Check that all the parts are mounted. 2. Clear the trouble code. Is this step complete? Replace ECU. Go to Step 6 Repeat the Diagnosis Flow. Go to Step 6 Replace the rear speed sensor. Go to Step 5 Repair the circuit. Go to Step 5 Go to Step 4 Action Yes No Repair and inspection front speed sensor tone wheel. Go to Step 6 The trouble is not reproduced. Refer to Troubles intermittently observed.

Repair the circuit. Go to Step 5

Return to Step 6

DRIVE LINE CONTROL SYSTEM (TOD) 4B239

Check flow 5

Trouble code 24 (P1733)

Phenomenon Rear speed sensor signal open or GND short, speed sensor COM open.

Standard 0.3 V > sensor voltage

NOTE: The following procedure shows the case that the front or rear sensor common grounding line is broken.

D04RY00004

4B240 DRIVE LINE CONTROL SYSTEM (TOD)

Step 1 1. Start the engine. 2. Select TOD mode. Is there the memory except DTC 24(P1733)? 2 1. Turn off the starter switch. 2. Disconnect the ECU connector (B48) and (B49). Is there the continuity between the connector (B48) terminal 23 and 25? 3 1. Disconnect the transfer connector (M27). Is there the continuity between the connector (B48) terminal 23 and the connector (M27) terminal 5, the connector (B49) terminal 12 and connector (M27) terminal 1, and the connector (B49) terminal 13 and connector (M27) terminal 9? 4 Is the memory DTC 14(P1731)? Go to Step 5 5 6 Is there the continuity between harnesses of terminal 32 and 45 (vehicle side terminal of the front and rear speed sensor)? Is there the continuity between harnesses of terminal 12 and 13 (vehicle side terminal of the speed sensor COM() and ref)? Go to Step 6 Replace front and rear speed sensor. Go to Step 7 Replace the rear speed sensor. Go to Step 7 Repair the circuit. Go to Step 7 Go to Step 3 Go to Step 4 Go to Step 2 Action Yes No

Repair the circuit. Go to Step 7 Refer to other trouble cheek flow. Repair the circuit Go to Step 7

Repair the circuit. Go to Step 7

1. Check that all the parts are mounted. 2. Clear the trouble code. Is the step complete? Verify the repair Return to Step 7

DRIVE LINE CONTROL SYSTEM (TOD) 4B241

Check flow 6

Trouble code 13 (P1735) 15 (P1736)

Phenomenon The reference is short-circuited to GND. The reference Vb is short-circuited.

Standard Reference ] 5 V

If the reference wire (15) is short-circuited to GND, the speed signal is not generated. If the wire is short-circuited to the battery voltage, the signal level becomes faulty.

D04RY00004

4B242 DRIVE LINE CONTROL SYSTEM (TOD)

Step 1 1. Start the engine. Does the voltage between terminals 12 and 13 meet the standard 5V? Action Yes The phenomenon is not respoduced. Refer to Troubles intermittently observed. Go to Step 3 No

Go to Step 2 Go to Step 7 The ECU is failed. Replace the ECU. Go to Step 8 Short to GND between (B49) 12 and (H17) 1. Repair the sircuit. Go to Step 8 The reference harness for the front speed sensor is shortcircuited to GND. Repair the circuit. Go to Step 6 The reference harness for the front speed sensor is shortcircuited to GND. Repair the circuit. Go to Step 8 The ECU has failed. Replace the ECU. Go to Step 8

2 3

Is the voltage below the standard? 1. Turn off the starter switch. 2. Disconnect the ECU connector. Is the continuity established between vehicle harness terminals (B49)12 and (B48)24?

Go to Step 4

1. Disconnect the H-17 connector. Is the continuity established between floor harness connector terminals (H-17)1 and (H-17)8? Go to Step 5

1. Disconnect the M-27 connector. Is the continuity established between transfer harness connector terminals (M27)2 and (M27)7? Replace the front speed sensor. Go to Step 8

1. Disconnect the M-27 connector. Is the continuity established between transfer harness connector terminals (M27)1 and (M27)7? Replace the rear speed sensor. Go to Step 8

1. Turn off the starter switch. 2. Disconnect the ECU connector. 3. Turn on the starter switch. Is the battery voltage observed between harness connector terminals (B49)12 and (B48)24?

Repair the harness circuit. Go to Step 8 Repeat the Diagnosis Flow

1. Check that all the parts are mounted. 2. Clear the trouble code. Is this step complete?

Go to Step 8

DRIVE LINE CONTROL SYSTEM (TOD) 4B243

Check flow 7

Trouble code 21 (P1716)

Phenomenon The voltage of the throttle position sensor (TPS) is faulty.

Standard See below table.

NOTE: The signal voltage from the TPS deviates from the standard range.

D04RY00004

4B244 DRIVE LINE CONTROL SYSTEM (TOD)

D04RY00012

DRIVE LINE CONTROL SYSTEM (TOD) 4B245

Step 1 Action 1. Turn off the starter switch. Is the battery voltage normal? Go to Step 2 2 1. Turn on the starter switch. Does the voltage between terminals 15 and 46 fall within the standard range? 3 1. Clear the trouble code. 2. Turn on the starter switch. Is there DTC21 (P1716)? 4 1. Turn off the starter switch. 2. Disconnect the ECU connector. 3. Turn on the starter switch. Does the voltage between terminals (B49)15 and (B48)24 fall within the standard range above? 5 Is the harness healthy? Go to Step 6 6 7 Is the TPS healthy? Go to Step 7 1. Check that all the parts are mounted. 2. Clear the trouble code. Is this step complete? Repeat the Diagnosis Flow. Go to Step 4 The ECU has failed. Replace the ECU. Go to Step 7 Go to Step 3 Go to Step 4 Refer to Trouble intermittently observed. Yes No Charge or replace the battery. Go to Step 7

Go to Step 5 Repair the harness. Go to Step 7 Replace the TPS. Go to Step 7

Go to Step 7

4B246 DRIVE LINE CONTROL SYSTEM (TOD)

Check flow 9

Trouble code 31 (P1721)

Phenomenon The electromagnetic coil is broken or shorted to the battery.

Standard

D04RY00008

DRIVE LINE CONTROL SYSTEM (TOD) 4B247

Step 1 Action 1. Turn off the starter switch. 2. Disconnect the ECU connector from ECU. Is the continuity established between terminals (B49)11 and (B49)22? 2 1. Connect the ECU connector. 2. Start the engine. 3. Set the TOD mode. Does the voltage between terminals 11 and 22 indicate at least 0.4V? 3 Is the battery voltage always observed between terminals 11 and 22? Go to Step 3 Go to Step 2 Go to Step 4 The ECU has failed. Replace the ECU. Go to Step 5 The phenomenon is not reproduced. Refer to Troubles intermittently observed. Replace the transfer electromagnetic coil (solenoid clutch). Go to Step 5 Yes No

The harness is shortcircuited on the battery. Repair the circuit. Go to Step 5

1. Disconnect the M27 connector. Is the continuity established between transfer connector terminals (M27)8 and (M27)7? The harness is broken. Repair the circuit. Go to Step 5 Repeat the Diagnosis Flow.

1. Check that all the parts are mounted. 2. Clear the trouble code. Is this step complete?

Return to Step 5

4B248 DRIVE LINE CONTROL SYSTEM (TOD)

Check flow 10

Trouble code 26

Phenomenon The electromagnetic coil GND is short-circuited.

Standard Resistance: 1.0 to 5.0 ohm (at ordinary temperature)

D04RY00008

DRIVE LINE CONTROL SYSTEM (TOD) 4B249

Step 1 Action 1. Turn off the starter switch. 2. Disconnect the ECU connector from ECU. Does the resistance between terminals (B49)11 and (B49)22 indicate 1.0 to 5.0 ohm? 2 1. Connect the ECU connector. 2. Start the engine. 3. Set the TOD mode. When the throttle is operated between full close and full open positions, does the voltage between terminals 11 and 22 indicate at least 0.1 to 1.0 V? 3 1. Disconnect the connector (M27). Does the resistance between transfer connector terminals (M27)8 and (M27)7 indicate 1.0 to 5.0ohm? The harness is broken. Repair the circuit. Go to Step 4 Repeat the Diagnosis Flow. Go to Step 2 The phenomenon is not reproduced. Refer to Troubles intermittently observed. Go to Step 3 Yes No

The ECU has failed. Replace the ECU. Go to Step 4 Replace the transfer electromagnetic coil. Go to Step 4

1. Check that all the parts are mounted. 2. Clear the trouble code. Is this step complete?

Return to Step 4

4B250 DRIVE LINE CONTROL SYSTEM (TOD)

Check flow 11

Trouble code 28 (P1760)

Phenomenon The shift on the fly system (front axle disconnect) works incorrectly.

Standard

NOTE: The shift on the fly system is not changed between 2WD and 4WD modes normally. CAUTION: If code 32 or 33 is also observed, remove the trouble associated with code 32 or 33 first.

D04RY00008

DRIVE LINE CONTROL SYSTEM (TOD) 4B251

Step 1 Action 1. Turn on the starter switch. 2. Set the transfer to the 2H mode. Is the battery voltage observed between terminals 23 and 46? 2 3 Is 5V observed between terminals 42 and 46? 1. Set the transfer to the high (TOD) mode. Does the voltage between terminals 23 and 46 indicate 0V? Go to Step 4 4 Does the voltage between terminals 42 and 46 indicate 0V? The phenomenon is not reproduced. Refer to Troubles intermittently observed. Go to Step 2 Go to Step 3 Go to Step 5 Go to Step 6 The ECU has failed. Replace the ECU. Go to Step 7 The shift on the fly system is failed (refer to Section Drive Line Control System and Front Axle). See Trouble Diagnosis Depending on The Status of TOD Indicator. The ECU has failed. Replace the ECU. Go to Step 7 Yes No

Does the TOD indicator show the 2H mode? The ECU has failed. Replace the ECU.

Set the transfer to the high (TOD) mode. Does the voltage between terminals 23 and 46 indicate 0V?

The shift on the fly system has failed (refer to Section Driveline Control System). Repeat the Diagnosis Flow.

1. Check that all the parts are mounted. 2. Clear the trouble code. Is this step complete?

Return to Step 7

4B252 DRIVE LINE CONTROL SYSTEM (TOD)

Check flow 12

Trouble code 32 (P1761)

Phenomenon The on/off signal (ADC) line of the shift on the fly system (front axle disconnect) is broken, or the line is short-circuited to the battery.

Standard

NOTE: The on/off signal line of the shift on the fly system is broken, or the line is shortcircuited to the battery.

D04RY00008

DRIVE LINE CONTROL SYSTEM (TOD) 4B253

Step 1 Action 1. Turn off the starter switch. 2. Disconnect the ECU connector from ECU. Is the continuity established between terminals (B48)1 and (B48)24? 2 Does the voltage between terminals (B48)1 and (B48)24 indicate 0V? Go to Step 3 3 1. 2. 3. 4. Turn off the starter switch. Connect ECU connector. Turn on the starter switch. Set the transfer to the 2H mode. The phenomenon is not reproduced Refer to Troubles intermittently observed. Repeat the Diagnosis Flow. Go to Step 2 Yes No The harness is broken. Repair the circuit. Go to Step 3 The battery is short-circuited. Repair the circuit. Go to Step 4

Is the battery voltage observed between terminals 23 and 46? 4 1. Check that all the parts are mounted. 2. Clear the trouble code. Is this step complete?

The ECU has failed. Replace the ECU. Go to Step 4

Return to Step 4

4B254 DRIVE LINE CONTROL SYSTEM (TOD)

Check flow 13

Trouble code 33 (P1762)

Phenomenon The ADC line is short-circuited to GND.

Standard

NOTE: D The on/off signal line of the shift on the fly system is shortcircuited to GND. D The system enters into the fail-safe mode because of fusing or system protection. (If a shortcircuit is observed on GND, the output to the on/off signal line becomes 0V.)

D04RY00008

DRIVE LINE CONTROL SYSTEM (TOD) 4B255

Step 1 Action 1. Turn off the starter switch. 2. Disconnect the ECU connector from ECU. Does the resistance between terminals (B48)1 and (B48)24 meet the standard, R = 21 4 ohms? Yes The phenomenon is not reproduced. Refer to Troubles intermittently observed. The signal line circuit of the shift on the fly system is short-circuited to GND. Repair the circuit. Go to Step 4 The signal line circuit of the shift on the fly system is layer short-circuited*. Replace the valve (VSV). Go to Step 4 Repeat the Diagnosis Flow. No

Go to Step 2

Is the resistance between terminals (B48)1 and (B48)24 R<2 ohms?

Go to Step 3

Is the resistance between terminals (B48)1 and (B48)24 R= 97ohms?

Go to Step 4

1. Check that all the parts are mounted. 2. Clear the trouble code. Is this step complete?

Return to Step 4

*Layer short-circuit : The coil is damaged by overcurrent.

4B256 DRIVE LINE CONTROL SYSTEM (TOD)

Trouble Diagnosis Depending on The Status of TOD Indicator

Functional check with TOD indicator light is conducted prior to check on Charts AH. D After the starter is switched on, check and see if the status has become as tabulated below.

C07RY00019

D If the status is as tabulated above, there is no problem. If not as tabulated above, inspect the harness.

DRIVE LINE CONTROL SYSTEM (TOD) 4B257

Chart A Function of circuit Fail condition Indicator lamp status

Indicator drive circuit The circuit informs the indicator of the working condition of the ECU. All the TOD indicator lamps and CHECK lamp are lit, and go off momentarily at an interval of about two seconds.

Transfer lever position 4WD Auto Switch

High/4L

D04RY00015

4B258 DRIVE LINE CONTROL SYSTEM (TOD)

Step 1 Turn on the starter switch. Is the battery voltage observed between terminals 14 and 46 or 34 and 46? 2 Check that all the parts are mounted. Is this step complete? Action Yes The ECU has failed. Replace the ECU. Go to Step 2 Repeat the Diagnosis Flow. No Check the battery circuit. Go to Step 2 Return to Step 2

DRIVE LINE CONTROL SYSTEM (TOD) 4B259

Chart B1 Function of circuit Fail condition Indicator lamp status

The 4WD switch circuit wires are broken or short-circuited to the GND Even after the transfer position is select from TOD to 2H, the indicator lamp status is not changed.

Transfer lever position 4WD Auto Switch

High

D04RY00015

4B260 DRIVE LINE CONTROL SYSTEM (TOD)

Step 1 Action 1. Turn on the starter switch. When the 4WD Auto Switch is select to the 4WD position, is 0 V observed between terminal 30 and 46? 2 When the 4WD Auto Switch is select to the 2WD position, is 12 V observed between terminals 30 and 46? Go to Step 3 3 When the transfer lever is shifted to the 4L position, is battery boltage observed between terminals 19 and 46? The phenomenon is not reproduced. Refer to Troubles intermittently observed. Repeat the Diagnosis Flow. Yes No Repair the 4WD Auto Switch circuit. Go to Step 4 Repair the 4WD Auto Switch circuit. Go to Step 4

Go to Step 2

Replace the ECU. Go to Step 4 Return to Step 4

Check that all the parts are mounted. Is this step complete?

DRIVE LINE CONTROL SYSTEM (TOD) 4B261

Chart B2 Function of circuit Fail condition Indicator lamp status

The 4WD AUTO SWITCH circuit is short to battery. Even after the transfer mode is select from 2H to TOD the indicator lamp status does not change.

Transfer lever position 4WD Auto Switch

High

D04RY00015

4B262 DRIVE LINE CONTROL SYSTEM (TOD)

Step 1 Action When the 4WD Auto Switch is select to the 4WD position, is 0 V observed between terminal 30 and 46? Go to Step 2 2 When the 4WD Auto Switch is select to the 2WD position, is 12 V observed between terminals 30 and 46? Go to Step 3 3 1. Disconnect the ECU connector. Is the continuity established between terminals (B49)14 and (B49)17? Go to Step 4 4 Is the continuity established between terminals (B49)14 and (B49)6? Yes No Repair the 4WD Auto Switch circuit. Go to Step 7 Repair the 4WD Auto Switch circuit. Go to Step 7 Replace TOD indicator lamp bulb or repair the circuit. Go to Step 7 Replace TOD indicator lamp bulb or repair the circuit. Go to Step 7 Replace TOD indicator lamp bulb or repair the circuit. Go to Step 7 Replace TOD indicator lamp bulb or repair the circuit. Go to Step 7 Return to Step 7

Go to Step 5 5 Is the continuity established between terminals (B49)14 and (B49)18?

Go to Step 6 6 Is the continuity established between terminals (B49)14 and (B49)19? Replace ECU. Go to Step 7 7 Check that all the parts are mounted. Is this step complete? Repeat the Diagnosis Flow.

DRIVE LINE CONTROL SYSTEM (TOD) 4B263

Chart C1 Function of circuit Fail condition

4H switch circuit wires are broken or the battery is short-circuited. When the 4WD Auto Switch is 4WD mode. When the lever is shifted from 4L to TOD, the 4L mode remains on the indicator and the TOD mode is displayed without turning off the previous mode.

Indicator lamp status

Transfer lever position 4WD Auto Switch

4L <> Middle between 4L and High <> High

D04RY00015

4B264 DRIVE LINE CONTROL SYSTEM (TOD)

Step 1 Action 1. Turn on the starter switch. When the transfer lever is shifted to the high position, is 12V observed between terminals 31 and 46 (4H switch)? 2 3 When the transfer lever is shifted to the 4L position, is 12V observed between terminals 31 and 46 (4H switch)? When the transfer lever is shifted to the middle position between 4L and High, is 0V observed between terminals 31 and 46 (4H switch)? 1. Turn off the starter switch. 2. Disconnect the ECU connector. 3. Turn on the starter switch. When the transfer lever is shifted to the high position between 4L and High, is 12V observed between terminals (B48)9 and (B48)24 (4H switch)? 5 6 When the transfer lever is shifted to the middle position, is 0V observed between terminals (B48)9 and (B48)24 (4H switch)? When the transfer lever is shifted to the 4L position, is 12V observed between terminals (B48)9 and (B48)24 (4H switch)? Go to Step 2 Go to Step 3 Replace the ECU. Go to Step 14 Go to Step 4 Go to Step 4 Yes No

Go to Step 4

Go to Step 5 Go to Step 6 The 4H switch circuit battery is short-circuited between ECU and transfer. Repair the circuit. Go to Step 14

Go to Step 7 Go to Step 7

Go to Step 7

Turn off the starter switch. When the transfer lever is shifted to the middle position between 4L and High, is the continuity established between terminals (B48)9 and (B48)24 (4H switch)?

Go to Step 8 Go to Step 11 The phenomenon is not reproduced. Refer to Troubles intermittently observed. The 4H switch circuit is broken between ECU and transfer. Repair the circuit. Go to Step 14 Repair the transfer assembly. Go to Step 14 Repair the transfer assembly. Go to Step 14

Go to Step 11 Go to Step 9

8 9

When the transfer lever is shifted to the high position, is the continuity established between terminals (B48)9 and (B48)24? When the transfer lever is shifted to the 4L position, is the continuity established between terminals (B48)9 and (B48)24?

The ECU has tailed. Replace the ECU. Go to Step 14

10

When the transfer lever is shifted to the middle position between 4L and High, is the continuity established between terminals (M27)4 and (M27)7?

Repair the transfer assembly. Go to Step 14

11

When the transfer lever is shifted to the high position, is the continuity established between transfer connector terminals (M27)4 and (M27)7? When the transfer lever is shifted to the 4L position, is the continuity established between transfer connector terminals (B48)9 and (M27)7?

Go to Step 12

12

Go to Step 13

DRIVE LINE CONTROL SYSTEM (TOD) 4B265

Step 13 Action Is the continuity established between transfer terminals (M27)4 and body? Yes The harness is shorted between terminal (M-27)4 and GND. Repair the circuit. Go to Step 14 Repeat the Diagnosis Flow. No

The ECU has failed. Replace the ECU. Go to Step 14 Return to Step 14

14

Check that all the parts are mounted. Is this step complete?

4B266 DRIVE LINE CONTROL SYSTEM (TOD)

Chart C2 Function of circuit Fail condition Indicator lamp status

The 4H switch circuit is short-circuited to GND. When the transfer lever is shifted to 4L, the indicator lamp status is not changed.

Transfer lever position 4WD Auto Switch

4L

D04RY00015

DRIVE LINE CONTROL SYSTEM (TOD) 4B267

Step 1 2 3 4 Action When the transfer lever is shifted to the High position, is 5V observed between terminals 31 and 46 (4H switch)? When the transfer lever is shifted to the neutral position, is 0V observed between terminals 31 and 46 (4H switch)? When the transfer lever is shifted to the 4L position, is 5V observed between terminals 31 and 46 (4H switch)? 1. Turn off the starter switch. Is the continuity established between terminals 14 and 17? Go to Step 5 5 Is the continuity established between terminals 14 and 6? Yes Go to Step 2 Go to Step 3 Go to Step 4 No Go to Step 14 Go to Step 14 Go to Step 14 Replace TOD indcator lamp bulb or repair the circuit. Go to Step 23 Replace TOD indicator lamp bulb or repair the circuit. Go to Step 23 Replace TOD indicator lamp bulb or repair the circuit. Go to Step 23 Replace TOD indicator lamp bulb or repair the circuit. Go to Step 23 Replace TOD indicator lamp bulb or repair the circuit. Go to Step 23 The ECU has failed. Replace the ECU. Go to Step 23 The ECU has failed. Replace the ECU. Go to Step 23 The ECU has failed. Replace the ECU. Go to Step 23 The ECU has failed. Replace the ECU. Go to Step 23

Go to Step 6 6 Is the continuity established between terminals 14 and 18?

Go to Step 7 7 Is the continuity established between terminals 14 and 19?

Go to Step 8 8 Is the continuity established between terminals 14 and 8?

Go to Step 9 9 1. Turn on the starter switch. 2. Shift the transfer lever is shifted to the 4L position. Is 0 V observed between terminals 17 and 22? 10 Is 0 V observed between terminals 6 and 22? Go to Step 10

Go to Step 11 11 Is 0 V observed between terminals 18 and 22?

Go to Step 12 12 Is 12 V observed between terminals 19 and 22?

Go to Step 13 13 Is 0 V observed between terminals 8 and 22? The phenomenon is not reproduced. Refer to Troubles intermittently observed.

The ECU has failed. Replace the ECU.

4B268 DRIVE LINE CONTROL SYSTEM (TOD)

Step 14 Action 1. Turn off the starter switch. 2. Disconnect the ECU connector. When the transfer lever is shifted to the neutral position, is the continuity established between terminals (B48)9 and (B48)24 (4H switch)? 15 16 When the transfer lever is shifted to the high position, is the continuity established between terminals (B48)9 and (B48)24? When the transfer lever is shifted to the 4L position, is the continuity established between terminals (B48)9 and (B48)24? Go to Step 17 17 1. Disconnect the H17 connector. When the transfer lever is shifted to the neutral position between high and 4L, is the continuity established between terminals (H-17)3 and (B-49)22? 18 When the transfer lever is shifted to the high position, is the continuity established between transfer connector terminals (H-17)3 and (B-49)22? When the transfer lever is shifted to the 4L position, is the continuity established between transfer connector terminals (H-17)3 and (B-49)22? Yes No

Go to Step 15 Go to Step 17

Go to Step 17 Go to Step 16 The ECU has failed. Replace the ECU. Go to Step 23

Go to Step 18

Go to Step 20

Go to Step 21

Go to Step 19 GND is short-circuited between terminals (B-49)22 and (H-17)3. Repair the circuit. Go to Step 23 Repair the transfer assembly. Go to Step 23

19

Go to Step 22 20 1. Disconnect the M27 connector. When the transfer lever is shifted to the neutral position between high and 4L, is the continuity established between terminals (M-27)4 and (M-27)7? 21 1. Disconnect the M27 connector. When the transfer lever is shifted to the high position, is the continuity established between terminals (M-27)4 and (M-27)7? 22 1. Disconnect the M27 connector. When the transfer lever is shifted to the 4L position, is the continuity established between terminals (M-27)4 and (M-27)7? Repair the transfer assembly. Go to Step 23 Repeat the Diagnosis Flow.

Go to Step 21 Repair the transfer assembly. Go to Step 23

Go to Step 22 GND is short-circuited between terminals (B-48)9 and (M27)4. Repair the circuit. Go to Step 23 Return to Step 23

23

Check that all the parts are mounted. Is this step complete?

DRIVE LINE CONTROL SYSTEM (TOD) 4B269

Chart D1 Function of circuit Fail condition Indicator lamp status

4L switch circuit wires are broken or the battery is short-circuited. The TOD mode is displayed in the neutral position between high and 4L. When the lever is shifted to the 4L position, the TOD mode is displayed.

Transfer lever position 4WD Auto Switch

4L

Middle between 4L and High

D04RY00004

4B270 DRIVE LINE CONTROL SYSTEM (TOD)

Step 1 Turn on the starter switch. When the transfer lever is shifted to the high position, is 12V observed between terminals 44 and 46 (4L switch)? 2 When the transfer lever is shifted to the middle position between 4L and High, is 0V observed between terminals 44 and 46 (4L switch)? When the transfer lever is shifted to the 4L position, is 0V observed between terminals 44 and 46 (4L switch)? Go to Step 2 Go to Step 4 Action Yes No

Go to Step 3 The ECU has failed. Replace the ECU. Go to Step 13

Go to Step 4

Go to Step 4

1. Turn off the starter switch. 2. Disconnect the ECU connector. 3. Turn on the starter switch. When the transfer lever is shifted to the high position, is 12V observed between terminals (B48)22 and (B48)24 (4L switch)? Go to Step 5 Go to Step 7

When the transfer lever is shifted to the middle position between 4L and High, is 0V observed between terminals (B48)22 and (B48)24 (4L switch)? When the transfer lever is shifted to the 4L position, is 0V observed between terminals (B48)22 and (B48)24 (4L switch)?

Go to Step 6 The 4L switch circuit battery is short-circuited between ECU and transfer. Repair the circuit Go to Step 13

Go to Step 7

Go to Step 7

Turn off the starter switch. When the transfer lever is shifted to the high position, is the continuity established between terminals (B48)22 and (B48)24 (4L switch)?

Go to Step 12

Go to Step 8

When the transfer lever is shifted to the middle position between High and 4L, is the continuity established between terminals (B48)22 and (B48)24 (4L switch)? When the transfer lever is shifted to the 4L position, is the continuity established between terminals (B48)22 and (B48)24 (4L switch)?

Go to Step 9 The phenomenon is not reproduced. Refer to Troubles intermittently observed. Wires are broken between transfer connector (M-27)12 and connector (B-48)22. Repair the circuit. Go to Step 13 Wire are broken between transfer connector (M-27)12 and (B-48)22. Repair the circuit. Go to Step 13

Go to Step 10

Go to Step 11

10

1. Disconnect the M27 connector. When the transfer lever is shifted to the middle position between High and 4L, is the continuity established between transfer connector terminals (M-27)12 and GND?

Repair the transfer assembly. Go to Step 13

11

When the transfer lever is shifted to the 4L position, is the continuity established between transfer connector terminals (M-27)12 and GND?

Repair the transfer assembly. Go to Step 13

DRIVE LINE CONTROL SYSTEM (TOD) 4B271

Step 12 Action When the transfer lever is shifted to the high position, is the continuity established between transfer connector terminals (M-27)12 and GND? Repair the transfer assembly. Go to Step 13 13 Check that all the parts are mounted. Is this step complete? Repeat the Diagnosis Flow. Yes No Wires are broken between transfer connector (M-27)12 and connector (B-48)22. Repair the circuit. Go to Step 13 Return to Step 13

4B272 DRIVE LINE CONTROL SYSTEM (TOD)

Chart D2 Function of circuit Fail condition Indicator lamp status

The 4L switch circuit is short-circuited to GND. The 4L mode is displayed even in the 2H or TOD.

Transfer lever position 4WD Auto Switch

High (2H or TOD)

D04RY00006

DRIVE LINE CONTROL SYSTEM (TOD) 4B273

Step 1 2 3 4 Action When the transfer lever is shifted to the high position, is 12V observed between terminals 44 and 46 (4L switch)? When the transfer lever is shifted to the neutral position, is 0V observed between terminals 44 and 46 (4L switch)? When the transfer lever is shifted to the 4L position, is 0V observed between terminals 44 and 46 (4L switch)? 1. Select the 4WD Auto Switch to the 2H position. Is 12V observed between terminals 17 and 46? Go to Step 5 5 Is 12V observed between terminals 6 and 46? Yes Go to Step 2 Go to Step 3 Go to Step 4 No Go to Step 7 Go to Step 7 Go to Step 7 The ECU has failed. Replace the ECU. Go to Step 16 The ECU has failed. Replace the ECU. Go to Step 16

Go to Step 6 6 Is 12V observed between terminals 18 and 46? The phenomenon is not reproduced. Refer to Troubles intermittently observed.

The ECU has failed. Replace the ECU. Go to Step 16

1. Turn off the starter switch. 2. Disconnect the ECU connector. When the transfer lever is shifted to the middle position between High and 4L, is the continuity established between terminals (B48)22 and (B48)24?

Go to Step 8

Go to Step 10

When the transfer lever is shifted to the 4L position, is the continuity established between terminals (B48)22 and (B48)24? When the transfer lever is shifted to the high position, is the continuity established between terminals (B48)22 and (B48)24?

Go to Step 9

Go to Step 11 The ECU has failed. Replace the ECU. Go to Step 16

Go to Step 12 10 1. Disconnect the H-17 connector. When the transfer lever is shifted to the middle position between High and 4L, is the continuity established between terminals (H-17)6 and (B-48)24? 11 When the transfer lever is shifted to the 4L position, is the continuity established between transfer connector terminals (H-17)6 and (B-48)24? When the transfer lever is shifted to the high position, is the continuity established between terminals (H-17)6 and (B-48)24?

Go to Step 11

Go to Step 13

Go to Step 12

Go to Step 14 GND is short-circuited between terminals (B48)22 and (H-17)6. Repair the circuit. Go to Step 16 Repair the transfer assembly. Go to Step 16

12

Go to Step 15 13 1. Disconnect the M-27 connector. When the transfer lever is shifted to the middle position between High and 4L, is the continuity established between terminals (M-27)12 and GND?

Go to Step 14

4B274 DRIVE LINE CONTROL SYSTEM (TOD)

Step 14 Action 1. Disconnect the M-27 connector. When the transfer lever is shifted to the 4L position, is the continuity established between terminals (M-27)12 and GND? 15 1. Disconnect the M-27 connector. When the transfer lever is shifted to the high position, is the continuity established between terminals (M-27)12 and GND? Repair the transfer assembly. Go to Step 16 Repeat the Diagnosis Flow. Yes No Repair the transfer assembly. Go to Step 16 GND is short-circuited between terminals (H17)6 and (M-27)12. Repair the circuit. Go to Step 16 Return to Step 16

Go to Step 15

16

Check that all the parts are mounted. Is this step complete?

DRIVE LINE CONTROL SYSTEM (TOD) 4B275

Chart E1 Function of circuit Fail condition Indicator lamp status

AXLE switch circuit wires are broken. Both the TOD and 4L modes are disabled. (The transition status is not removed.)

Transfer lever position 4WD Auto Switch

Hight

4L

D04RY00007

4B276 DRIVE LINE CONTROL SYSTEM (TOD)

Step 1 Start the engine. When the transfer lever is shifted to the neutral position between high and 4L, is 5V observed between terminals 42 and 46? 2 When the transfer lever is shifted to the high position and 4WD Auto switch selected to 4WD position, is 0V observed between terminals 42 and 46? When the transfer lever is shifted to the 4L position, is 0V observed between terminals 42 and 46? Shift the transfer lever to the 4L position. Is 0V observed between terminals 17 and 46? Go to Step 5 5 Is 0V observed between terminals 6 and 46? Go to Step 2 Go to Step 7 Action Yes No

Go to Step 3 Go to Step 4

Go to Step 7 Go to Step 7 The ECU has failed. Replace the ECU. Go to Step 19 The ECU has failed. Replace the ECU. Go to Step 19

3 4

Go to Step 6 6 Is 0V observed between terminals 18 and 46? The phenomenon is not reproduced. Refer to Troubles intermittently observed. Go to Step 19

The ECU has failed. Replace the ECU. Go to Step 19

When the transfer lever is shifted to the high position and 4WD Auto Switch selected to the 2WD position, is the battery voltage observed between terminals 23 and 46? When the transfer lever is shifted to the middle position between High and 4L, is the battery voltage observed between terminals 23 and 46? When the transfer lever is shifted to the high position (TOD mode), is 0V observed between terminals 23 and 46? When the transfer lever is shifted to the 4L position, is 0V observed between terminals 23 and 46? Is any of the trouble codes 28(P1760), 32(P1761) and 33(P1762) recorded?

Go to Step 8

Go to Step 11

Go to Step 9 Go to Step 10 Go to Step 12 Examine the trouble based on Diagnosis from Trouble Codes.

Go to Step 11 Go to Step 11 Go to Step 11 The ECU has failed. Replace the ECU. Go to Step 19 Repair the circuit or replace the VSV. Go to Step 19 Repair the circuit or replace the VSV. Go to Step 19 Repair the circuit or replace the VSV. Go to Step 19 Repair the circuit or replace the VSV. Go to Step 19

9 10 11

12

1. Turn off the starter switch. 2. Disconnect the ECU connector. Does the resistance between terminals (B48)1 and (B48)24 meet the standard, 17< R < 25 ohm? Go to Step 13

13

1. Turn on the starter switch. When the 4WD Auto Switch is select to the 2WD position, is the battery voltage supplied to each VSV?

Go to Step 14

14

When the transfer lever is shifted to the middle position between High and 4L, is the battery voltage supplied to each VSV? Go to Step 15

15

When the transfer lever is shifted to the high position and 4WD Auto Switch selected to 4WD position, is 0V observed on each VSV? Go to Step 16

DRIVE LINE CONTROL SYSTEM (TOD) 4B277

Step 16 Action When the transfer lever is shifted to the 4L position, is 0V observed on each VSV? Go to Step 17 17 Is the vacuum pressure supplied to the VSV? Go to Step 18 18 Can the single AXLE switch enable and disable the continuity? Repair the shift on the fly system (refer to Driveline Control System). Go to Step 19 Repeat the Diagnosis Flow. Yes No Repair the circuit or replace the VSV. Go to Step 19 Repair the vacuum system. Go to Step 19 Replace the AXLE switch (refer to Driveline Control System). Go to Step 19 Return to Step 19

19

Check that all the parts are mounted. Is this step complete?

4B278 DRIVE LINE CONTROL SYSTEM (TOD)

Chart E2 Function of circuit Fail condition Indicator lamp status

The AXLE switch circuit is short-circuited to GND. Even after the 4WD Auto Switch is select to the 2WD position, the 2WD mode is not enabled. (The transition status is not removed.)

Transfer lever position 4WD Auto Switch

High

D04RY00007

DRIVE LINE CONTROL SYSTEM (TOD) 4B279

Step 1 Start the engine. When the transfer lever is shifted to the middle position between High and 4L, is 5V observed between terminals 42 and 46? 2 When the transfer lever is shifted to the high position and 4WD Auto Switch selected to 4WD position, is 0V observed between terminals 42 and 46? When the transfer lever is shifted to the 4L position, is 0V observed between terminals 42 and 46? Select the 4WD Auto Switch to the 2WD position. Is 12V observed between terminals 17 and 46? Go to Step 5 5 Is 12V observed between terminals 6 and 46? Go to Step 6 6 Is 12V observed between terminals 18 and 46? The phenomenon is not reproduced. Refer to Troubles intermittently observed. Go to Step 8 Go to Step 2 Go to Step 7 Action Yes No

Go to Step 3 Go to Step 4

Go to Step 7 Go to Step 7 The ECU has failed. Replace the ECU. Go to Step 19 The ECU has failed. Replace the ECU. Go to Step 19

3 4

The ECU has failed. Replace the ECU. Go to Step 19 Go to Step 11

7 8

When the 4WD Auto Switch is select to the 2WD position, is the battery voltage observed between terminals 23 and 46? When the transfer lever is shifted to the middle position between High and 4L, is the battery voltage observed between terminals 23 and 46? When the transfer lever is shifted to the high position and 4WD Auto Switch selected to 4WD position, is 0V observed between terminals 23 and 46? When the transfer lever is shifted to the 4L position, is 0V observed between terminals 23 and 46? Is any of the trouble codes 28(P1760), 32(P1761) and 33(P1762) recorded?

Go to Step 9

Go to Step 11

Go to Step 10 Go to Step 12 Examine the trouble based on Diagnosis from Trouble Codes.

Go to Step 11 Go to Step 11 The ECU has failed. Replace the ECU. Go to Step 19 Repair the circuit or replace the VSV. Go to Step 19 Repair the circuit or replace the VSV. Go to Step 19 Repair the circuit or replace the VSV. Go to Step 19 Repair the circuit or replace the VSV. Go to Step 19

10 11

12

1. Turn off the starter switch. 2. Disconnect the ECU connector. Does the resistance between terminals (B48)1 and (B48)24 meet the standard, 17< R < 25 ohm? Go to Step 13

13

1. Connect the ECU connector. 2. Turn on the starter switch. When the 4WD Auto Switch is select to the 2WD position, is the battery voltage supplied to each VSV? Go to Step 14

14

When the transfer lever is shifted to the middle position between High and 4L, is the battery voltage supplied to each VSV? Go to Step 15

15

When the transfer lever is shifted to the high position and 4WD Auto Switch selected to 4WD position, is 0V observed on each VSV? Go to Step 16

4B280 DRIVE LINE CONTROL SYSTEM (TOD)

Step 16 Action When the transfer lever is shifted to the 4L position, is 0V observed on each VSV? Go to Step 17 17 Is the vacuum pressure supplied to the VSV? Go to Step 18 18 Can the single AXLE switch enable and disable the continuity? Repair the shift on the fly system (refer to Driveline Control System). Go to Step 19 Repeat the Diagnosis Flow. Yes No Repair the circuit or replace the VSV. Go to Step 19 Repair the vacuum system. Go to Step 19 Replace the AXLE switch (refer to Driveline Control System). Go to Step 19 Return to Step 19

19

Check that all the parts are mounted. Is this step complete?

DRIVE LINE CONTROL SYSTEM (TOD) 4B281

Chart G Function of circuit Fail condition

The trouble codes are displayed.

Indicator lamp status

Transfer lever position 4WD Auto Switch

4B282 DRIVE LINE CONTROL SYSTEM (TOD)

D04RY00009

Step 1

Action Disconnect the ECU connector from ECU. Is the continuity established between terminals (B48)7 and (B48)24?

Yes

No The ECU has failed. Replace the ECU. Go to Step 3 Repair the self-diagnostic connector circuit. Go to Step 3

Go to Step 2

Is the self-diagnostic connector short-circuited?

Go to Step 3 3 1. Check that all the parts are mounted. 2. Clear the trouble codes. Is this step complete? Repeat the Diagnosis Flow.

Repeat to Step 3

DRIVE LINE CONTROL SYSTEM (TOD) 4B283

Chart H Function of circuit Fail condition Indicator lamp status

lighting switch circuit Reads in the status of lighting switch, reducing the indicator at night. Even if the lighting switch is pressed on and off, brightness does not change.

Transfer lever position 4WD Auto Switch

All position (exsample TOD mode)

D04RY00009

4B284 DRIVE LINE CONTROL SYSTEM (TOD)

Step 1 Action 1. Disconnect ECU terminal. 2. Turn on the starter switch. Is battery voltage observed between ECU terminals (B48)18 and (B48)24? 2 Turn lighting SW ON. Is 0 V observed between ECU terminal (B48)18 and (B48)24? Go to Step 3 3 Connect ECU terminal. While the lighting switch is pressed on and off, does the brightness of the indicator change? The phenomenon is not reproduced. Refer to Troubles intermittently observed Repeat the Diagnosis Flow. Yes No Wires are broken lighting SW circuit. Repair the circuit. Go to Step 4 Lighting SW circuit battery short. Repair the circuit. Go to Step 4

Go to Step 2

The ECU has failed. Replace the ECU. Go to Step 4 Return to Step 4

Check that all the parts are mounted. Is this step complete?

DRIVE LINE CONTROL SYSTEM (TOD) 4B285

Diagnosis from Symptom

Troubles that are not indicated by the warning lamp are listed in the table below. These troubles are caused by the faults that cannot be detected by the self-diagnostic function of the control unit. If this type of trouble is observed, interview the customer and conduct test runs to reproduce the trouble, cross-check the reported trouble with the listed phenomena, and diagnose and analyze the trouble on the item by item basis. Phenomena 1 The tight corner braking is observed when the vehicle is subject to full steering. D D D D Major cause The standard tires are not used. The tire pressure is incorrect. The tires are worn inuniformity. The transfer or wiring is imperfect. D The limited slip differential is failed. D The transfer or wiring is imperfect. D The shift on the fly system is failed. D D D D The standard tires are not used. The tire pressure is incorrect. The tires are worn inuniformity. The transfer or wiring is imperfect. D The limited slip differential is failed. D The wiring is imperfect. D The shift on the fly system is failed. D The wiring is imperfect. D The ABS is failed. Corrective action Check and recondition the vehicle according to Chart 1.

Even if the 4WD Auto Switch is select to the 4WD position, the 4WD mode is not active, resulting in remarkable rear wheel spin. D When the 4WD Auto Switch is select to the 4WD position, the drive resistance of the 4WD system is too large to get sufficient running speed. D Noised drive line. The shift on the fly system (front axle) generates gear noises. The braking distance gets long even when the ABS is active.

Check and recondition the vehicle according to Chart 2.

Check and recondition the vehicle according to Chart 1.

Check and recondition the vehicle according to Chart 3. Check and recondition the vehicle according to Chart 4.

4B286 DRIVE LINE CONTROL SYSTEM (TOD)

Chart 1 Function of circuit Fail condition

The tight corner braking is observed. When the vehicle is subject to full steering in the TOD mode, the drive resistance gets large or the judder occurs. Otherwise, the above phenomenon is observed only when the brake is applied.

D04RY00009

DRIVE LINE CONTROL SYSTEM (TOD) 4B287

Step 1 Action Are the front and rear tires in specified size? Yes No Replace the tires with specified ones, and service the new tires. Go to Step 16 Inflate the tires to recommended pressure. Go to Step 16 Replace the tires with specified ones, and service the new tires. Go to Step 16 Replace the tires with specified ones, and service the new tires. Go to Step 16

Go to Step 2 2 Is the tire pressure correct?

Go to Step 3 3 Are the tires free from abnormal wear?

Go to Step 4 4 Are different types of tires used?

Go to Step 5 5 1. Start the engine. 2. Shift the transfer lever to the high (TOD) position and switch the 4WD AUTO switch to the 4WD position. 3. Fully turn the steering to the left (or right) end, and select the D range and start the creep run. Does the tight corner braking occur? Is the judder with chug-chug sound observed? * Use caution on the operation. 6 1. Shift the transfer lever to the high position and switch the 4WD AUTO switch to the 2H position. 2. Fully turn the steering to the left (or right) end, and select the D range and start the creep run. Does the tight corner braking occur? Is the judder with chug-chug sound observed? * Use caution on the operation. 7 8 Is an LSD mounted to the rear differential? Is the genuine LSD oil used in the rear differential? Go to Step 9 9 Does the engine output the power correctly? Go to Step 10 10 Do the speed sensors work correctly? (Check trouble codes.) The ECU has failed. Replace the ECU. Go to Step 16 Go to Step 7 Go to Step 8 Go to Step 6

Go to Step 11

Go to Step 14 Go to Step 9 Replace the differential oil. Go to Step 16 Check the engine. Go to Step 16 Replace the speed sensors. Go to Step 16 Conduct full steering under WOT. Go to Step 5 Repair the circuit of terminal 33 (ABS IN). Go to Step 16

11

Is the tight corner braking observed only when the brake is applied? Go to Step 12

12

Turn on the starter switch. Is the battery voltage observed between terminals 33 and 46? Go to Step 13

4B288 DRIVE LINE CONTROL SYSTEM (TOD)

Step 13 Action 1. Apply the brake and fully turn the steering to the left (or right) end, and start the creep run. Does the voltage between terminals 11 and 22 range between 0.1 and 1.0V? 14 1. Shift the transfer lever to the high (TOD) position and switch the 4WD AUTO switch to 4WD position. 2. Fully turn the steering to the left (or right) end, and select the D range and start the creep run. Does the voltage between terminals 11 and 22 range between 0.1 and 1.0V? 15 1. Select the 4WD Auto Switch to the 2WD position. 2. Jack up the right front wheel. Does the front tire rotate smoothly? Go to Step 15 The phenomenon is not reproduced. Refer to Troubles intermittently observed. Repeat the Diagnosis Flow. Go to Step 10 Yes Repair the transfer assembly. Go to Step 16 No The ECU has failed. Replace the ECU. Go to Step 16

Repair the transfer assembly. Go to Step 16 Return to Step 16

16

Check that all the parts are mounted. Is this step complete?

*NOTE: Before checking this item, run the vehicle more than 10 meters with the steering wheel in straight position so that the 4L mechanical lock sleeve can be released certainly.

DRIVE LINE CONTROL SYSTEM (TOD) 4B289

Chart 2 Function of circuit Fail condition

The 4WD mode is not active. The rear wheels spin in the TOD mode, so the driving torque is not transmitted to the front wheels. The indicator lamps will not show the 4L and TOD status.

D04RY00009

4B290 DRIVE LINE CONTROL SYSTEM (TOD)

Step 1 Action Is the trouble code 31(P1721) or 26 recorded? Yes Examine the trouble based on Diagnosis from Trouble Codes. Go to Step 7 Examine the trouble based on Diagnosis from Trouble Codes. No

Go to Step 2

Is any of the trouble codes 28(P1760), 32(P1761) and 33(P1762) recorded?

Go to Step 3 Examine the trouble based on Trouble Diagnosis Depending on The Status of TOD Indicator. Repair the transfer assembly. Go to Step 7 The ECU has failed. Replace the ECU. Go to Step 7 The ECU has failed. Replace the ECU. Go to Step 7 Return to Step 7

When the transfer lever and 4WD switch are in the specified position, do the TOD indicator lamps show the correct status?

Go to Step 4 4 Shift the transfer lever to the 4L position, fully turn the steering to the left (or right) end, and start the creep run. Does the tight corner braking occur? Go to Step 5 5 1. Shift the transfer lever to the high (TOD) position. 2. Turn on the starter switch. Does the voltage between terminals 11 and 22 indicate at least 3V while the throttle is completely open? 6 Does the voltage between terminals 11 and 22 indicate at least 0.1V while the throttle is completely closed? Go to Step 6 The TOD clutch is worn. Repair the transfer assembly. Go to Step 7 Repeat the Diagnosis Flow.

Check that all the parts are mounted. Is this step complete?

DRIVE LINE CONTROL SYSTEM (TOD) 4B291

Chart 3 Function of circuit Fail condition

The shift on the fly system generates gear noises. (The fuel economy is bad in the 2H mode.) When the vehicle is run in the 2H mode, the shift on the fly system generates gear noises or the front wheel gears are engaged to generate a shock.

D04RY00015

4B292 DRIVE LINE CONTROL SYSTEM (TOD)

Step 1 Action Do the indicator lamps show the correct status? Yes No Examine the trouble based on Trouble Diagnosis Depending on The Status of TOD Indicator. Go to Step 2

Go to Step 2 2 Is any of the trouble codes 28(P1760), 32(1761) and 33(P1762) recorded? Examine the trouble based on Diagnosis from Trouble Codes. Go to Step 4 The phenomenon is not reproduced. Refer to Troubles intermittently observed. Repair the battery circuit. Go to Step 6 6 Check that all the parts are mounted. Is this step complete? Repeat the Diagnosis Flow.

Go to Step 3 Go to Step 5 The shift on the fly system is failed (refer to Section 4B1 and 4C). Go to Step 6 Repair the battery and charging system. Go to Step 6 Return to Step 6

3 4

Turn on the starter switch. Is the battery voltage observed between terminals 14 and 22? When the 4WD Auto Switch is select to the 2WD position, are the front axle gears correctly disengaged (and when the left front tire is jacked up and turned, is the front propeller shaft standstill)?

Does the battery voltage maintain the correct level?

DRIVE LINE CONTROL SYSTEM (TOD) 4B293

Chart 4 Function of circuit Fail condition

The braking distance gets long even when the ABS is active. Enough deceleration is not obtained and the braking distance gets long even when the ABS is active in the 2H mode.

D04RY00009

4B294
Step 1

DRIVE LINE CONTROL SYSTEM (TOD)

Action Are the brake and ABS systems healthy? Go to Step 2 Yes No Repair the brake and ABS. Go to Step 4 Repair the battery system. Go to Step 4

Turn on the starter switch. Is the battery voltage observed between terminals 14 and 22? Go to Step 3 1. Select the 4WD SW to the 2WD position. 2. The voltage between terminals 36 and 46 ranges between 7.5 and 16V (0.12 seconds make a cycle)

Does the voltage within the range specified? 4 Check that all the parts are mounted. Is this step complete?

Go to Step 4 Repeat the Diagnosis Flow".

The ECU has failed. Replace the ECU. Go to Step 4 Return to Step 4

SECTION
DRIVE SHAFT SYSTEM
TROOPER

4C1

DRIVELINE/AXLE
DRIVE SHAFT SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Hub and Disc (2WD Model) . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . Front Hub and Disc (4WD Model) . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . Front Drive Shaft Joint . . . . . . . . . . . . . . . . . . . Front Drive Shaft Joints Replacement . . . . Front Axle Drive Shaft . . . . . . . . . . . . . . . . . . . Front Axle Drive Shaft and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Bushing Replacement . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Shift On The Fly System . . . . . . . . . . . . . . . . . 4C2 4C2 4C3 4C4 4C4 4C4 4C6 4C6 4C9 4C10 4C11 4C11 4C11 4C12 4C12 4C16 4C17 4C18 4C18 4C19 4C19 4C20 4C21 4C21 4C22 4C24 Shift On The Fly System and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . Front Propeller Shaft . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . Front Propeller Shaft and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly (Except TOD 44) . . . . . . . . . Universal Joint Disassembly . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Universal Joint Reassembly . . . . . . . . . . . . . Reassembly (Except TOD 44) . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . Rear Propeller Shaft . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . Rear Propeller Shaft and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Universal Joint Disassembly . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Universal Joint Reassembly . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . 4C24 4C24 4C26 4C31 4C32 4C33 4C33 4C34 4C34 4C35 4C36 4C37 4C38 4C41 4C42 4C43 4C44 4C44 4C44 4C44 4C45 4C46 4C47 4C48 4C49 4C50 4C51

4C2

DRIVE SHAFT SYSTEM

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

General Description
This publication contains essential removal, installation, adjustment and maintenance procedures. The front axle utilizes a central disconnect type front axle/transfer case system. The drive axles are completely flexible assemblies, consisting of inner and outer constant velocity (CV) drive shaft joints connected by an axle shaft. For description of front propeller shaft and universal joint, refer to Front Propeller Shaft in this section.

DRIVE SHAFT SYSTEM

4C3

Diagnosis
Condition Oil Leak At Front Axle Oil Leak At Pinion Shaft Possible cause Worn or defective oil seal. Front axle housing cracked. Too much gear oil. Oil seal worn or defective. Pinion flange loose or damaged. Noises In Front Axle Drive Shaft Joint Clank When Accelerating From Coast Shudder or Acceleration Vibration During Broken or worn drive shaft joints and bellows (BJ and DOJ). Loose drive shaft joint to output shaft bolts. Damaged inner drive shaft joint. Excessive drive shaft joint angle. Worn or damaged drive shaft joints. Sticking spider assembly (inner drive shaft joint). Sticking joint assembly (outer drive shaft joint). Vibration At Highway Speeds Noises in Front Axle Out of balance or out of round tires. Front end out of alignment. Insufficient gear oil. Wrong or poor grade gear oil. Drive pinion to ring gear backlash incorrect. Worn or chipped ring gear, pinion gear or side gear. Pinion shaft bearing worn. Wheel bearing worn. Differential bearing loose or worn. Wanders and Pulls Wheel bearing preload too tight. Incorrect front alignment. Steering linkage loose or worn. Steering gear out of adjustment. Tire worn or improperly inflated. Front or rear suspension parts loose or broken. Front Wheel Shimmy Wheel bearing worn or improperly adjusted. Incorrect front alignment. Worn ball joint or bush. Steering linkage loose or worn. Steering gear out of adjustment. Tire worn or improperly inflated. Shock absorber worn. Correction Replace the oil seal. Repair or replace. Correct the oil level. Replace the oil seal. Tighten or replace. Replace the drive shaft joints and bellows. Tighten. Replace. Repair. Replace. Lubricate or replace. Lubricate or replace. Balance or replace. Align. Replenish the gear oil. Replace the gear oil. Adjust the backlash. Replace the ring gear, pinion gear or side gear. Replace the pinion shaft bearing. Replace the wheel bearing. Tighten or replace. Adjust the wheel bearing preload. Adjust the front alignment. Tighten or replace. Adjust or replace the steering gear. Adjust the inflation or replace. Tighten or replace. Adjust or replace. Adjust the front alignment. Replace the ball joint or bush. Tighten or replace. Tighten or replace. Replace or adjust the inflation. Replace the shock absorber.

4C4

DRIVE SHAFT SYSTEM

Front Hub and Disc (2WD Model)

Disassembled View

411RY00003

Legend (1) Bolt (2) Cover and Gasket (3) Packing (4) Lock Washer (5) Hub Nut (6) Outer Bearing

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

Hub and Disc Assembly ABS Sensor Ring Inner Bearing Oil Seal Bolt Wheel Pin

Disassembly
1. Before disassembly, jack up the front of vehicle and support frame with jack stands. 2. Remove the two bolts from the rear side of the knuckle arm, then remove the brake caliper, with the brake hose attached. Use a wire to attach the brake caliper to the upper link. Refer to Disk Brakes in Brake section.

DRIVE SHAFT SYSTEM

3. Remove cover bolt. 4. Remove cover and gasket. 5. Remove lock washer. 6. Remove hub nut, using front hub nut wrench J36827.

4C5

11. Remove bolt. 12. If necessary, replace the wheel pin in the following manner. D Scribe mark(1) on hub to disc before disassembly to insure proper assembly.

901RW054

411RS003

7. Remove outer bearing. 8. Remove oil seal. 9. Remove inner bearing. 10. Use a brass bar to remove the outer bearing outer race(1), oil seal, inner bearing and inner bearing outer race(2) from the hub.

D Clamp hub and disc assembly in vise, using protective pads. Remove six(6) disc-to-hub retaining bolts.

411RS021

411RS002

4C6

DRIVE SHAFT SYSTEM

NOTE: Be sure wheel stud is started squarely and seats completely.

D Place hub on a suitable work surface and remove wheel studs, as required, using a hammer.

411RS004

411RS005

2. Align index marks(1) and install hub to disc.

Inspection and Repair

Check the following parts for wear, damage or other abnormal conditions. D Hub D Hub bearing D Bearing outer race D Disc D Oil seal

Reassembly
1. Install wheel pin. D Place hub on a wood workbench or a block of wood approx. 6 by 6 to protect the wheel stud ends and threads. D Install wheel stud, using a hammer.
411RS003

DRIVE SHAFT SYSTEM

3. Install bolt. Tighten the bolts to the specified torque. Torque: 103 Nm (76 lb ft)

4C7

5. Install inner bearing. Install the outer race by driving it into the hub by using installer J36829 and grip J8092.

411RS023 411RS021

4. Install outer bearing. Install the outer race by driving it into the hub by using installer J36828 and grip J-8092.

6. Install oil seal by using installer J36830 and grip J8092. Apply Multipurpose grease NLGI No. 2 or equivalent to the lip portion.

901RW056 901RW057

4C8

DRIVE SHAFT SYSTEM

7. Apply Multipurpose grease NLGI No.2 in the hub and bearing. Hub Outer bearing Inner bearing 35 g (1.23 oz) 10 g (0.35 oz) 15 g (0.53 oz)

8. Install hub nut by using wrench J36827. Turn the place where there is a chamfer in the tapped hole to the outer side, and attach the nut.

411RS011

9. Install lock washer. D Turn the side with larger diameter of the tapered bore to the vehicle outer side, then attach the washer. If the bolt holes in the lock plate are not aligned with the corresponding holes in the nut, reverse the lock plate. If the bolt holes are still out of alignment, turn in the nut just enough to obtain alignment. Screw is to be fastened tightly so its head may come lower than the surface of the washer.
901RW054

Preload Adjustment 1. Tighten the hub nut to 29.4 Nm (21.7 lb ft), then loosen the nut to the full. 2. Tighten the hub nut to the value given below, using a spring scale on the wheel pin. Bearing Preload New bearing and New oil seal Used bearing and New oil seal 19.6 24.5 N (4.4 5.5 lb) 11.8 17.7 N (2.6 4.0 lb)

If the measured bearing preload is outside the specifications, adjust it by loosening or tightening the bearing nut.

411RS012

10. Install the paking. 11. Install cover and tighten the cover bolt. 12. Install brake caliper and tighten fixing bolt.

DRIVE SHAFT SYSTEM

4C9

Main Data and Specifications

Torque Specifications

E04RW00001

4C10

DRIVE SHAFT SYSTEM

Special Tools
ILLUSTRATION TOOL NO. TOOL NAME

J36827 Wrench; Hub nut

J36829 Installer; Inner bearing

J36828 Installer; Outer bearing

J36830 Installer; Oil seal

DRIVE SHAFT SYSTEM

4C11

Front Hub and Disc (4WD Model)

Disassembled View

411RW001

Legend (1) Bolt (2) Cap (3) Snap Ring and Shim (4) Hub Flange (5) Lock Washer and Lock Screw (6) Hub Nut

(7) (8) (9) (10) (11) (12) (13)

Outer Bearing Bolt Hub and Disc Assembly Wheel Pin ABS Sensor Ring Inner Bearing Oil Seal

Disassembly
1. Before disassembly, select the 2WD position with the 4WD switch. 2. Jack up the front of vehicle and support frame with jack stands.

3. Remove the disc brake caliper assembly and hang it on the frame with wires. Refer to Disk Brakes in Brake section. 4. Remove Bolt. 5. Remove cap. 6. Remove snap ring and shim. 7. Remove hub flange.

4C12

DRIVE SHAFT SYSTEM

D Place hub on a suitable work surface and remove the studs by using a hammer.

8. Remove lock washer and lock screw. 9. Use wrench J36827, remove hub nut.

901RW054

411RS004

10. Remove hub and disc assembly. 11. Remove ABS sensor ring. 12. Remove outer bearing. 13. Remove oil seal. 14. Remove inner bearing. 15. Remove bolt , if necessary, replace the wheel pin in the following manner. D Apply a scribe mark(1) to disc to hub. D Clamp the hub and disc assembly in a vise, using protective pads. Remove the 6 disctohub retaining bolts.

Inspection and Repair

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. Check the following parts. D Hub D Hub bearing oil seal D Knuckle spindle D Disc D Caliper D Shift on the fly system parts (Cap, Hub flange, Shim, Snap ring) D ABS sensor ring For inspection and servicing of disc caliper and related parts, refer to Disc Brakes in Brake section.

Reassembly
1. Install wheel pin. D Place the hub on a wood workbench or a block of wood approx. 6 by 6 to protect the wheel stud ends and threads.

411RS003

DRIVE SHAFT SYSTEM

D Insert a wheel stud using a hammer. Be sure the wheel stud is started squarely and seats completely.

4C13

3. Use installer J36829 and grip J8092, then install the inner bearing by driving it into the hub.

901RW055

411RS005

2. Align scribe marks(1) and attach the hub to the disc, then tighten the bolts to the specified torque. Torque: 103 Nm (76 lb ft)

4. Use installer J36828 and grip J8092 then install the outer bearing by driving it into the hub.

901RW056

411RS003

4C14

DRIVE SHAFT SYSTEM

8. Install hub nut. Turn to the place where there is a chamfer in the tapped hole to the outer side, then attach the nut by using front hub nut wrench J36827.

5. Apply grease (NLGI No.2 or equivalent) to the lip portion, then install oil seal by using installer J36830 and grip J8092.

901RW057

6. Install ABS sensor ring, then tighten the bolts to the specified torque. Torque: 18 Nm (13 lb ft) 7. Install hub and disc assembly. D Apply grease in the hub. D Apply wheel bearing type grease NLGI No. 2 or equivalent to the outer and inner bearing. Grease Amount D Hub: 35 g (1.23 oz) D Outer bearing: 10 g (0.35 oz) D Inner bearing: 15 g (0.53 oz)

901RW054

Preload Adjustment 1. Tighten the hub nut to 29 Nm (22 lb ft), then fully loosen the nut. 2. Tighten the hub nut to the value given below, using a spring scale on the wheel pin. New bearing and New oil seal Bearing Preload: 20 N 25 N (4.4 lb 5.5 lb) Used bearing and New oil seal Bearing Preload: 12 N 18 N (2.6 lb 4.0 lb) If the measured bearing preload is outside the specifications, adjust it by loosening or tightening the bearing nut.

411RS009

Legend (1) Inner Bearing (2) Hub (3) Outer Bearing

411RS011

DRIVE SHAFT SYSTEM

9. Install lock washer and lock screw in the following manner. D Turn the side with larger diameter of the tapered bore to the vehicle outer side, then attach the washer. D If the bolt holes in the lock plate are not aligned with the corresponding holes in the nut, reverse the lock plate. D If the bolt holes are still out of alignment, turn in the nut just enough to obtain alignment. D Screw is to be fastened tightly so its head may come lower than the surface of the washer. 12. Install hub cap. 13. Tighten the bolts to the specified torque. Torque: 59 Nm (43 lb ft)

4C15

411RS012

10. Apply adhesive (LOCTITE 515 or equivalent) to both joining flange faces then install hub flange. 11. Install snap ring and shim. D Adjust the clearance between the free wheeling hub body and the snap ring. Clearance: 0 mm0.3 mm (0 in0.012 in) Shims Available: 0.2 mm, 0.3 mm, 0.5 mm, 1.0 mm (0.008 in, 0.012 in, 0.020 in, 0.039 in)

411RW002

4C16

DRIVE SHAFT SYSTEM

Main Data and Specifications

Torque Specifications

E04RW001

DRIVE SHAFT SYSTEM

4C17

Special Tools
ILLUSTRATION TOOL NO. TOOL NAME

J36827 Wrench; Hub nut

J36829 Installer; Inner bearing

J36828 Installer; Outer bearing

J36830 Installer; Oil seal

4C18

DRIVE SHAFT SYSTEM

Front Drive Shaft Joint

Front Drive Shaft Joints Replacement
D Refer to Front Drive Axle Assembly Replacement in this section, and refer to Front Hub and Disc in Suspension section. 1. Open filler plug and make sure that the oil is up to the plug port. If the level oil is low, replenish with gear oil GL5 grade. 2. Tighten the filler plug to specified torque. Torque: 78 Nm (58 lb in)

Front Hub Bearing Preload Check

Check the hub bearing preload at the wheel pin. New bearing and new oil seal: 19.6 24.5 N (4.4 5.5 lb) Used bearing and new oil seal: 11.8 17.7 N (2.6 4.0 lb)

411RS001

Inspection Of Shift On The Fly System Gear Oil

412RT002

DRIVE SHAFT SYSTEM

4C19

Front Axle Drive Shaft

Front Axle Drive Shaft and Associated Parts

412RW003

Legend (1) Axle Case and Differential (2) DOJ Case Assembly (3) Snap Ring (4) Bearing (5) Snap Ring (6) Oil Seal (7) Bracket (8) DOJ Case (9) Circlip (10) Bolt (11) Drive Shaft Joint Assembly (12) Snap Ring

(13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25)

Spacer Ball Snap Ring Ball Retainer Ball Guide Band Bellows Band Band Bellows Band BJ Shaft Dust Seal

4C20

DRIVE SHAFT SYSTEM

4. Remove drive shaft joint assembly. 5. Using snap ring pliers, remove the snap ring.

Disassembly
NOTE: For the left side, follow the same steps as right side. 1. Raise the hooked end of the band (1) with a screwdriver or equivalent.

412RS011

6. Remove spacer. 7. Remove the six balls (1) with a screwdriver or equivalent.
412RS009

2. Remove band. 3. Pry off circlip (1) with a screwdriver or equivalent.

412RS012

412RS010

DRIVE SHAFT SYSTEM

8. Using snap ring pliers, remove the snap ring (1) fastening the ball retainer to the center shaft.

4C21

Inspection and Repair

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: 1. Drive shaft joint assembly 2. DOJ case, ball, ball guide, ball retainer 3. Bellows 4. Bearing 5. Dust seal, oil seal

Bushing Replacement
D Remove the bushings using a remover J393781 and hammer.

412RS013

9. Remove ball retainer, ball guide and bellows. 10. Raise the hooked end of the band (1) with a screwdriver or equivalent.

412RS015

D By using installer J393782 and base J393783, press fit the bushings into the bracket.

412RS014

11. Remove band. 12. Remove bellows. 13. Remove dust seal. 14. Remove BJ shaft assembly. 15. Remove the mounting bracket fixing bolts, and then remove DOJ case assembly from the axle case. 16. Remove snap ring and bearing. 17. Remove snap ring and oil seal. 18. Remove bracket.

412RS016

4C22

DRIVE SHAFT SYSTEM

12. Using snap ring pliers, install the snap ring (1) securing the ball retainer to the shaft.

Reassembly
1. Install DOJ case to bracket. 2. Install oil seal and fix snap ring. 3. Install bearing and fix snap ring. 4. Install bracket to axle case. Tighten the bracket bolt to the specified torque. Torque: 116 Nm (85 lb ft) 5. Apply 150g of the specified grease in BJ . 6. Install dust seal . 7. Apply a thin coat of grease to the shaft for smooth installation then install bellows. 8. Install band. Note the setting direction. After installation, check that the bellows is free from distortion.

412RS013

13. Align the track on the ball (1) retainer with the window in the cage, and install the six balls into position.

412RS017

9. Install another bellows and fix band. 10. Install the ball guide with the smaller diameter side ahead onto the shaft. 11. Install ball retainer.

412RS018

DRIVE SHAFT SYSTEM

14. Install spacer. 15. Install snap ring. 16. Enclose 150g of the specified grease in DOJ case, then install drive shaft joint assembly. After reassembly, move the DOJ longitudinally several times to get to fit. 17. Install the circlip (1) so that open ends are positioned away from the ball groove.

4C23

18. Install bellows. Adjust the air pressure within the bellows by inserting a screwdriver or equivalent, so that it equals atmospheric pressure.

412RS021

19. Install Band. After installation, check that the bellows is free from distortion.

412RS019

412RS020

Legend (1) Outer Case (2) Circlip (3) Open Ends

4C24

DRIVE SHAFT SYSTEM

Shift On The Fly System

Shift On The Fly System and Associated Parts

412RW004

Legend (1) Filler Plug (2) Bolt (3) Oil Seal (4) Snap Ring(External) (5) Inner Shaft Bearing (6) Snap Ring(Internal) (7) Inner Shaft

(8) (9) (10) (11) (12) (13) (14) (15)

Needle Bearing Clutch Gear Sleeve Housing Front Axle Drive Shaft (LH side)with Bracket Bolt Actuator Assembly Bolt

Disassembly
1. Remove filler plug and gasket, drain oil. 2. Loosen mounting bracket fitting bolts and remove front axle drive shaft from front axle case. 3. Remove Actuator Assembly and draw out actuator ASM.

4. Remove housing. 5. Remove sleeve.

DRIVE SHAFT SYSTEM

6. Remove clutch gear. 7. Remove snap ring from front axle case by using snap ring pliers.

4C25

10. Remove inner shaft bearing by using a remover J37452 and press. NOTE: Be careful not to damage the shaft.

412RW017

8. Take out inner shaft from front axle case. 9. Remove snap ring from inner shaft by using snap ring pliers.

412RW015

11. Remove needle bearing from inner shaft by using a remover J26941 and sliding hammer J261901. NOTE: Be careful not to damage the shaft.

412RW016 412RS045

12. Remove oil seal from front axle case. NOTE: Be careful not to damage the front axle case.

4C26

DRIVE SHAFT SYSTEM

Inspection and Repair

Inspect the removed parts. If there are abnormalities such as wear and damage, take corrective action or replace.

Inner Shaft RunOut

With both end centers supported, rotate the shaft slowly and measure deflection with a dial gauge. Limit: 0.5 mm (0.02 in) NOTE: Do not heat the shaft to correct its bend.

Visual Check
1. Check and see if the inner shaft has any abnormalities such as wear and damage.

412RS026

412RW014

Inner Shaft Bearing

2. When inspecting the inner shaft, be sure to check and see if its splined part is twisted, worn, or cracked. If so, replace with a new shaft. In case of an abnormality in its gear part (a slide with sleeve), replace the shaft.

412RW006

420RS008

Legend (1) Inner Shaft Bearing (2) Inner Shaft (3) Clutch Gear 1. Inspect the state of inner shaft bearing. If any abnormality such as roughness is found, replace with a new inner shaft bearing. 2. Insert a clutch gear and check the state of needle bearing. 3. If there is an abnormality such as roughness, replace the needle bearing.

DRIVE SHAFT SYSTEM

4C27

Sleeve Condition
Check and see that there is no wear, damage, or cracking in the sleeve. NOTE: Close inspection of the groove and inner gear are required because those are important parts.

Clutch Gear Condition

Check and see that there is no wear, damage, cracking, or any other abnormality in the clutch gear.

Clutch Gear Function

Sleeve Function

412RW010

412RW011

Operate the sleeve with the inner shaft combined with the clutch gear. If roughness is felt, replace the sleeve. NOTE: Gear oil should be applied to the contact surface of gear. Check the width of sleeve center groove. Limit: 7.1 mm (1.28 in)

If there is an abnormality such as roughness when operated in combination with sleeve, replace the clutch gear. NOTE: When inspecting, gear oil should be applied to the contact surface of gear.

Clutch Gear Journal Diameter

Make sure of the size illustrated. Limit: 36.98 mm (1.456 in)

412RW022 412RW009

4C28

DRIVE SHAFT SYSTEM

Actuator
Check and see that there is no damage, cracking, or other abnormality. Functional Check

412RW007

Disconnect the shift position switch and make sure of function with a vacuum of 400 mmHg applied to Ports A and B, in accordance with the table below.
412RW021

State C D

Port A 400 mmHg A/P

Port B A/P 400 mmHg

Function E F

If there is an abnormality, replace the actuator as an assembly. NOTE: 1. If the actuator works under 400mmHg or less, there is no functional problem.

412RW013

DRIVE SHAFT SYSTEM

2. Be careful not to permit the entry of water or dust into the ports of the actuator. Dimensional Check Measure illustrated sizes 1, 2, and 3. Limit 1=64.1 mm (2.52 in) 2=6.7 mm (0.26 in) 3=6.7 mm (0.26 in)

4C29

2. Force a new needle bearing into inner shaft by using a installer J41694 and grip J8092.

412RS051

3. Place a new snap ring(internal) in inner shaft. Force a new inner shaft bearing into the inner shaft by using a installer J37452 and press.

412RS037

Reassembly
1. Install the new oil seal which has been immersed in differential gear oil, by using an oil seal installer J41693 and grip J8092.

412RS044

4. Install snap ring(external). NOTE: Be careful not to damage the inner shaft. 5. Clean the housing contact surface of the front axle case and insert inner shaft assembly into the front axle case. NOTE: Be careful not to damage seal.
412RS043

4C30

DRIVE SHAFT SYSTEM

10. Tighten bolts to specified torque. Torque: 116Nm(85 lb ft) 11. Clean the actuator contact surface with the housing then Install and tighten shift position switch to specified torque. Torque: 39Nm (29 lb ft) 12. Apply liquid gasket to the contact surface on the actuator side.

6. Install snap ring (internal) in the groove of front axle case. NOTE: Be sure to install the snap ring properly.

412RW017

7. Apply differential gear oil to clutch gear, then install clutch gear. 8. Apply differential gear oil to sleeve, then install sleeve. 9. Clean contact surface with the front axle and actuator mounting surface. Apply liquid gasket to the contact surface on the front axle case, then install in the housing.

412RW012

13. Align shift arm with the groove of sleeve and install the actuator. 14. Tighten bolts to specified torque. Torque: 13Nm(113 lb ft) 15. Install front axle drive shaft and mounting bracket. Tighten fitting bolts to specified torque. Torque: 116Nm (85 lb ft) 16. Pour specified amount of differential gear oil to filler plug. Front Differential Oil Capacity: 1.4lit (1.48US qt) Actuator Housing Oil Capacity: 0.12lit(0.13US qt) 17. Install filler plug through gasket and tighten to specified torque. Torque: 7.8Nm (58lb ft)

412RW023

DRIVE SHAFT SYSTEM

4C31

Main Data and Specifications

General Specifications
Front drive axle oil capacity Type of lubricant Axle shaft type 1.4 liter (1.48 US qt)(Differential) 0.12 liter (0.13 US qt)(Actuator Housing:Shift on the fly) GL5 (Multi grade type) Refer to chart in General Information Constant velocity joint(Birfield joint type and double offset joint)

Torque Specifications

E04RW004

4C32

DRIVE SHAFT SYSTEM

Special Tools
ILLUSTRATION TOOL NO. TOOL NAME ILLUSTRATION TOOL NO. TOOL NAME

J39378 Remover and Installer; Front Axle mount bushing

J8092 Grip

J37452 Remover and Installer; Inner shaft bearing

J 26941 Remover;Bearing needle

J261901 Hammer; Sliding

J41693 Installer; Oil seal

J41694 Installer; Bearing needle

DRIVE SHAFT SYSTEM

4C33

Front Propeller Shaft

General Description
Since the propeller shaft is balanced carefully, welding or any other modifications are not permitted. Alignment marks should be applied to each propeller shaft before removal.

401RW002

4C34

DRIVE SHAFT SYSTEM

Front Propeller Shaft and Associated Parts

401RW058

Legend (1) Bolt, Nut and Washer (Front Axle Side) (2) Front Propeller Shaft (3) Bolt, Nut and Washer (Transfer Side)

(4) (5) (6) (7)

Front Propeller Shaft (with TOD) Coupling LJ Constant Velocity Joint BJ Constant Velocity Joint

Removal
1. Jack up the vehicle and support it on the chassis stands. 2. Gear shift lever should be placed in neutral position and parking brake released. 3. Remove the exhaust and transfer protectors. NOTE: Apply alignment marks on the flange at the front propeller shaft both front and rear side.

401RS020

DRIVE SHAFT SYSTEM

4C35

401RW053

401RW051

Installation
NOTE: Never install the shaft assembly backwards. Completely remove the black paint from the connecting surface of flange coupling on each end of propeller shaft. Clean so that no foreign matter will be caught in between. 1. Align the mark which was applied at removal. Install front propeller shaft and tighten the bolts to the specified torque. Torque: 63 Nm (46 lb ft) 2. Install the exhaust and transfer protectors. 3. After installing the propeller shaft, be sure to apply black paint (1) to exposed area (other than connecting surface) of the entire surface of flange coupling .

401RW052

4. Remove bolt, nut and washer (Front axle side). 5. Remove bolt, nut and washer (Transfer side). 6. Remove front propeller shaft. NOTE: If equipped with torque on demand (TOD), when removing, installing or carring for front propeller shaft, be sure to wind a piece of cloth round the part of the boot with which fittings may interfere so that the boot can be protected. The boot may be damaged if bending force is applied to the constant velocity joint of the shaft.

401RS019

4C36

DRIVE SHAFT SYSTEM

Disassembly (Except TOD 44)

401RW057

Legend (1) Sleeve Yoke

(2) Seal (3) Tube Assembly

1. Apply alignment marks (1) on the sleeve yoke and tube assembly then remove sleeve yoke.

2. Remove seal. 3. Remove tube assembly.

401RW056

DRIVE SHAFT SYSTEM

4C37

Universal Joint Disassembly

401RW055

Legend (1) Flange Yoke (2) Spider

(3) Snap Ring (4) Needle Roller Bearing (5) Grease Fitting

1. Apply alignment marks (1) on the yokes of the universal joint, then remove snap ring.

2. Tap out the needle roller bearing by gently striking the shoulder of the yoke, using a mallet or a copper hammer.

401RS028 401RS006

4C38

DRIVE SHAFT SYSTEM

3. Make sure of proper position for reinstallation by applying setting marks, then remove spider .

Inspection and Repair

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition is found through inspection. NOTE: When any part of the journal assembly (spider, needle roller bearing) requires replacement, be sure to replace the entire assembly. Check the following parts for wear, damage, noise or any other abnormal conditions: 1. Spider 2. Needle roller bearing 3. Yoke 4. Flange 5. Constant velocity joint
401RS027

Outside Diameter of Spider Pin

Standard: 17.00 mm (0.669 in) Limit: 16.90 mm (0.665 in)

Play in Splines in Normal Direction of Rotation

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

401RS007

Propeller Shaft Runout

Support the ends of the propeller shaft on V-blocks (2) and check for runout by holding the probe of a dial indicator (1) in contact with the center part of the shaft. If the amount of runout is beyond the standard value for assembly, correct with a bench press or replace the shaft with a new propeller shaft assembly. Standard: 0.3 mm (0.012 in) Limit: 0.5 mm (0.02 in)

401RS009

DRIVE SHAFT SYSTEM

4C39

Play in Universal Joint

Limit: Less than 0.1 mm (0.004 in)

401RW049

Boot of Constant Velocity Joint

401RS010

Constant Velocity Joint

NOTE: LJ and BJ constant velocity joints are unremovable types. Check the joint for play and the boot for damage, wear, and leak of grease. If abnormality is found, replace propeller shaft as an assembly.

Check the boot (2) for crack, damage and grease leak, and the boot band (1) for loosening and damage. Check the both sides of the joint and make sure that there is no leak of grease from the cover press-in parts(3).

Play in Constant Velocity Joint

Fix the shaft in a vise throrgh pieces of wood, and try to move the joint vertically, right and left, and back and forth to make sure of smooth motions and no remarkable play.

401RW048

401RW050

4C40

DRIVE SHAFT SYSTEM

2. Set a dial gage at right angle near the inner circumference and check the run-out of the flange. Limit: 0.15 mm (0.006 in)

401RW047

Front Axle Flange Run-out

1. Set a dial gage at right angle near the outer circumference of the flange face and check the run-out of the flange face. Limit: 0.15 mm (0.006 in)
401RW045

3. If vibration is felt during the 4H AUTO drive, disconnct the propeller shaft at the front axle. Reinstall the propeller shaft at 60, 120, 180, 240, and 300 and conduct test drive in each position and check if there is vibration.

401RW046

401RW044

DRIVE SHAFT SYSTEM

4C41

Universal Joint Reassembly

1. Install spider to flange yoke. Be sure to install the spider by aligning the setting marks made during disassembly. 2. Apply a molybdenumdisulfide grease or a multipurpose type grease NLGI No. 2 to inside of the bearing cap. Grease Amount: Approx. 1.2 g (0.042 oz)

4. Align setting marks (1) and join the yokes.

401RS028

5. Install snap ring. NOTE: Discard used snap rings and install new ones. When the bearing cap is in position, select and attach a snap ring of suitable thickness so that the end play of the spider pin is held within 0.1 mm (0.004 in). Snap ring thickness and Identification color 1.5 mm (0.059 in); Blue 1.53 mm (0.060 in); White 1.59 mm (0.063 in); Yellow 1.62 mm (0.064 in); Green 1.68 mm (0.066 in); Not colored NOTE: Be sure to use snap rings of the same thickness on both sides.

401RS011

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

401RS012

4C42

DRIVE SHAFT SYSTEM

Reassembly (Except TOD 44)

401RW057

Legend (1) Sleeve Yoke

(2) Seal (3) Tube Assembly

1. Discard used seal and install new one. 2. Align the alignment marks and install tube assembly to sleeve yoke.

DRIVE SHAFT SYSTEM

4C43

Main Data and Specifications

General Specifications
Engine Transmission Construction Outside diameter Length M/T 6VE1(3.5 L) A/T A/T with TOD Hollow steel tube with constant velocty joints. 40.0 mm (1.57 in) 577 mm (22.72 in) Hollow steel tube with yoke and spider type universal joints. 40.0 mm (1.57 in) 559 mm (22.01 in) 40.0 mm (1.57 in) 559 mm (22.01 in)

Torque Specifications

E04RW005

4C44

DRIVE SHAFT SYSTEM

Rear Propeller Shaft

General Description
Since the propeller shaft is balanced carefully, welding or any other modifications are not permitted. Alignment marks should be applied to each propeller shaft before removal.

401RW003

Rear Propeller Shaft and Associated Parts

401RW059

Legend (1) Bolt, Nut and Washer

(2) Rear Propeller Shaft (3) Bolt, Nut and Washer

Removal
1. Jack up the vehicle and support it on the chassis stands.

2. Gear shift lever should be placed in neutral position and parking brake released. NOTE: Apply alignment marks on the flange at the rear propeller shaft both front and rear side.

DRIVE SHAFT SYSTEM

4C45

401RS023

3. Remove bolt, nut and washer (Rear axle side). 4. Remove bolt, nut and washer (Transfer side). 5. Remove rear propeller shaft.

Installation
NOTE: Never install the shaft assembly backwards. 1. Completely remove the black paint from the connecting surface of flange coupling on each end of propeller shaft. Clean so that no foreign matter will be caught in between. 2. Align the mark which is applied at removal . Install rear propeller shaft and tighten the bolts to the specified torque. Torque: 63 Nm (46 lb ft) 3. After installing the propeller shaft, be sure to apply black paint (1) to exposed area (other than connecting surface) of the entire surface of flange coupling .

401RS022

4C46

DRIVE SHAFT SYSTEM

Disassembly

401RW057

Legend (1) Sleeve Yoke

(2) Seal (3) Tube Assembly

1. Apply alignment marks (1) on the sleeve yoke and tube assembly then remove sleeve yoke.

2. Remove seal. 3. Remove tube assembly.

401RW056

DRIVE SHAFT SYSTEM

4C47

Universal Joint Disassembly

401RW054

Legend (1) Flange Yoke (2) Spider with Grease Fitting

(3) Snap Ring (4) Needle Roller Bearing (5) Grease Fitting

1. Apply alignment marks (1) on the yokes of the universal joint, then remove snap ring.

2. Tap out the needle roller bearing by gently striking the shoulder of the yoke, using a mallet or a copper hammer.

401RS028 401RS006

4C48

DRIVE SHAFT SYSTEM

3. Make sure of proper position for reinstallation by applying setting marks, then remove spider with grease fitting.

Inspection and Repair

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

Outside Diameter of Spider Pin

Standard: 17.00 mm (0.669 in) Limit: 16.90 mm (0.665 in)

401RS008

Play in Splines in Normal Direction of Rotation

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

401RS007

Propeller Shaft Run-out

Support the ends of the propeller shaft on V-blocks (2) and check for run-out by holding the probe of a dial indicator (1) in contact with the center part of the shaft. If the amount of run-out is beyond the standard value for assembly, correct with a bench press or replace the shaft with a new propeller shaft assembly . Standard: 0.3 mm (0.012 in) Limit: 0.5 mm (0.02 in)

401RS009

DRIVE SHAFT SYSTEM

4C49

Play in Universal Joint

Limit: Less than 0.1 mm (0.004 in)

401RS012

4. Align setting marks (1) and join the yokes.

401RS010

NOTE: Assemble the spider and spline yoke so that their grease fittings are arranged on the same side.

Universal Joint Reassembly

1. Install spider to flange yoke. Be sure to install the spider by aligning the setting marks made during disassembly. 2. Before installing needle roller bearing, apply a molybdenumdisulfide grease or a multipurpose type grease NLGI No. 2 to inside of the bearing cap. Grease Amount: Approx. 1.2 g (0.042 oz)

401RS028

5. Install snap ring. NOTE: Discard used snap rings and install new ones. When the bearing cap is in position, select and attach a snap ring of suitable thickness so that the end play of the spider pin is held within 0.1 mm (0.004 in). Snap ring thickness and identification color 1.5 mm (0.059 in): Blue 1.545 mm (0.061 in): White 1.59 mm (0.063 in): Yellow 1.635 mm (0.064 in): Green 1.68 mm (0.066 in): Not colored NOTE: Be sure to use snap rings of the same thickness on both sides.

401RS011

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

4C50

DRIVE SHAFT SYSTEM

Reassembly

401RW057

Legend (1) Sleeve Yoke

(2) Seal (3) Tube Assembly

1. Discard used seal and install new one. 2. Align the alignment marks and install tube assembly to sleeve yoke.

DRIVE SHAFT SYSTEM

4C51

Main Data and Specifications

General Specifications
Engine Transmission Construction Outside diameter Length M/T 68.9 mm (2.71 in) 1093 mm (43.03 in) 6VE1(3.5 L) A/T 68.9 mm (2.71 in) 1093 mm (43.03 in) A/T with TOD 68.9 mm (2.71 in) 1075 mm (42.32 in) Hollow steel tube with yoke and spider type universal joints.

Torque Specifications

E04RW006

SECTION
TRANSFER CASE (STANDARD TYPE)
TROOPER

4D11

DRIVELINE/AXLE
TRANSFER CASE (STANDARD TYPE)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Transfer Rear Oil Seal . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Case Assembly . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Rear Case Assembly . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D11 4D12 4D14 4D14 4D14 4D16 4D16 4D17 4D19 4D19 4D110 4D113 4D114 4D114 Detent, Shift Arm, and Interlock Pin (Transfer Case Assembly) . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Case Assembly . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D116 4D116 4D117 4D118 4D118 4D120 4D120 4D121 4D123 4D127 4D133 4D136

Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.

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

4D12 TRANSFER CASE (STANDARD TYPE)

General Description
M/T model

A07RW019

TRANSFER CASE (STANDARD TYPE)

A/T model

4D13

A07RW001

The transfer case is used to provide a means of providing power flow to the front axle. The transfer case also provides a means of disconnecting the front axle, providing better fuel economy and quieter operation when the vehicle is driven on improved roads where four wheel drive is not required. In addition, the transfer case provides an additional gear reduction when placed in low range, which is useful when difficult offroad conditions are encountered. A floor mounted shift lever is used to select the operating range. When four wheel drive has been selected, the four wheel drive indicator light is designed to come on when the front axle has been engaged.

4D14 TRANSFER CASE (STANDARD TYPE)

Transfer Rear Oil Seal

Removal
1. Disconnect the rear propeller shaft from the transfer case side. 2. Remove end nut and rear companion flange, use the companion flange holder J861411 to remove the end nut.

Installation
To install, follow the removal steps in the reverse order, noting the following points: 1. Install oil seal and apply engine oil to the oil seal outer surfaces. 2. Apply the recommended grease (BESCO L2) or equivalent to the oil seal lip. 3. Use the oil seal installer J39208 to install the rear seal to the transfer rear case.

266RW001

3. Use the universal puller to remove the rear companion flange and Oring. 4. Remove the oil seal from the transfer case.

220RS016

4. Rear companion flange and end nut. 5. Install the rear companion flange and Oring. 6. Use the companion flange holder J37221 to install a new end nut and tighten to the specified torque. Torque: 167 Nm (123 lb ft) 7. Use the punch J39209 to stake the end nut at two spots. NOTE: Be sure to confirm that there is no crack at the staked portion of the end nut after staking.

266RS001

TRANSFER CASE (STANDARD TYPE)

4D15

266RW002

8. Connect the rear propeller shaft to the transfer case and tighten to the specified torque. Torque: 63 Nm 46 (lb ft)

4D16 TRANSFER CASE (STANDARD TYPE)

Transfer Case Assembly

260R200002

Legend (1) Transfer Protector (2) Rear Propeller Shaft (3) Front Propeller Shaft (4) Front Console

(5) Select Lever Assembly (A/T) Grommet Assembly (M/T) (6) Transfer Control Lever (7) Wiring Harness Connector (8) Transmission Transfer Bolt (9) Transfer Case Assembly

Removal
NOTE: Before removing transmission & transfer assembly from vehicle, change the transfer mode to 2WD by pushing button switch on dash panel. 1. Disconnect the battery ground cable. 2. Drain the transfer case fluid. 3. Remove transfer protector. 4. Remove rear propeller shaft.

5. Remove the rear and front propeller shaft from the transfer case side. 6. Disconnect the four oxygen sensor connectors from the transmission harness. 7. Remove the right and left catalytic converter assemblies and exhaust pipe. 8. Remove the transfer control lever knob. 9. Remove the selector lever assembly. Refer to Selector Lever in the Section 7A.

TRANSFER CASE (STANDARD TYPE)

10. Remove transfer control lever. 11. Disconnect the 4WD switch and speed sensor harness connector and 2WD4WD actuator harness connector from the transmission harness. 12. Remove transmissiontransfer bolt and support the transfer case with a transmission jack. 13. Remove four transmissiontransfer bolts and the three nuts. 14. Remove the transfer case assembly from the vehicle.

4D17

Installation
To install, follow the removal steps in the reverse order, noting the following points: 1. Install transfer case assembly and apply a thin coat of molybdenum disulfide grease to the input shaft spline. 2. Tighten the transmissiontransfer bolt to the specified torque. Torque: 46 Nm (34 lb ft)

260RW001

3. Tighten the exhaust pipe to exhaust manifold bolt to the specified torque. Torque: 67 Nm (49 lb ft) 4. Tighten the exhaust pipe flange bolt to the specified torque. Torque: 43 Nm (32 lb ft) 5. Tighten the propeller shaft bolt to the specified torque. Torque: 63 Nm (46 lb ft)

4D18 TRANSFER CASE (STANDARD TYPE)

6. Tighten the transfer protector bolt to the specified torque. Torque: 37 Nm (27 lb ft)

256RW026

TRANSFER CASE (STANDARD TYPE)

4D19

Transfer Rear Case Assembly

Removal
1. Remove the speedometer sensor. 2. Remove the plate. 3. Remove the speedometer driven gear bushing and driven gear. NOTE: Apply a reference mark to the driven gear bushing before removal. 4. Remove front companion flange. 5. Remove rear companion flange, use the flange companion holder J861411 to remove the end nut. 10. Pull the 2WD4WD 2WD4WD shift rod. actuator assembly with

262RW009

6. Remove the front and rear companion flange. NOTE: Use the universal puller to remove the rear companion flange. 7. Remove control box assembly. 8. Disconnect the actuator breather hose from the 2WD4WD actuator assembly. Legend (1) Shift Rod: 2WD4WD (Position: 2WD) (2) 2WD4WD Actuator Assembly (3) Pull (4) Rear Case Assembly (5) Position: 4WD (6) Mode: 2WD

220RW027

220RW085

9. Remove the 2WD4WD actuator assembly bolts.

4D110 TRANSFER CASE (STANDARD TYPE)

11. Off set the actuator assembly.

Installation
1. Install transfer rear case assembly. 2. Install transfer case assembly and apply the recommended liquid gasket (LOCTITE 17430) or its equivalent to the transfer rear case fitting faces.

220RW028

12. Remove the actuator assembly.

220RS017

3. Perform the following steps before fitting the transfer rear case: 1. Shift the highlow shift to the 4H side. 2. Turn the select rod counterclockwise so that the select block projection A may enter into the 2WD4WD shift block. 3. The cutaway portion of the select rod head (9) should align with that of the rear case holes stopper (10).

220RW029

Legend (7) Position: 4WD (8) Mode: 2WD 13. Remove transfer case assembly. 14. Remove transfer rear case assembly.

230RW004

4. Tighten the transfer rear case bolts to the specified torque. Torque: 37 Nm (27 lb ft) 5. Shift the 2WD4WD shift rod (11) to the 4WD side.

TRANSFER CASE (STANDARD TYPE)

6. Join the rod grooves of 2WD4WD actuator assembly (12) and shift rod (11).

4D111

8. Tighten the 2WD4WD actuator bolts to the specified torque. Torque: 19 Nm (14 lb ft) 9. Connect the actuator breather hose to actuator. 10. Install control box assembly. Torque: 19 Nm (14 lb ft) 11. Install rear companion flange. 12. Install front companion flange, use the companion flange holder J861411 to tighten the flange nuts to the transfer case.

220RW030

Legend (11) Shift Rod: 2WD4WD (Position: 4WD) (12) 2WD4WD Actuator Assembly (Mode: 2WD) (13) Rear Case Assembly 7. Push the 2WD4WD actuator assembly (12) with 2WD4WD shift rod (11) till the shift rod (11) reaches the 2WD position.
262RW009

13. Tighten the new transfer flange nuts to the specified torque. Torque Rear companion flange: 167 Nm (123 lb ft) Front companion flange: 137 Nm (101 lb ft)

220RW031

Legend (14) Position: 2WD (15) Mode: 2WD

4D112 TRANSFER CASE (STANDARD TYPE)

14. Use the punch J39209 to stake the rear companion flange nut at two spots. 15. Stake the front companion flange nut at one spot. NOTE: Be sure to confirm that there is no crack at the staked portion of the flange nut after staking. 16. Install the Oring (8) to the speedometer driven gear bushing (7). 17. Install the driven gear to the speedometer driven gear bushing (7). 18. Install the speedometer driven gear assembly to the transfer rear cover. 19. Install the plate (6) to the transfer rear case and tighten to the specified torque. Torque: 15 Nm (11 lb ft) 20. Install the speedometer sensor and tighten to the specified torque. Torque: 27 Nm (20 lb ft)

266RS001

225RW005

266RW002

TRANSFER CASE (STANDARD TYPE)

4D113

Disassembly

226RW131

Legend (1) Rear Output Shaft Assembly (2) Rear Output Shaft (3) Bearing Snap Ring (4) Ball Bearing

(5) (6) (7) (8) (9)

Bearing Snap Ring Ball Speedometer Drive Gear Ball Bearing Transfer Rear Case (with oil seal)

1. Remove bearing snap ring, use a pair of snap ring pliers to remove the snap ring.

226RS060

4D114 TRANSFER CASE (STANDARD TYPE)

2. Remove the rear output shaft assembly from the transfer rear case. 3. Remove ball bearing, use a bench press and the bearing remover J2291201 to remove the ball bearing.

Reassembly
1. Install transfer rear case (with oil seal). Oil seal replacement D Remove the oil seal from the transfer rear case. D Apply engine oil to the oil seal outer surfaces. D Fill in recommended grease (BESCO L2) or equivalent in the oil seal lip. D Use the oil seal installer to install J39208 to the rear oil seal to the transfer rear case.

226RS061

4. Remove speedometer drive gear. 5. Remove ball. 6. Remove bearing snap ring, use a pair of snap ring pliers to remove the snap ring. 7. Remove ball bearing. 8. Remove rear output shaft, use a bench press and the bearing remover J2291201 to remove the ball bearing.

220RS019

2. Install rear output shaft. 3. Install ball bearing, use the ball bearing installer J37223 and the adapter J37486A to install the ball bearing.

226RS062

9. Remove transfer rear case (with oil seal).

262RW021

Inspection and Repair

Refer to TRANSFER CASE ASSEMBLY in this section for inspection and repair.

4. Install bearing snap ring. 5. Install ball.

TRANSFER CASE (STANDARD TYPE)

6. Install speedometer drive gear.

4D115

226RS064

7. Install ball bearing, use the ball bearing installer J37223 to install the ball bearing.

226RS065

8. Install the rear output shaft assembly to the transfer rear case. 9. Install bearing snap ring. NOTE: The snap ring must be fully inserted into the transfer rear case snap ring groove.

4D116 TRANSFER CASE (STANDARD TYPE)

Detent, Shift Arm, and Interlock Pin (Transfer Case Assembly)

Disassembled View

262R200004

Legend (1) Transfer Case (2) Detent Ball, Spring, Spacer and Plug (3) Spring (4) Interlock Pin (5) 4WD Indicator Switch (6) Shift Block (7) Spring Pin (8) Spring

(9) (10) (11) (12) (13) (14) (15) (16)

Shift Arm 2WD4WD Shift Rod Spring Pin and Bridge Select Rod Assembly Spring Pin HighLow Shift Rod Shift Arm Shift Block

TRANSFER CASE (STANDARD TYPE)

4D117

Disassembly
1. Remove detent ball, spring and plug. 2. Remove spring pin and bridge, use a spring pin remover to remove the spring pin from the bridge.

8. Remove 4WD indicator switch. 9. Remove interlock pin. 10. Remove spring, use a magnetic tool to remove the interlock pin from the transfer case.

262RS005 262RW011

3. Remove spring pin. 4. Remove spring. 5. Engage the 2WD4WD sleeve with front output gear. Remove the spring pin from the block. Remove the shift rod.

11. Remove select rod assembly. 12. Remove spring pin. 13. Remove highlow shift rod, use a spring pin remover to remove the shift arm spring pin from the shift arm and shift block. Remove the highlow shift rod.

262RS006 262RW022

6. Remove shift arm. 7. Remove shift block.

14. Remove shift arm. 15. Remove shift block. 16. Remove transfer case.

4D118 TRANSFER CASE (STANDARD TYPE)

Inspection and Repair

Refer to TRANSFER CASE ASSEMBLY in this section for inspection and repair.

10. Install the shift rod: 2WD4WD (2) with interlock pin pushed in.

Reassembly
1. Install transfer case. 2. Install shift block. 3. Install shift arm. 4. Install highlow shift rod. 5. Engage the HighLow sleeve with the 4H (1) side. 6. Install the spring pin to the shift block and shift arm.

262RW013 262RW012

7. Install select rod assembly. 8. Install spring. 9. Engage the HighLow sleeve with the 4H side and install the interlock pin (4) in the proper direction.

Legend (2) 2WD4WD (3) 4H Side (4) Interlock pin (5) 2WD (6) 4WD (7) Rod: 24 (8) Rod: HL (9) 4H (10) 4L (11) 42 (12) 44 11. Install 4WD indicator switch and tighten to the specified torque. Torque: 39 Nm (29 lb ft) 12. Install shift block. 13. Install shift arm. 14. Install 2WD4WD shift rod. 15. Install spring.

TRANSFER CASE (STANDARD TYPE)

16. Engage the 2WD4WD sleeve with the 4WD side and install the spring pin.

4D119

262RW022

17. Install spring pin and bridge. 18. Install detent ball, spring and plug and tighten the plug to the specified torque. Torque: 25 Nm (18 lb ft)

4D120 TRANSFER CASE (STANDARD TYPE)

Transfer Case Assembly

Disassembled View

226RW132

Legend (1) Transfer Case (with oil seal) (2) Bearing Snap Ring (3) Front Output Gear Assembly (4) Ball Bearing (5) Front Output Shaft (6) Stopper Plate (7) 2WD4WD Clutch Hub and Assembly (8) Block Ring (9) Outside Ring (10) Inside Ring (11) Front Output Gear (12) Needle Bearing (13) SubGear (antilash plate) (M/T) (14) Belleville Spring (M/T) (15) Spacer (M/T) (16) SubGear Snap Ring (M/T) (17) Bearing Collar (18) Ball Bearing (19) Bearing Snap Ring (20) Snap Ring (21) Ball Bearing

(22) (23) (24) (25) (26) (27) (28) (29) (30) (31) (32) (33) (34) (35) (36) (37) (38) (39) (40) (41) (42)

Counter Gear SubGear (antilash plate) Belleville Spring Spacer Ball Bearing Snap Ring Counter Gear Assembly Bearing Snap Ring Input Shaft Assembly Input Shaft Ball Bearing Snap Ring Plate Ball Bearing Collar Needle Bearing Transfer Input Gear HighLow Clutch Hub and Sleeve Assembly Lock Nut Ball Bearing Bearing Snap Ring

TRANSFER CASE (STANDARD TYPE)

4D121

Disassembly
1. Remove bearing snap ring, use a pair of snap ring pliers to remove the snap ring. 2. Remove ball bearing, use a bearing remover J37217 and puller J37487 to remove the ball bearing.

5. Remove the front companion flange. 6. Remove snap ring. 7. Remove the input shaft assembly from the transfer case.

265RW001

262RW016

3. Install the front companion flange temporarily. 4. Use the Companion flange holder J861411 and lock nut wrench J37219 to remove the lock nut.

8. Remove highlow clutch hub and sleeve. 9. Remove transfer input gear, use the universal puller to remove the highlow clutch hub and sleeve, and transfer input gear.

226RS070 226RW130

4D122 TRANSFER CASE (STANDARD TYPE)

10. Remove needle bearing. 11. Remove bearing collar. 17. Remove front output gear assembly, use a pair of snap ring pliers to expand the bearing snap ring and use a plastic hammer to tap the front output gear assembly free.

226RS071

12. Remove ball. 13. Remove plate. 14. Remove ball bearing, use a bench press and the ball bearing remover J2291201 to remove the ball bearing.

262RS009

18. Remove bearing snap ring. 19. Remove ball bearing. 20. Remove bearing collar. 21. Remove subgear snap ring. (M/T) 22. Remove spacer.(M/T) 23. Remove belleville spring.(M/T) 24. Remove subgear (antilash plate).(M/T) 25. Remove front output gear. 26. Remove needle bearing, use a bench press and the bearing remover J2291201 to remove the parts above.

265RS002

15. Remove input shaft. 16. Remove bearing snap ring.

262RS010

TRANSFER CASE (STANDARD TYPE)

27. Remove inside ring. 28. Remove outside ring. 29. Remove block ring. 30. Disassemble the 2WD4WD clutch hub and sleeve assembly. D Springs (1) D Inserts (2) D Clutch Hub (3) D Sleeve (4)

4D123

33. Remove front output shaft. 34. Remove bearing snap ring. 35. Remove the counter gear assembly from the transfer case. 36. Remove snap ring, use a pair of snap ring pliers to remove the snap ring. 37. Remove ball bearing, use a bench press and the bearing remover J2291201 to remove the ball bearing. 38. Remove snap ring, use a pair of snap ring pliers to remove the snap ring. 39. Remove ball bearing, use a bench press and the bearing remover J2291201 to remove the ball bearing.

226RW133

31. Remove stopper plate. NOTE: Do not reuse the stopper plate. 32. Remove ball bearing, use the ball bearing remover J2291201 to remove the ball bearing.
226RS073

40. Remove spacer. 41. Remove belleville spring. 42. Remove subgear (antilash plate). 43. Remove counter gear.

Inspection and Repair

1. Make the necessary repair or parts replacement if wear, damage or any other abnormal conditions are found during inspection. 2. Wash all parts thoroughly in clean solvent. Be sure all old lubricant, metallic particles, dirt, or foreign material are removed from the surfaces of every part. Apply compressed air to each oil feed port and channel in each case half to remove any obstructions or cleaning solvent residue.

Gears
262RS011

1. Inspect all the gear teeth for signs of excessive wear or damage and check all the gear splines for burrs, nicks, wear or damage. Remove the minor nicks or scratches on an oil stone. Replace any part exhibiting excessive wear or damage.

4D124 TRANSFER CASE (STANDARD TYPE)

Gear Inside Diameter 1. Use an inside dial indicator to measure the gear inside diameter. 2. If the measured value exceeds the specified limit, the gear must be replaced. Gear inside diameter Standard : 48.00048.013 mm (1.88981.8903 in) Limit : 48.10 mm (1.894 in)

Bearings
1. Inspect the condition of all the needles and ball bearings. Wash bearings thoroughly in a cleaning solvent. Apply compressed air to the bearings. NOTE: Do not allow the bearings to spin. Turn them slowly by hand. Spinning bearings may damage the rollers. 2. Lubricate the bearings with a light oil and check them for roughness by slowly turning the race by hand. Ball Bearing Play 1. Use a dial indicator to measure the ball bearing play. 2. If the measured value exceeds the specified limit, the ball bearing must be replaced. Limit : 0.2 mm (0.008 in)

226RS040

Clutch Hub Spline Play

1. Set a dial indicator to the clutch hub to measured. 2. Move the clutch hub as far as possible to both the right and the left. Note the dial indicator reading. 3. If the measured value exceeds the specified limit, the clutch hub must be replaced. Clutch hub spline play Standard : 00.1 mm (00.004 in) Limit : 0.2 mm (0.008 in)

226RS043

226RS042

TRANSFER CASE (STANDARD TYPE)

4D125

Block Ring and Insert Clearance

1. Use a vernier caliper to measure the clearance between the block ring and the insert. 2. If the measured value exceeds the specified limit, the block ring and the insert must be replaced. Block ring and insert clearance Standard : 3.463.74 mm (0.1360.147 in) Limit : 4.0 mm (0.158 in)

Clutch Hub and Insert Clearance

1. Use a thickness gauge to measure the clearance between the clutch hub and the insert. 2. If the measured value exceeds the specified limit, the clutch hub and the insert must be replaced. Clutch hub and insert clearance Standard : 0.010.19 mm (0.00040.0075 in) Limit : 0.3 mm (0.012 in)

226RS037

226RS038

2WD4WD Synchronizer (3Cone)

1. Use a thickness gauge to measure the clearance between the block ring and the dog teeth. 2. If the measured value exceeds the specified limit, the 2WD4WD synchronizer assembly must be replaced. Block ring and insert clearance Standard : 1.5 mm (0.059 in) Limit : 0.8 in (0.031 in)

Detent Springs
1. Inspect the springs for distortion, cracks or wear. Replace if these conditions are present.

226RW142

4D126 TRANSFER CASE (STANDARD TYPE)

Detent Spring Free Length 1. Use a vernier caliper to measure the detent spring free length. 2. If the measured value is less than the specified limit, the detent spring must be replaced. Detent spring free length Detent spring Standard Inner : 23.2 mm (0.913 in) Outer : 26.2 mm (1.06 in) Limit Inner : 22.6 mm (0.890 in) Outer : 26.2 mm (1.03 in) Interlock pin Standard : 1.59 mm (0.063 in) Limit : 1.53 mm (0.060 in)

220RS013

Shift Arm
1. Inspect the shift arms for wear, distortion or scoring. Replace if these conditions are present. Shift Arm Thickness 1. Use a micrometer to measure the shift arm thickness. 2. If the measured value is less than the specified limit, the shift arm must be replaced. Shift arm thickness Standard : 9.609.85 mm (0.3780.388 in) Limit : 9.0 mm (0.354 in)

220RW035

Detent Spring Tension 1. Use a spring tester to measure the detent spring tension. 2. If the measured value is less than the specified limit, the detent spring must be replaced. Detent spring set length Detent spring Compressed height : 19.7 mm (0.776 in) Standard Inner : 22.632.4 N (5.087.29 Ib)
230RS006

Outer : 91.2101 N (20.522.7 Ib) Interlock pin Compressed height : 11.5 mm (0.453 in) Standard : 9.8 N (2.2 lb)

TRANSFER CASE (STANDARD TYPE)

4D127

Reassembly
1. Install transfer case (with oil seal). Input shaft oil seal (1) replacement 1. Remove the oil seal from the transfer case. 2. Apply engine oil to the oil seal outer surfaces. 3. Apply recommended grease (BESCO L2) or equivalent to the oil seal lip. 4. Use the oil seal installer J38592 to install the oil seal to the transfer case.

4. Use the oil seal installer J38594 to install the oil seal to the transfer case.

220RW033

2. Install counter gear. 3. Install subgear and apply chassis grease (3) to the subgear and the counter gear thrust surfaces.

220RW032

Front output shaft oil seal (2) replacement 1. Remove the oil seal from the transfer case. 2. Apply engine oil to the oil seal outer surfaces. 3. Apply recommended grease (BESCO L2) or equivalent to the oil seal lip.

226RW134

4D128 TRANSFER CASE (STANDARD TYPE)

4. Install belleville spring. 5. Install spacer. 6. Install ball bearing. 7. Select a snap ring that will allow the minimum axial play. Clearance : 00.1 mm (00.004 in) Snap ring availability: Thickness 1.50 mm (0.059 in) 1.55 mm (0.061 in) 1.60 mm (0.063 in) Colorcoding White Yellow Blue SubGear (antilash plate) Preload 1. Hook a length of piano wire (4) over one of the subgear (5) teeth. 2. Attach the other end of the piano wire (4) to a spring balancer. 3. Measure the subgear preload. Preload : 5998 N (1322 lb)

8. Use a pair of snap ring pliers to install the snap ring to the counter gear.

226RS075

9. Install ball bearing. 10. Install snap ring. 11. Install the counter gear assembly to the transfer case. 12. Install bearing snap ring, use a pair of snap ring pliers to install the snap ring to the transfer case. NOTE: The snap ring must be fully inserted into the transfer case snap ring groove.
226RS170

13. Install front output shaft. 14. Install ball bearing, use a bench press to install the ball bearing to the front output shaft.

226RS021

262RS012

TRANSFER CASE (STANDARD TYPE)

15. Install stopper plate. 16. Assemble the clutch sleeve and hub assembly.

4D129

18. Install a new stopper plate and the clutch sleeve and hub assembly to the front output shaft.

226RW140

226RW135

17. Engage the springs in the same insert with the open ends away from each other.

Legend (6) Front Output Gear 19. The clutch hub face (with the heavy boss) must be facing the front output gear side. 20. Use a bench press to slowly force the clutch sleeve and hub assembly together with the stopper plate into place. 21. Align the inserts with the block ring insert grooves. Install the block ring to the clutch sleeve and hub assembly. 22. Install outside ring. 23. Install the outside ring, inside ring and needle bearing to the front output gear and bearing collar. NOTE: Coat all parts with transmission oil before installing them.

226RW141

226RW139

24. Install needle bearing. 25. Install front output gear. 26. Install subgear (antilash plate). (M/T)

4D130 TRANSFER CASE (STANDARD TYPE)

27. Install belleville spring. (M/T) 28. Install spacer and apply engine oil to the thrust surfaces of the subgear, the belleville spring, and the spacer. (M/T) 32. Install bearing snap ring and select a snap ring that will allow the minimum axial play. Clearance : 00.1 mm (00.004 in) Snap ring availability: Snap ring thickness 1.55 mm (0.061 in) 1.60 mm (0.063 in) 1.65 mm (0.065 in) 1.70 mm (0.067 in) 1.75 mm (0.069 in) 1.80 mm (0.071 in) 1.85 mm (0.073 in) 1.90 mm (0.075 in) Color coding White Yellow Blue Pink Green Brown Red Orange

262RW060

29. Install subgear snap ring. (M/T) 30. Install bearing collar, use a bench press to install the needle bearing collar together with the front output gear.

262RS015

262RS014

31. Install ball bearing.

226RS021

TRANSFER CASE (STANDARD TYPE)

33. Use a pair of snap ring pliers to install the snap ring to the output shaft. Sub gear (anti lash plate) preload (M/T) 1. Hook a length of piano wire (4) over one of the subgear (5) teeth. 2. Attach the other end of the piano wire to (4) a spring balancer. 3. Measure the subgear preload. Preload: 5998 N (1322 lb) (M/T)

4D131

38. Install plate. 39. Install ball. 40. Install bearing collar. 41. Install needle bearing. 42. Install transfer input gear. 43. Install highlow clutch hub and sleeve and the clutch hub face (with the heavy boss) must be facing the transfer input gear side (7).

226RW136

226RS075

34. Install front output gear assembly. 35. Install bearing snap ring, use a pair of snap ring pliers to install the snap ring to the transfer case. NOTE: The snap ring must be fully inserted into the transfer case snap ring groove. 36. Input shaft. 37. Install ball bearing, use a bench press to install the ball bearing to the input shaft.

44. Install input shaft assembly. 45. Install the snap ring to the input shaft. 46. Install the input shaft assembly to the transfer case. 47. Install the snap ring to the transfer case. NOTE: The snap ring must be fully inserted into the transfer case snap ring groove. 48. Install the front companion flange temporarily and use the flange holder J861411 and lock nut wrench J37219 to install the lock nut. Torque: 137 Nm (101 lb ft)

226RW137 265RS003

4D132 TRANSFER CASE (STANDARD TYPE)

49. Use the punch to stake the lock nut at one spot. 50. Install ball bearing, use a suitable drift and hammer to install the ball bearing.

226RS079

51. Install bearing snap ring.

TRANSFER CASE (STANDARD TYPE)

4D133

Main Data and Specifications

General Specifications
Type Control method Synchronized type gears shifting between the 2 and 4 wheel drive mode. Constant mesh type gears shifting between low and high. Remote control with the gear shift lever on the floor for gear shifting between low and high . Electric control with the button switch on the instrument panel for gear shifting between the 2 and 4 wheel drive mode. High; 1.000 Low; 2.050 1.45 lit. (1.53 U.S. quart) Besco Transaxle Oil Refer to chart in Section 0

Gear ratio Oil capacity Type of lubricant

Torque Specifications

E07RW008

4D134 TRANSFER CASE (STANDARD TYPE)

E07RW009

TRANSFER CASE (STANDARD TYPE)

4D135

E07RW010

4D136 TRANSFER CASE (STANDARD TYPE)

Special Tools
ILLUSTRATION PART NO. PART NAME ILLUSTRATION PART NO. PART NAME

J2291201 Bearing remover/installer

J39208 Rear oil seal installer

J38592 Transfer case oil seal installer

J37486A Bearing installer adapter

J37219 Mainshaft nut wrench

J861411 Flange holder

J37223 Rear output shaft and bearing installer

J37217 Mainshaft end bearing remover

J39209 Punch, end nut

J37487 Puller

J38594 Front output shaft oil seal installer

J8092 Driver handle

SECTION
TRANSFER CASE (TOD)
TROOPER

4D21

DRIVELINE/AXLE
TRANSFER CASE (TOD)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . Transfer Case Assembly . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Rear Oil Seal . . . . . . . . . . . . . . . . . . . Transfer Rear Oil Seal and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . TOD ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Cover Assembly . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Case Assembly Clutch Pack and Clutch Cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . 4D21 4D22 4D22 4D23 4D25 4D25 4D25 4D25 4D27 4D27 4D27 4D28 4D28 4D29 4D29 4D29 4D210 4D212 4D212 4D212 4D214 4D216 4D216 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Sprocket and Mechanical Lock . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Output Shafts and Shift Control Shaft . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Output Shafts and Shift Control Shaft . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Sprocket and Mechanical Lock . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Pack and Clutch Cam . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D216 4D218 4D218 4D218 4D220 4D220 4D221 4D223 4D223 4D223 4D226 4D230 4D230 4D230 4D234 4D234 4D235 4D237 4D237 4D237 4D239 4D239 4D239 4D241 4D243

Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.

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

4D22 TRANSFER CASE (TOD)

Transfer Case Assembly

Removal

F07RW083

Legend (1) Transfer Protector (2) Rear Propeller Shaft (3) Front Propeller Shaft (4) Front Console (5) Selector Lever Assembly (6) Transfer Control Lever

(7) (8) (9) (10) (11) (12) (13)

Breather Hose Exhaust Pipe Seat Belt Tension Rod Speed Sensor Harness Connector Transfer Harness Connector Transfer Case Bolt Transfer Case

1. Disconnect the ground cable (-). 2. Remove the transfer protector. 3. Remove the rear propeller shaft from the transfer case.

4. Remove the front propeller shaft from the transfer case. 5. Remove the shift control rod from the selector lever assembly.

TRANSFER CASE (TOD)

6. Disconnect the wiring harness, transfer control lever knob, and shift lock cable and then remove the front console.

4D23

Installation
To install, follow the removed steps in the reverse order, noting the following points. 1. Apply a thin coat of grease (Besco L2) or equivalent to the input shaft spline.

256RW028

7. Remove the selector lever assembly and put it aside. 8. Remove the transfer control lever. 9. Disconnect the breather hose. 10. Remove the left exhaust pipe fixing bolts and nuts, and put the exhaust pipe aside. 11. Remove the left seat belt tension rod and put the rear proper shaft aside.

261RW024

2. Mount the transfer case.

260RW006

12. Disconnect the transfer harness connector from the top of the transfer case. 13. Disconnect the speed sensor harness connector. 14. Remove the fuel pipe clip fixing bolt on the transfer case. 15. Support the transfer case with a jack. 16. Remove the seven bolts from the transfer case. 17. Remove the transfer case assembly.

4D24 TRANSFER CASE (TOD)

3. Tighten the transfer case bolts (see the figure below). Torque : 46 Nm (34 lb ft)

261RW0041

4. Tighten propeller shaft bolt. Torque : 63 Nm (46 lb ft)

TRANSFER CASE (TOD)

4D25

Transfer Rear Oil Seal

Transfer Rear Oil Seal and Associated Parts

261RW005

Legend (1) Oil Seal (2) End Nut and Rear Companion Flange

Removal
1. Remove the rear propeller shaft from the transfer case. 2. Using the flange holder J-8614-11, remove the end nut. 3. Using the universal puller, remove the rear companion flange and O-ring. 4. Remove the oil seal from the transfer rear case.

Installation
1. Apply engine oil to the circumference of the oil seal. Fill the oil seal lip with grease (Besco L2).

261RW006

Legend (1) Inside (2) Outside

4D26 TRANSFER CASE (TOD)

2. Using the oil seal installer J-42804, install the oil seal. NOTE: When installing the oil seal, pay attention to the direction. 5. Stake the end nut at one place so that there is no gap between a flat portion on the shaft and the nut staked portion. NOTE: Check the staked end nut is free from cracks.

261RW035

Rear Output Shaft Oil Seal

Distance between the transfer case and oil seal. NOTE: When installing the oil seal to the specified dimension, be careful not to damage it. Distance : 9.8510.35 mm (0.390.41 in)

266RY00003

260R200005

6. Install the rear propeller shaft to the transfer case and tighten to the specified torque. Torque : 63 Nm 46 (lb ft)
A04RW004

3. Mount the rear companion flange, O-ring , washer, and nuts to the transfer in this order. 4. Using the flange holder J-8614-11, install a new end nut. Torque : 167 Nm (123 lb ft)

TRANSFER CASE (TOD)

4D27

TOD ECU
Removal
1. Disconnect the ground cable (-). 2. Move the right-hand seat forward and remove the second seat foot rest (1). 3. Disconnect the connector from the ECU (2). 4. Remove the set bolts and detach the ECU (2) from the bracket.

F07RW021

Installation
1. Perform the removal steps in reverse order.

4D28 TRANSFER CASE (TOD)

Unit Repair
Inspection
Before disassembling and after assembling, check the following items on the transfer connector terminals. No. 1 2 3 4 5 6 7 8 9 10 11 12 NAME Ref . (Rr . ) Ref . (Frt . ) SW GND 4H SW (+) Rer . (+) Frt . (+) POWER GND EMC (+) COM () (Rr .) COM () (Frt .) NC 4L SW (+) CONTENTS Rear speed sensor reference output Front speed sensor reference output SW GND 4H SW plus terminal Rear speed sensor plus Front speed sensor plus Power GND Electromagnetic solenoid Rear speed sensor GND Front speed sensor GND Not used 4L SW plus terminal COLOR LG LG B R B/LG LB B Y GR/ R GR/ R Y

4H and 4L switch
Check whether the 4H switch (terminals 4 and 7) and 4L switch (terminals 12 and 3 ) work as specified in the table below. If yes, the continuity is established on these switches. If not, check the switches, shift rails, transfer case, and rear cover, and replace the failed parts. Position 4H SW 4L SW High OFF OFF Neutral ON ON 4L OFF ON

Power GND
Check that there is a continuity between the power GND pin (terminal 7) and transfer case. If not, replace the grounding wire.

Resistance of electromagnetic coil

Check the resistance between electromagnetic coil (terminal 8) and power GND (terminal 7). If not, replace the electromagnetic coil. Standard : 1.4 2.0W Allowable : 1.0 5.0W

810RW002

TRANSFER CASE (TOD)

4D29

Transfer Case
Disassembled View

266RW004

Legend (1) Front Companion Flange (2) 4H and 4L Switch, Ground Cable, and Center Connector (3) Offset Lever

(4) (5) (6) (7)

Spring Pin Transfer Case Assembly Transfer Cover Assembly Rear Companion Flange

Disassembly
1. Remove the drain plug from the transfer case and drain the oil. 2. Disconnect the 4H and 4L switch and ground cable. 3. Remove the clip fixing the harness. 4. Remove the flange nut, using the flange holder J-8614-11, and remove the front companion flange. 5. Remove the flange nut, using the flange holder J-8614-11, and remove the rear companion flange.

266RW005

4D210 TRANSFER CASE (TOD)

6. Remove the offset lever set bolt on the right side. 8. Remove the offset lever.

261RW015

261RW017

7. Remove the offset lever lock spring pin. NOTE: When removing the spring pin, note the recess position of the pin.

9. Remove the sixteen bolts and detach the transfer cover assembly from the transfer case assembly. NOTE: When removing the transfer cover assembly, be careful not to damage the oil seal.

Reassembly
1. Apply liquid gasket (Loctite 598 or equivalent) uniformly to the mating face that contacts the transfer case.

261RW016

261RW023

2. Tighten the sixteen bolts with the specified torque. Torque : 31 Nm (23 lb ft) 3. Wind the sealing tape around the drain plug thread and tighten the plug with the specified torque. Torque : 25 Nm (18 lb ft)

TRANSFER CASE (TOD) 4D211

4. Mount the offset lever to the transfer shift and install the spring pin.

266R200005

261RW016

9. Fix the harness with the clip. 10. Tighten the 4L and 4H switch to the specified torque. Torque : 24 Nm (17 lb ft) 11. Fill the transfer case with ATF II or III (1.9 liters). 12. Wind the sealing tape around the filler plug thread and tighten the plug to the specified torque. Torque : 25 Nm (18 lb ft)

5. Attach the O-ring and washer to the companion flange. NOTE: Securely push the O-ring to the hollow of the companion flange, and then attach the washer. 6. Use the flange holder J-8614-11 to tighten the flange nut. 7. Tighten the flange nut with the specified torque. Torque : 167 Nm (123 lb ft) 8. Securely stake the flange nut at one place so that there is no gap between a flat poriton on the shaft and the nut staked portion. NOTE: Check the staked flange nut is free from cracks.

266RY00003

4D212 TRANSFER CASE (TOD)

Transfer Cover Assembly

Disassembled View

261RW007

Legend (1) Coil Assembly (2) Snap Ring (3) Ball Bearing

(4) (5) (6) (7)

Speed Gear and Tone Wheel Ball Bearing Transfer Cover Assembly Front and Rear Speed Sensors

Disassembly
1. Using snap ring pliers, remove the snap ring.

261RW047

TRANSFER CASE (TOD) 4D213

2. Strike the speed gear and tone wheel with a rod or other appropriate tool from the outside of the transfer cover assembly, and remove the ball bearing and speed gear and tone wheel. NOTE: Be careful not to damage the speed gear teeth. 4. Using a terminal pull-out tool or an equivalent tool, push down the lock to unlatch the terminal for the coil assembly, and pull the terminal out. NOTE: Pay attention not to damage other terminals.

261RW032 266RW018

3. Remove the stopper plate on the back with a precision screwdriver or other appropriate tool starting from the small lock of the plate. NOTE: Be careful not to damage the stopper plate during the work.

5. Remove the fixing nuts of the coil assembly from the outside of the transfer cover assembly. Remove the coil assembly from the transfer cover.

261RW030

261RW042

4D214 TRANSFER CASE (TOD)

6. Using the bearing remover J-42805 and slide hammer J-2619-01, remove the ball bearing for the front output shaft. 3. Using the oil seal installer J-42804, install the oil seal to the transfer cover assembly.

261RW035 901RW087

7. Remove the bolts and front and rear speed sensors. NOTE: Be careful not to damage the speed sensors during the work.

Rear Output Shaft Oil Seal

Distance between the transfer case end and oil seal. NOTE: When installing the oil seal to the specified dimension, be careful not to damage it. Dimension : 9.8510.35 mm (0.390.41 in)

261RW033

Reassembly
1. Remove the oil seal from the transfer cover assembly. 2. Apply oil to the circumference of the new oil seal and fill the lip with grease (Besco L2 or equivalent).

A04RW004

4. Apply a thin coat of grease to the seal ring of each front and rear speed sensor, and mount the sensor carefully. 5. Tighten the bolt to the specified torque. Torque : 5 Nm (43 lb in) NOTE: Pay attention not to mount the front (or rear) sensor to the rear (or front) sensor position. 6. Install the ball bearing (1) for the front output shaft as flat as shown in the figure. 7. Mount the coil assembly and tighten the set nuts to the specified torque. Torque : 10 Nm (87 lb in)

TRANSFER CASE (TOD) 4D215

8. Connect the terminal in the central connector. NOTE: Be careful not to damage other terminals. 9. Install speed gear and tone wheel. 10. Install the ball bearing (2) as flat as shown in the figure.

261RW0091

11. Using snap ring pliers, install the snap ring to the transfer cover assembly. NOTE: Securely install the snap ring to the groove of the transfer cover assembly.

4D216 TRANSFER CASE (TOD)

Transfer Case Assembly Clutch Pack and Clutch Cam

Disassembled View

266RW006

Legend (1) Clutch Pack Assembly (2) Insulator Washer (3) Armature Plate (4) Snap Ring

(5) (6) (7) (8) (9)

Wave Spring Cam Pulley Cam Ball Cam and Coil Housing Thrust Bearing

Disassembly
1. Remove the thrust bearing. 2. Remove the cam and coil housing. NOTE: When the cam and coil housing is removed, the cam balls may be detached together with the housing. Be careful not to lose the ball. 3. Remove the cam ball.

266RW013

TRANSFER CASE (TOD) 4D217

4. Remove the cam pulley. 5. Remove the wave spring. 6. Using snap ring pliers, remove the snap ring. NOTE: Be careful not to damage the snap ring.

266RW009

7. Remove the armature plate. 8. Remove the insulator washer. 9. Remove the clutch pack assembly as a package.

266RW017

4D218 TRANSFER CASE (TOD)

Sprocket and Mechanical Lock

Disassembled View

266RW008

Legend (1) Strainer (2) Hose (3) Oil Pump Assembly (4) Thrust Washer (5) Mechanical Lock Hub (6) Lock-up Sleeve

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

Lock-up Fork Chain Lower Driven Sprocket Front Tone Wheel Drive Sprocket Sprocket Spacer

Disassembly
1. Remove the sprocket spacer. 2. Remove the front tone wheel.

TRANSFER CASE (TOD) 4D219

3. Remove the drive sprocket, lower driven sprocket, and chain together from the front and rear output shafts.

266RW010

4. Remove the mechanical lock hub. 5. Remove the lock-up fork. 6. Remove the spring retainers from the connection between the rail shaft and lock-up fork. 7. Remove the lock-up sleeve.

261RW018

8. Remove the thrust washer. 9. Remove the magnet from the strainer set position together with the oil pump assembly. 10. Remove the strainer from the oil pump assembly. 11. Remove the hose from the oil pump assembly.

4D220 TRANSFER CASE (TOD)

Output Shafts and Shift Control Shaft

Disassembled View

261RW0101

Legend (1) Transfer Case Assembly (2) Detent Spring (3) Front Output Shaft (4) Reduction Hub (5) Output Shaft (6) Reduction Fork Assembly (7) Lock-up shaft (8) Spring Pin (9) Reduction Fork

(10) (11) (12) (13) (14) (15) (16) (17) (18) (19)

Cam Assembly Snap Ring Washer Cam Cam Pilot Block Shifter Shaft Assembly Shifter Lever Shaft Snap Ring Reduction Lever Assembly Snap Ring

TRANSFER CASE (TOD) 4D221

Disassembly
1. Remove the output shaft.

6. Remove the spring pin that fixes the reduction fork to the lock-up shaft.

261RW020 266RW011

2. Remove the detent spring. 3. Remove the cam pilot block bolts. 4. Remove the shifter shaft assembly and cam assembly. 5. Remove the reduction fork assembly together with the reduction hub.

7. Remove the reduction fork. 8. Remove the lock-up shaft. 9. Using snap ring pliers, remove the snap ring from the cam pilot block.

261RW029

261RW019

10. Remove the washer. 11. Remove the cam. 12. Remove the cam pilot block.

4D222 TRANSFER CASE (TOD)

13. Using snap ring pliers, remove the snap ring from the shifter shaft assembly.

261RW021

14. Remove the reduction lever assembly. 15. Remove the snap ring. 16. Remove the shifter lever shaft. 17. Remove the front output shaft.

266RW012

18. Remove the transfer case assembly.

TRANSFER CASE (TOD) 4D223

Transfer Case
Disassembled View

265RW015

Legend (1) Transfer Case (2) Ball Bearing (3) Ring Gear (4) Snap Ring (5) Input Shaft and Carrier Assembly (6) Snap Ring

(7) (8) (9) (10) (11) (12) (13)

Ball Bearing Snap Ring Thrust Plate Carrier Assembly Snap Ring Circular Hub Input Shaft

4D224 TRANSFER CASE (TOD)

Disassembly
1. Remove ball bearing (for front output shaft). 2. Expand the snap ring through the opening in the planetary gear assembly.

4. Remove the snap ring from the transfer case.

261RW036

5. Using snap ring pliers, remove the snap ring before the ball bearing.
265RY00002

3. While expanding the snap ring, remove the input shaft, ball bearing, carrier assembly, and thrust plate from the transfer case.

265RW009

261RW037

TRANSFER CASE (TOD) 4D225

6. Using the bearing remover J-22912-01, remove the ball bearing from the input shaft. 10. Remove the circular hub. 11. Remove the snap ring before the ring gear.

265RW004

261RW025

7. Remove the thrust plate. 8. Remove the carrier assembly. 9. Remove the snap ring from the carrier assembly.

12. Using the special tool J-42806, remove the ring gear. NOTE: Removing the ring gear needs a high-load press. This means the transfer case may be damaged. To remove and replace the ring gear, it is recommended that the transfer case assembly should be replaced.

265RW006

261RW011

4D226 TRANSFER CASE (TOD)

Thickness of Reduction Hub D Measure the thickness with a micrometer. D If the measurement exceeds the limit, replace the reduction hub. Standard : 3.05-3.30 mm (0.120-0.130 in) Allowable limit : 2.5 mm (0.098 in)

265RW007

Inspection and Repair

When wear, damage, or any other defects are observed during the inspection, the part or parts must be repaired or replaced. Wash all the parts with clean solvent, and check that old oil, metallic particles, dirt, or foreign materials are completely removed. Blow the air into oil holes and grooves to remove foreign materials or residual solvent.

265RW005

Lock-up Sleeve Mount the lock-up hub, drive sprocket assembly, and lock-up sleeve to the output shaft. If the lock-up sleeve does not move smoothly, replace the sleeve. NOTE: Apply ATF to the area engaging the gear. Thickness of Lock-up Sleeve D If the measurement exceeds the limit, replace the lock-up sleeve. Standard : 7.16-7.32 mm (0.282-0.288 in) Allowable limit : 7.9 mm (0.311 in)

Chain
D Check whether the face that contacts the sprocket is free from excessive wear or damage. If defects are observed, replace the part. D If the chain interference mark is found on the inside wall of the transfer cover or the chain is so slack that a skipped engagement occurs between the chain and sprocket, replace the chain.

Sprocket
D Check whether the sprocket tooth surface is excessively worn or damaged, and there is evidence of burrs, chipping, wear, or damage on the gear spline. Remove minor flaws or scratches with oil stone. If excessive wear or damage is observed, replace the part. D If excessive wear or damage is observed on the sprocket inside sliding surface, replace the part.

Gear
Check whether the gear tooth surface is excessively worn or damaged, and there is evidence of burrs, chipping, wear, or damage on the gear spline. Remove minor flaws or scratches with oil stone. If excessive wear or damage is observed, replace the part.

266RW014

TRANSFER CASE (TOD) 4D227

Reduction Fork Check the reduction fork and shaft for wear, distortion, and scratches. If defects are observed, replace the parts. Thickness of Reduction Fork D If the measurement exceeds the limit, replace the reduction fork. Standard : 3.41-3.79 mm (0.134-0.149 in) Allowable limit : 4.4 mm (0.173 in)

Bearing
Check the profile of the needle, roller, ball, and thrust bearings. Wash the bearings with clean solvent completely, and dry with air. NOTE: If the bearing is rotated excessively, the rollers may be damaged. So, rotate the bearing slowly with your hand. Apply grease to the bearing, and check the smoothness of the bearing while slowly rotating the race with your hand. Allowable limit : 0.23 mm (0.009 in)

261RW026

Lock-up Fork D Check the lock-up fork and shaft for wear, distortion, and scratches. If defects are observed, replace the parts. Thickness Lock-up Fork If the measurement exceeds the limit, replace the lock-up fork. Standard : 6.99-7.09 mm (0.275-0.279 in) Allowable limit : 6.3 mm (0.248 in)

226RW143

Lock-up Fork Spring Check the lock-up fork spring for distortion, cracking, and wear. If defects are observed, replace the part. Free Length of the Lock-up Fork Spring D If the measurement exceeds the limit, replace the spring. Standard : 60.96 mm (2.40 in) Allowable limit : 55.0 mm (2.17 in)

220RW045 261RW027

4D228 TRANSFER CASE (TOD)

Tension of Lock-up Fork Spring D If the measurement exceeds the limit, replace the spring. (When compressed to 41.4 mm) Standard : 27.1-33.8 N {2.76-3.45 kg} Allowable limit : 24.5 N {2.5 kg}

Multi Plate Disk Clutch

D If the burned, mirror-surfaced clutch facing, or scraping is observed on the clutch plates, clutch housing, armature plate, and insulator washer, replace the part or parts.

266RW003 014RW048

Tension of Detent Spring Assembly D If the measurement exceeds the limit, replace the spring. N {kg} (When compressed by 3 mm from the free length) Standard : 139 N -203 {14.2-20.7 kg} Allowable limit : 130 N {13.3 kg}

Coil Assembly
D Check the resistance of the coil with a tester. If defects are observed, replace the assembly. * (ordinary temperature) Standard : 1.42.0 W Allowable limit : 1.05.0 W

261RW041

261RW031

Oil Pump
D Remove foreign materials from the strainer. If the strainer is damaged, replace it. D If the area into which the shaft is inserted is excessively worn or damaged, replace the pump.

TRANSFER CASE (TOD) 4D229

Cam Pulley, Cam Ball, and Cam&Coil Housing

D Check the cam balls and cam for excessive wear or damage. If defective, replace the parts.

261RW049

Switch Stroke
266RW016

4H Switch Signal B to Switch Body

4L Switch Signal A to C

The Parts 4H and 4L Switch

D Check the continuity of 4H and 4L switch. 1 2 3

The correspo nding position of transfer lever High 4L Neutral

Open Open Close

Open Close Close

261RW003

4D230 TRANSFER CASE (TOD)

Transfer Case
Disassembled View

265RW015

Legend (1) Transfer Case (2) Ball Bearing (3) Ring Gear (4) Snap Ring (5) Input Shaft and Carrier Assembly (6) Snap Ring

(7) (8) (9) (10) (11) (12) (13)

Ball Bearing Snap Ring Thrust Plate Carrier Assembly Snap Ring Circular Hub Input Shaft

Reassembly
1. Remove the oil seal from the transfer case. 2. Apply engine oil to the circumference of the new oil seal and fill the lip with grease (Besco L2 or equivalent).

TRANSFER CASE (TOD) 4D231

3. Using the front output shaft oil seal installer J-42807, install the oil seal to the transfer case. 4. Using the input shaft (main) oil seal installer J-42808, install the oil seal to the transfer case.

261RW014

261RW012

Front Output Shaft Oil Seal

Distance between the transfer case end and oil seal. NOTE: When installing the oil seal to the specified dimension, be careful not to damage it. Distance : 0.931.43 mm (0.0370.056 in)

Input Shaft Oil Seal

Distance between the transfer case end and oil seal. NOTE: When installing the oil seal to the specified dimension, be careful not to damage it. Distance : 3.253.75 mm (0.130.15 in)

A04RW003 A04RW002

4D232 TRANSFER CASE (TOD)

5. Using the special tool J-42809, press-fit the ring gear. Pay attention to the following points. D Identify the correct direction of gear. D Do not damage the gear. D Do not press-fit the ring gear slantingly. D Press-fit the ring gear to the innermost. D Remove burrs generated by press-fitting. D If the transfer case has serrations, match them with those of the gear and press-fit the gear. 6. Install the snap ring. 7. Install the circular hub. 8. Install the snap ring to the carrier. 9. Mount the carrier assembly to the input shaft. 10. Check the direction of thrust plate and mount it to the input shaft.

265RW008

11. Mount the ball bearing to the input shaft so that the snap ring will be installed to the input shaft.

261RW013

265RW003

12. Install the snap ring to the input shaft. 13. Install the snap ring to the transfer case.
261RW034

TRANSFER CASE (TOD) 4D233

14. Using the snap ring pliers, expand the snap ring through the opening between the ring gear and carrier assembly and securely install the input shaft and carrier assembly.

261RW038

15. Install the ball bearing (for front output shaft)

4D234 TRANSFER CASE (TOD)

Output Shafts and Shift Control Shaft

Disassembled View

261RW0101

Legend (1) Transfer Case Assembly (2) Detent Spring (3) Front Output Shaft (4) Reduction Hub (5) Output Shaft (6) Reduction Fork Assembly (7) Lock-up Shaft (8) Spring Pin (9) Reduction Fork

(10) (11) (12) (13) (14) (15) (16) (17) (18) (19)

Cam Assembly Snap Ring Washer Cam Cam Pilot Block Shifter Shaft Assembly Shifter Lever Shaft Snap Ring Reduction Lever Assembly Snap Ring

TRANSFER CASE (TOD) 4D235

Reassembly
1. Apply ATF to the inside of the ball bearing for the front output shaft. 2. Mount the front output shaft to the transfer case.

6. Mount the cam to the cam pilot block. 7. Attach the washer to the cam pilot block and fix the washer with the snap ring.

261RW029

266RW012

3. Mount the shifter lever shaft in the transfer case assembly. 4. Install the snap ring to the shifter lever shaft. 5. Mount the reduction lever assembly to the shifter lever shaft and fix the assembly with the snap ring.

8. Mount the reduction fork to the lock-up shaft. 9. Install the spring pin to the reduction fork and lock-up shaft.

261RW020

261RW021

4D236 TRANSFER CASE (TOD)

10. Install the reduction fork assembly together with the reduction hub to the transfer case assembly.

261RW019

11. Install the cam assembly and tighten the cam pilot block set bolts to the specified torque. Torque : 12 Nm (104 lb in) 12. Tighten the detent spring to the specified torque. Torque : 24 Nm (17 lb ft)

261RW022

13. Apply ATF to the needle bearing inside the output shaft assembly. 14. Install the output shaft to the transfer case assembly.

TRANSFER CASE (TOD) 4D237

Sprocket and Mechanical Lock

Disassembled View

266RW008

Legend (1) Strainer (2) Hose (3) Oil Pump Assembly (4) Thrust Washer (5) Mechanical Lock Hub (6) Lock-up Sleeve

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

Lock-up Fork Chain Lower Driven Sprocket Front Tone Wheel Drive Sprocket Sprocket Spacer

Reassembly
1. Connect the hose and strainer to the oil pump assembly. 2. Install the oil pump assembly to the output shaft and set the magnet to the strainer position. 3. Install thrust washer. 4. Install the spring to the lock-up fork. 5. Mount the lock-up sleeve together with the lockup fork to the output shaft and lock-up shaft.

4D238 TRANSFER CASE (TOD)

6. Install the spring retainer to the lock-up fork.

261RW018

7. Install mechanical lock hub. 8. Apply ATF to the chain. 9. Engage the chain to both sprockets. 10. Install the chain and sprocket assembly to both the output shafts.

266RW010

11. Install the front tone wheel and sprocket spacer.

TRANSFER CASE (TOD) 4D239

Clutch Pack and Clutch Cam

Disassembled View

266RW006

Legend (1) Clutch Pack Assembly (2) Insulator Washer (3) Armature Plate (4) Snap Ring

(5) (6) (7) (8) (9)

Wave Spring Cam Pulley Cam Ball Cam and Coil Housing Thrust Bearing

Reassembly
1. Mount the clutch pack assembly to which the multi plate disk clutch is already installed to the output shaft. NOTE: Mount the clutch pack assembly while adjusting the phase of both the clutch housing and drive sprocket. 2. Install the insulator washer. 3. Install the armature plate. 4. Using snap ring pliers, attach the snap ring.

266RW009

4D240 TRANSFER CASE (TOD)

5. Install the wave spring. 6. Install the cam pulley. 7. Place a ball on each groove of the cam pulley.

266RW013

8. Install the cam and coil housing. 9. Install the thrust bearing.

TRANSFER CASE (TOD) 4D241

Main Data and Specifications

Leading Particulars
Type 2H TOD 4L Control system Gear ratio Oil quantity, Lit Oil H L Transfer case with low range reduction mechanisn Rear wheel drive Electronically controlled torque split four wheel drive Low-speed mechanical lock-up four wheel drive Floor direct control 1.000 2.480 1.9 ATF DEXRON-IIE or ATF DEXRON-III

Torque Specifications

E07RW011

4D242 TRANSFER CASE (TOD)

E04RW013

TRANSFER CASE (TOD) 4D243

Special Tools
ILLUSTRATION TOOL NO. TOOL NAME ILLUSTRATION TOOL NO. TOOL NAME

J861411 Flange Holder

J42806 Ring Gear Replacer

J42804 Rear Oil Seal Installer

J42807 Front Out Oil Seal Installer

J39209 Punch

J42808 Input Shaft Oil Seal Installer

J42805 Bearing Remover

J42809 Ring Gear Installer

J261901 Slide Hammer

J2291201 Bearing Remover

SECTION
BRAKE CONTROL SYSTEM
TROOPER

5A1

BRAKES
CONTENTS
Brake Control System . . . . . . . . . . . . . . . . . . . . Antilock Brake System . . . . . . . . . . . . . . . . . . 5A1 5B1 Power-Assisted Brake System . . . . . . . . . . . . Parking Brakes . . . . . . . . . . . . . . . . . . . . . . . . . 5C1 5D1

BRAKE CONTROL SYSTEM

CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . System Components . . . . . . . . . . . . . . . . . . . Electronic Hydraulic Control Unit (EHCU) . ABS Warning Light . . . . . . . . . . . . . . . . . . . . Wheel Speed Sensor . . . . . . . . . . . . . . . . . . G-Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Normal and Anti-lock Braking . . . . . . . . . . . Brake Pedal Travel . . . . . . . . . . . . . . . . . . . . Acronyms and Abbreviations . . . . . . . . . . . . General Diagnosis . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . ABS Service Precautions . . . . . . . . . . . . . . . Computer System Service Precautions . . . General Service Precautions . . . . . . . . . . . . Note on Intermittents . . . . . . . . . . . . . . . . . . . Test Driving ABS Complaint Vehicles . . . . . ABS Warning Light . . . . . . . . . . . . . . . . . . . Normal Operation . . . . . . . . . . . . . . . . . . . . . Basic Diagnostic Flow Chart . . . . . . . . . . . . Basic Inspection Procedure . . . . . . . . . . . . . Tech 2 Scan Tool . . . . . . . . . . . . . . . . . . . . . . Getting Started . . . . . . . . . . . . . . . . . . . . . . . . Operating Procedure . . . . . . . . . . . . . . . . . . . Data List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EHCU Connector Pin-out Checks . . . . . . . . . Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . Connector List . . . . . . . . . . . . . . . . . . . . . . . . Part Location . . . . . . . . . . . . . . . . . . . . . . . . . Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . Chart A1 ABS Works Frequently But Vehicle Does Not Decelerate . . . . . . . . . . . Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2) . . . . . . . . . . . . . . . . . . . . . . . . Chart A-2 Uneven Braking Occurs While ABS Works . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart A-3, TA-3 The Wheels Are Locked . Chart A-4 Brake Pedal Feed Is Abnormal . Chart A-5,TA-5 Braking Sound (From EHCU) Is Heard While Not Braking Diagnostic Trouble Codes . . . . . . . . . . . . . . . . Diagnosis By ABS Warning Light Illumination Pattern . . . . . . . . . . . . . . . . . . . . . 5A2 5A3 5A3 5A3 5A4 5A4 5A4 5A4 5A4 5A4 5A5 5A5 5A5 5A5 5A5 5A5 5A5 5A6 5A6 5A6 5A7 5A8 5A9 5A9 5A11 5A12 5A13 5A16 5A18 5A19 5A19 5A20 5A20 5A21 5A21 5A22 5A23 5A24 Diagnostic Trouble Codes (DTCs) . . . . . . . Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated. . . . . . . . . . . . . . . . . . Chart B-2 EHCU Abnormality (DTC 14) . . . Chart B-3 Power Voltage Drop (DTC 15) . . Chart B-4 CLASS-2 Communication Line Abnormality (DTC 16) . . . . . . . . . . . . . . . . . Chart B-5 G-Sensor Circuit (DTC 21) . . . . . Chart B-6 Abnormal Transmission Input (DTC 23) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart B-7 Transfer Monitor (DTC 24) . . . . . Chart B-8 EHCU Pump Motor And Motor Relay Circuit (DTC 32) . . . . . . . . . . . . . . . . . Chart B-9 EHCU Pump Valve And Valve Relay Circuit (DTC 35) . . . . . . . . . . . . . . . . . Chart B-10 FL Isolation Solenoid Valve Abnormality (DTC 41) . . . . . . . . . . . . . . . . . Chart B-11 FL Dump Solenoid Valve Abnormality (DTC 42) . . . . . . . . . . . . . . . . . Chart B-12 FR Isolation Solenoid Valve Abnormality (DTC 43) . . . . . . . . . . . . . . . . . Chart B-13 FR Dump Solenoid Valve Abnormality (DTC 44) . . . . . . . . . . . . . . . . . Chart B-14 Rear Isolation Solenoid Valve Abnormality (DTC 45) . . . . . . . . . . . . . . . . . Chart B-15 Rear Dump Solenoid Valve Abnormality (DTC 46) . . . . . . . . . . . . . . . . . Chart B-16 FL Speed Sensor Disconnection (DTC 51) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart B-17 FR Speed Sensor Disconnection (DTC 52) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart B-18 RL Speed Sensor Disconnection (DTC 53) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart B-19 RR Speed Sensor Disconnection (DTC 54) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart B-20 FL Speed Sensor Short Circuit (DTC 61) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart B-21 FR Speed Sensor Short Circuit (DTC 62) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart B-22 RL Speed Sensor Short Circuit (DTC 63) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart B-23 RR Speed Sensor Short Circuit (DTC 64) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart B-24 Sensor Signal Input Abnormality (DTC 65) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensor Signal Abnormality Criteria using TECH 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unit Inspection Procedure . . . . . . . . . . . . . . . . 5A24 5A27 5A27 5A28 5A28 5A28 5A29 5A30 5A30 5A31 5A31 5A31 5A32 5A32 5A32 5A33 5A33 5A34 5A34 5A35 5A36 5A37 5A38 5A39 5A40 5A40 5A41

5A2

BRAKE CONTROL SYSTEM

5A41 5A42 5A42 5A43 Chart TC-1 Sensor Output Inspection Procedure (Use TECH 2) . . . . . . . . . . . . . . Chart C-2 Transmission Input Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart TC-2 Transmission Input Inspection Procedure (Use TECH 2) . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A43 5A44 5A44 5A46

Chart C-1-1 FL Sensor Output Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart C-1-2 FR Sensor Output Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart C-1-3 RL Sensor Output Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart C-1-4 RR Sensor Output Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

BRAKE CONTROL SYSTEM

5A3

General Description
The Anti-lock Brake System (ABS) works on all four wheels. A combination of wheel speed sensor and Electronic Hydraulic Control Unit (EHCU) can determine when a wheel is about to stop turning and adjust brake pressure to maintain best braking. This system helps the driver maintain greater control of the vehicle under heavy braking conditions.

C05RW002

Legend (1) Electronic (2) Hydraulic (3) Electronic Hydraulic Control Unit (EHCU)

(4) (5) (6) (7)

Front Wheel Speed Sensor Rear Wheel Speed Sensor G-Sensor Proportioning and Bypass (P&B) Valve

System Components
Electronic Hydraulic Control Unit (EHCU), four Wheel Speed Sensors, Warning Light, and G-sensor.

Electronic Hydraulic Control Unit (EHCU)

The EHCU consists of ABS control circuits, fault detector, and a fail-safe. It drives the hydraulic unit according to the signal from each sensor, cancelling ABS to return to normal braking when a malfunction has occurred in the ABS. The EHCU has a self-diagnosing function which can indicate faulty circuits during diagnosis.

The EHCU is mounted on the engine compartment front right side. It consists of a Motor, Plunger Pump, Solenoid Valves and Check Valve. On the outside, the relay box containing a motor relay and a valve relay is installed. Solenoid Valves: Reduces or holds the caliper fluid pressure for each front disc brake or both rear disc brakes according to the signal sent from the EHCU. Reservoir: Temporarily holds the brake fluid that returns from the front and rear disc brake caliper so that pressure of front disc brake caliper can be reduced smoothly. Plunger Pump: Feeds the brake fluid held in the reservoir to the master cylinder.

5A4

BRAKE CONTROL SYSTEM

The G-sensor judges whether the friction coefficient of road surface is low or high, and changes the EHCUs operating system to ensure ABS control.

Motor: Drives the pump according to the signal from EHCU. Check Valve: Controls the brake fluid flow.

ABS Warning Light

Normal and Anti-lock Braking

Under normal driving conditions, the Anti-lock Brake System functions the same as a standard power assisted brake system. However, with the detection of wheel lock-up, a slight bump or kick-back will be felt in the brake pedal. This pedal bump will be followed by a series of short pedal pulsations which occurs in rapid succession. The brake pedal pulsation will continue until there is no longer a need for the anti-lock function or until the vehicle is stopped. A slight ticking or popping noise may be heard during brake applications when the Anti-lock features is being used. When the Anti-lock feature is being used, the brake pedal may rise even as the brakes are being applied. This is also normal. Maintaining a constant force on the pedal will provide the shortest stopping distance.

Brake Pedal Travel

Vehicles equipped with the Anti-lock Brake System may be stopped by applying normal force to the brake pedal. Although there is no need to push the pedal beyond the point where it stops or holds the vehicle, by applying more force the pedal will continue to travel toward the floor. This extra brake pedal travel is normal.

821RW033

Vehicles equipped with the Anti-lock Brake System have an amber ABS warning light in the instrument panel. The ABS warning light will illuminate if a malfunction in the Anti-lock Brake System is detected by the Electronic Hydraulic Control Unit (EHCU). In case of an electronic malfunction, the EHCU will turn ON the ABS warning light and disable the Anti-lock braking function. The ABS light will turn ON for approximately three seconds after the ignition switch is to the ON position. If the ABS light stays ON after the ignition switch is the ON position, or comes ON and stays ON while driving, the Anti-lock Brake System should be inspected for a malfunction according to the diagnosis procedure.

Acronyms and Abbreviations

Several acronyms and abbreviations are commonly used throughout this section: ABS Anti-lock Brake System CKT Circuit DLC Data Link Connector EHCU Electronic Hydraulic Control Unit FL Front Left FR Front Right GEN Generator MV Millivolts RL Rear Left RR Rear Right RPS Revolution per Second VDC Volts DC

Wheel Speed Sensor

It consists of a sensor and a rotor. The sensor is attached to the knuckle on the front wheels and to the axle shaft bearing holder on the rear wheels. The rotor is press-fit in the axle shaft. The flux generated from electrodes magnetized by a magnet in the sensor varies due to rotation of the rotor, and the electromagnetic induction generates alternating voltage in the coil. This voltage draws a sine curve with the frequency proportional to rotor speed and it allows detection of wheel speed.

G-Sensor
The G-sensor installed inside the center console detects the vehicle deceleration speed and sends a signal to the EHCU. In 4WD operation, all four wheels may be decelerated in almost the same phase, since all wheels are connected mechanically. This tendency is noticeable particularly on roads with low friction coefficient, and the ABS control is adversely affected.

BRAKE CONTROL SYSTEM

VAC Volts AC W/L Warning Light WSS Wheel Speed Sensor

5A5

General Diagnosis
General Information
ABS malfunction can be classified into two types, those which can be detected by the ABS warning light and those which can be detected as a vehicle abnormality by the driver. In either case, locate the fault in accordance with the BASIC DIAGNOSTIC FLOWCHART and repair. Please refer to Section 5C for the diagnosis of mechanical troubles such as brake noise, brake judder (brake pedal or vehicle vibration felt when braking), uneven braking, and parking brake trouble.

D If welding work is to be performed on the vehicle using an electric arc welder, the EHCU and valve block connectors should be disconnected before the welding operation begins. D The EHCU and valve block connectors should never be connected or disconnected with the ignition ON . D EHCU of the Anti-lock Brake System are not separately serviceable and must be replaced as assemblies. Do not disassemble any component which is designated as non-serviceable in this Section. D If only rear wheels are rotated using jacks or drum tester, the system will diagnose a speed sensor malfunction and the ABS warning light will illuminate. But actually no trouble exists. After inspection stop the engine once and re-start it, then make sure that the ABS warning light does not illuminate. If the battery has been discharged The engine may stall if the battery has been completely discharged and the engine is started via jumper cables. This is because the Anti-lock Brake System (ABS) requires a large quantity of electricity. In this case, wait until the battery is recharged, or set the ABS to a non-operative state by removing the fuse for the ABS (40A). After the battery has been recharged, stop the engine and install the ABS fuse. Start the engine again, and confirm that the ABS warning light does not light.

ABS Service Precautions

Required Tools and Items: D Box Wrench D Brake Fluid D Special Tool Some diagnosis procedures in this section require the installation of a special tool. J-39200 High Impedance Multimeter When circuit measurements are requested, use a circuit tester with high impedance.

Note on Intermittents
As with virtually any electronic system, it is difficult to identify an intermittent failure. In such a case duplicating the system malfunction during a test drive or a good description of vehicle behavior from the customer may be helpful in locating a most likely failed component or circuit. The symptom diagnosis chart may also be useful in isolating the failure. Most intermittent problems are caused by faulty electrical connections or wiring. When an intermittent failure is encountered, check suspect circuits for: D Suspected harness damage. D Poor mating of connector halves or terminals not fully seated in the connector body (backed out). D Improperly formed or damaged terminals.

Computer System Service Precautions

The Anti-lock Brake System interfaces directly with the Electronic Hydraulic Control Unit (EHCU) which is a control computer that is similar in some regards to the Powertrain Control Module. These modules are designed to withstand normal current draws associated with vehicle operation. However, care must be taken to avoid overloading any of the EHCU circuits. In testing for opens or shorts, do not ground or apply voltage to any of the circuits unless instructed to do so by the appropriate diagnostic procedure. These circuits should only be tested with a high impedance multimeter (J-39200) or special tools as described in this section. Power should never be removed or applied to any control module with the ignition in the ON position. Before removing or connecting battery cables, fuses or connectors, always turn the ignition switch to the OFF position.

Test Driving ABS Complaint Vehicles

In case that there has been an malfunction in the lighting pattern of ABS warning light, the fault can be located in accordance with the DIAGNOSIS BY ABS WARNING LIGHT ILLUMINATION PATTERN . In case of such trouble as can be detected by the driver as a vehicle symptom, however, it is necessary to give a test drive following the test procedure mentioned below, thereby reproducing the symptom for trouble diagnosis on a symptom basis: 1. Start the engine and make sure that the ABS W/L goes OFF. If the W/L remains ON, it means that the Diagnostic Trouble Code (DTC) is stored. Therefore, read the code and locate the fault. 2. Start the vehicle and accelerate to about 30 km/h (19 mph) or more.

General Service Precautions

The following are general precautions which should be observed when servicing and diagnosing the Anti-lock Brake System and/or other vehicle systems. Failure to observe these precautions may result in Anti-lock Brake System damage.

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BRAKE CONTROL SYSTEM

to the trouble is stored in the EHCU. Only the ordinary brake system is available when the ABS is turned off. When the ABS warning light is actuated, if the starter switch is set ON after setting it OFF once, the EHCU checks up on the entire system and, if there is no abnormality, judges ABS to work currently and the warning light works normally even though the trouble code is stored. NOTE: Illumination of the ABS warning light indicates that anti-lock braking is no longer available. Power assisted braking without anti-lock control is still available.

3. Slowly brake and stop the vehicle completely. 4. Then restart the vehicle and accelerate to about 40 km/h (25 mph) or more. 5. Brake at a time so as to actuate the ABS and stop the vehicle. 6. Be cautious of abnormality during the test. If the W/L is actuated while driving, read the DTC and locate the fault. 7. If the abnormality is not reproduced by the test, make best efforts to reproduce the situation reported by the customer. 8. If the abnormality has been detected, repair in accordance with the SYMPTOM DIAGNOSIS . NOTE: D Be sure to give a test drive on a wide, even road with little traffic. D If an abnormality is detected, be sure to suspend the test and start trouble diagnosis at once.

Normal Operation
ABS Warning Light When the ignition is first moved from OFF to ON , the amber ABS warning light will turn ON . The ABS warning light will turn ON during engine starting and will usually stay ON for approximately three seconds after the ignition switch is returned to the ON position. The warning light should remain OFF at all other times.

ABS Warning Light

When ABS trouble occurs and actuates when possible the ABS warning light, the trouble code corresponding

Basic Diagnostic Flow Chart

Step 1 Action 1. Customer complaint. 2. Questioning to customer. 3. Basic inspection (Refer to Basic inspection procedure) Using TECH 2? 2 3 Make sure of DTC by mode F0 : Diagnostic Trouble Codes. Is EHCU including DTC? 1. Repair of faulty part. 2. Elimination of DTC. 3. Inspection of ABS W/L Illumination pattern with ignition SW ON. 4. Test drive. Dose repeat trouble? 4 Check if the DTC is stored. Is EHCU including DTC? Go to Step 3 Repeat the diagnosis it the symptom or DTC appears again Go to Step 1 Go to Step 5 Go to Step 2 Go to Step 4 Yes No

Go to Step 5 Trouble diagnosis based on symptom (Refer to SYMPTOM DIAGNOSIS) Go to Step 3

Go to Step 3 5 1. Reconnect all components and ensure all component are properly mounted. 2. Clear diagnostic trouble code. Was this step finished? Finished

Go to Step 5

BRAKE CONTROL SYSTEM

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Basic Inspection Procedure 1. Basic Inspection of System Brake

Step 1 Is the fluid level normal? Go to Step 2 2 3 4 5 Does fluid leak? Is the booster functioning normal? Go to Step 4 Is the pad and rotor normal? Go to Step 5 Reconnect all components and ensure all component are properly mounted. Was this step finished? Finished Go to Step 5 Repair. Go to Step 3 Action Yes No Replenish with fluid. Go to Step 2 Go to Step 3 Repair. Go to Step 4 Repair. Go to Step 5

2. Inspection of Front Axle Switch

Step 1 Action Turn the key switch on and shift to 4WD position by pressing the 4WD switch. Does the 4WD light come on? 2 Reconnect all components and ensure all components are properly mounted. Was this step finished? Finished Go to Step 2 Go to Step 2 Yes No

Repair. Go to Step 2

3. Ground Inspection
Step 1 2 Action Are ABSrelated ground points ok? Go to Step 2 Reconnect all components and ensure all components are properly mounted. Was this step finished? Finished Go to Step 2 Yes No Repair. Go to Step 2

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BRAKE CONTROL SYSTEM

Tech 2 Scan Tool

From 98 MY, Isuzu dealer service departments are recommended to use Tech 2. Please refer to Tech 2 scan tool user guide.

901RW257

Legend (1) PCMCIA Card (2) SAE 16/19 Adaptor

(3) DLC Cable (4) Tech2

BRAKE CONTROL SYSTEM

5A9

Getting Started
D Before operating the Isuzu PCMCIA card with the Tech 2, the following steps must be performed: 1. The Isuzu 98 System PCMCIA card (1) inserts into the Tech 2 (4). 2. Connect the SAE 16/19 adapter (2) to the DLC cable (3). 3. Connect the DLC cable to the Tech 2 (4). 4. Make sure the vehicle ignition is off. 5. Connect the Tech 2 SAE 16/19 adapter to the vehicle DLC connector.

Operating Procedure
The power up screen is displayed when you power up the tester with the Isuzu systems PCMCIA card. Follow the operating procedure below.

821RW021

6. The vehicle ignition turns on. 7. Power up the Tech 2. 8. Verify the Tech 2 power up display.

060RX065

060RW009

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BRAKE CONTROL SYSTEM

060RX064

BRAKE CONTROL SYSTEM

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Data List
Display Battery Voltage Brake Light Switch Front Left Wheel Speed Front Right Wheel Speed R Rear Left L ft Wheel Wh l Speed S d Rear Left Wheel Speed Wheel Sensor Status Gsensor Transfer Monitor(TOD) OffRoad Switch (Transmission Input) Valve Relay ABS State ABS Relay Return Pump Relay Front Left Isolation Valve Front Left Dump Valve Front Right Isolation Valve Front Right Dump Valve Rear Isolation Valve Rear Dump Valve ABS Warning Lamp ON/OFF To be ON usually (while engine stopped) Content Voltage Open/Close MPH(km/h) OK/NG Criteria for Data Between 1016.9V Open(0V) when pedal is released Closed(12V) when pedal is depressed. Start the vehicle and make sure of linear change in each wheel speed. Turn each wheel by hand and make sure that each speed data change. OK/NG Low/High 2 Wheel Drive 4 Wheel Drive Active/Inactive Active/Inactive ON/OFF Active/Inactive Active/Inactive Active/Inactive To be OK usually To be Low usually When 2WD: 2 Wheel Drive When 4WD: 4 Wheel Drive When shift lever position is 1, 2 and R : Active (M/T) When shift lever position is L and R : Active (A/T) To be Active usually To be OFF usually To be Active usually To be Inactive usually To be Inactive usually

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BRAKE CONTROL SYSTEM

EHCU Connector Pin-out Checks

D Disconnect Electronic Brake Control Module. D Perform checks with high impedance digital multimeter J-39200 or equivalent. No. Circuit to be Tested Ignition Switch Position OFF ON 2 3 4 Stop light switch Ground connection FL speed sensor OFF OFF OFF OFF OFF 5 FR speed sensor OFF OFF OFF 6 RL speed sensor OFF OFF OFF 7 RR speed sensor OFF OFF OFF 8 9 G-sensor Transmission Input ON ON 20DCV Multimeter Scale/Range 20DCV 20DCV 20DCV 200m 2km 200km 200mACV 2km 200km 200mACV 2km 200km 200mACV 2km 200km 200mACV Measure between Pin Number 8 (+), 15 () 8 (+), 15 () 10, 15 12, Ground 15, Ground 20, 21 20, 15 20, 21 4, 5 4, 15 4, 5 22, 23 22, 15 22, 23 2, 3 2, 15 2, 3 26, 8 6 (+), 15 () Nominal Value Note

Ignition enable

0V to 0.1V 11.5V to 14.5V 10.5V to 14.5V Less than 2m 1.3k to 1.9km more than 100km more than 200mV 1.3k to 1.9km more than 100km more than 200mV 1.3k to 1.9km more than 100km more than 200mV 1.3k to 1.9km more than 100km more than 200mV 1k to 2km Less than 6V (shift lever position L, R) 6.6 to 9.0V (other shift position) More than 9.6V (shift lever position 1, 2, R) 6.6 to 9.0V (other shift position) Internal Resistance Insulation Resistance Turn wheel at 1RPS Internal Resistance Insulation Resistance Turn wheel at 1RPS Insulation Resistance Internal Resistance Turn wheel at 1RPS Internal Resistance Insulation Resistance Turn wheel at 1RPS Horizontal vehicle A/T Battery voltage 12V Press brake pedal

M/T Battery voltage 12V

BRAKE CONTROL SYSTEM

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Circuit Diagram

D08RW033

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BRAKE CONTROL SYSTEM

D08RW034

BRAKE CONTROL SYSTEM

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D08RW035

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BRAKE CONTROL SYSTEM

Connector List

D05RW002

BRAKE CONTROL SYSTEM

5A17

D05RW003

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BRAKE CONTROL SYSTEM

Part Location

D08RW369

Legend (1) F2 (2) F3 (3) I9 (4) C63 (5) H7, H8, H24, H25 (6) B25 (7) C16 (8) Fuse Box (9) B13 or B14 (10) C13 (11) H10, H11

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

C41 H41, H42 C4 C85 Relay & Fuse Box (X15) H12, H15, H16 C39 M1 M8 H33 I10

BRAKE CONTROL SYSTEM

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Symptom Diagnosis
The symptoms that cannot be indicated by the warning light can be divided in the following five categories: 1. ABS works frequently but vehicle does not decelerate. 2. Uneven braking occurs while ABS works. 3. The wheels lock during braking. No No. 1 2 3 4 5 Symptom Sym tom

4. Brake pedal feel is abnormal. 5. Braking sound (from EHCU) is heard while not braking. These are all attributable to problems which cannot be detected by EHCU self-diagnosis. Use the customer complaint and a test to determine which symptom is present. Then follow the appropriate flow chart listed below. Diagnostic Flow Charts Without TECH 2 Chart A1 Chart A2 Chart A3 Chart A4 Chart A5 With TECH 2 Chart TA1 Chart TA3 Chart TA5

ABS works frequently but vehicle does not decelerate. Uneven braking occurs while ABS works. The wheels are locked. Brake pedal feel is abnormal. Braking sound (from EHCU) is heard while not braking.

Chart A1 ABS Works Frequently But Vehicle Does Not Decelerate

Step 1 Action 1. Turn key off. 2. G Sensor connector and EHCU connector disconnected. Is there continuity between EHCU terminals 26 and 8? 2 3 Connect EHCU connector. Is there continuity between the G sensor and the EHCU? Is the G sensor normal? (Refer to chart B-5) Go to Step 4 4 Is braking force distribution normal between the front and rear of the vehicle? Go to Step 5 5 6 Are axle parts installed normally? Is there play in each wheel speed sensor? Go to Step 6 Repair wheel speed sensor. Go to Step 11 Replace sensor or sensor ring. Go to Step 11 Go to Step 3 Go to Step 2 Go to Step 3 Repair circuit. Go to Step 1 Replace G sensor. Go to Step 11 Repair brake parts. Go to Step 11 Repair axle parts. Go to Step 11 Yes No

Go to Step 7

Is there damage, or powered iron sticking to each wheel speed sensor/sensor ring? Is the output of each wheel speed sensor normal? (Refer to chart C-1 or TC-1)

Go to Step 8 Replace wheel speed sensor or repair harness. Go to Step 11 Replace switch or repair harness. Go to Step 11

Go to Step 9 9 Is the input of transmission normal? (Refer to chart C-2 or TC-2) Go to Step 10

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Step 10

BRAKE CONTROL SYSTEM

Action Is the input of 4WD controller normal? Yes No Replace controller or repair harness. Go to Step 11

Go to Step 11 11 Reconnect all components and ensure all components are properly mounted. Was this step finished? Repeat the Basic diagnostic flow chart.

Go to Step 11

Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)
Step 1 Action 1. Connect TECH 2. 2. Make sure of the output conditions of each wheel speed sensor by mode F1: Data Display. Is the output of each sensor normal? 2 3 Return to Chart A-1. Was the Chart A-1 finished? Reconnect all components, ensure all components are properly mounted. Was this step finished? Go to Step 3 Repeat the Basic diagnostic flow chart. Go to Step 2 Go to Step 2 Yes No Replace wheel speed sensor. Go to Step 3

Go to Step 3

Chart A-2 Uneven Braking Occurs While ABS Works

Step 1 2 3 Action Is there play in each sensor? Is there damage or powdered iron sticking to each sensor/sensor ring? Is the output of each sensor normal? (Refer to chart C-1 or TC-1) Go to Step 4 4 Is brake pipe connecting order correct? Replace EHCU. Go to Step 5 5 Reconnect all components, ensure all components are properly mounted. Was this step finished? Repeat the Basic diagnostic flow chart. Yes Repair. Go to Step 5 Repair. Go to Step 5 No Go to Step 2 Go to Step 3 Replace sensor or repair harness. Go to Step 5 Reconnect brake pipe correctly. Go to Step 5

Go to Step 5

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Chart A-3, TA-3 The Wheels Are Locked

Step 1 2 3 Is ABS working? Is vehicle speed under 10 km/h (6mph)? Is sensor output normal? (Chart C-1 or TC-1) Go to Step 4 4 Is transmission input normal? (Chart C-2 or TC-2) Go to Step 5 5 Is front 4WD controller normal? Replace EHCU. Go to Step 9 6 Is transmission input normal? (Chart C-2 or TC-2) Go to Step 7 7 Is front 4WD controller normal? Action Yes Go to Step 2 Normal. No Go to Step 6 Go to Step 3 Replace sensor or repair harness. Go to Step 9 Replace SW or repair harness. Go to Step 9 Replace 4WD controller or repair harness. Go to Step 9 Replace SW or repair harness Go to Step 9 Replace 4WD controller or repair harness. Go to Step 9 Correct. Go to Step 9

Go to Step 8 8 9 Is hydraulic unit grounded properly? Reconnect all components, ensure all components are properly mounted. Was this step finished? Replace EHCU. Go to Step 9 Repeat the Basic diagnostic flow chart.

Go to Step 9

Chart A-4 Brake Pedal Feed Is Abnormal

Step 1 2 Action Is the stop light actuated when the brake pedal is depressed? 1. Turn the ignition switch off. 2. Disconnected EHCU connector. 3. Measure voltage between the EHCU connector terminal 10 and 15 when brake pedal is depressed. Is the voltage equal to the battery voltage? 3 Is stop light fuse C-14 normal? Go to Step 5 4 Is there continuity between EHCU connector terminals, 12 and 15 to body ground? Go to Step 6 5 Is the brake SW normal? Repair stop light harness. Go to Step 7 Go to Step 4 Yes Go to Step 2 No Go to Step 3 Harness NG between brake SW and EHCU. Go to Step 7 Replace fuse C-14. Go to Step 7 Repair body grounded harness. Go to Step 7 Replace brake SW. Go to Step 7

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Step 6

BRAKE CONTROL SYSTEM

Action Is the check harness/connector for suspended disconnection? Yes Hydraulic system leakage or air entry (Refer to servicing Leakage or brake fluid ) Go to Step 7 Repeat the Basic diagnostic flow chart. No

Repair harness. Go to Step 7

Reconnect all components and ensure all components are properly mounted. Was this step finished?

Go to Step 7

Chart A-5,TA-5 Braking Sound (From EHCU) Is Heard While Not Braking
Step 1 Action Is this the first time the vehicle is being driven after starting the engine? Is vehicle speed under 10 km/h (6 mph)? Yes It is self checking sound. Normal. It is self checking sound. Normal. No

Go to Step 2

Go to Step 3

Check for the following condition: D At the time of shift down or clutch operation. D At the time of low m drive (ice or snow road) or rough road drive. D At the time of high-speed turn. D At the time of passing curb. D At the time of operating electrical equipment switches. D At the time of racing the engine (over 5000 rpm). Did it occur under any one condition above? Is there play in each sensor/wheel speed sensor rings?

ABS may sometime be actuated even when brake pedal is not applied. Go to Step 5

Go to Step 4 Repair. Go to Step 7 Repair. Go to Step 7

4 5 6

Damage or powdered iron sticking to each sensor/wheel speed sensor ring? Is each sensor output normal?(Refer to chart C-1 or TC-1).

Go to Step 6 Check harness/ connector for suspected disconnection. If no disconnection is found, replace EHCU. Go to Step 7 Repeat the Basic diagnostic flow chart.

Repair. Go to Step 7

Reconnect all components, ensure all components are properly mounted. Was this step finished?

Go to Step 7

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Diagnostic Trouble Codes

Choose and trace an appropriate flowchart by the numbers listed below to find fault and repair. Code 12 14 15 16 21 23 24 32 35 41 42 43 44 45 46 51 52 53 54 61 62 63 64 65 Start Code EHCU Function Power Voltage Drop CLASS2 Communication Line Abnormality G-sensor Transmission Input Transfer Monitor Motor & Motor Relay Valve Relay FL Holding Solenoid Valve FL Decompression Solenoid Valve FR Holding Solenoid Valve FR Decompression Solenoid Valve Rear Holding Solenoid Valve Rear Decompression Solenoid Valve FL Wheel Speed Sensor FR Wheel Speed Sensor RL Wheel Speed Sensor RR Wheel Speed Sensor FL Wheel Speed Sensor FR Wheel Speed Sensor RL Wheel Speed Sensor RR Wheel Speed Sensor Sensor Signal Input Shorted or disconnected coil Shorted or disconnected coil/wiring Shorted or disconnected coil/wiring Shorted or disconnected coil/wiring Shorted or disconnected coil/wiring Shorted or disconnected coil/wiring Shorted or disconnected coil/wiring Shorted or disconnected coil/wiring Disconnected coil/wiring Disconnected coil/wiring Disconnected coil/wiring Disconnected coil/wiring Shorted coil/wiring Shorted coil/wiring Shorted coil/wiring Shorted coil/wiring Wrong number of teeth Wiring disconnection Input abnormality Item Normal Abnormality in input/output, operational and control circuits Diagnosis Chart No. B-2 B-3 B-4 B-5 B-6 B-7 B-8 B-9 B-10 B-11 B-12 B-13 B-14 B-15 B-16 B-17 B-18 B-19 B-20 B-21 B-22 B-23 B-24

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BRAKE CONTROL SYSTEM

or if the warning light is actuated during driving, trouble should be diagnosed on a illumination pattern basis as follows:

Diagnosis By ABS Warning Light Illumination Pattern

In the event that there is abnormality in the ABS warning light illumination pattern while the key is in the ON position No. 1 Condition Warning light is actuated normally

ABS Warning Light Illumination Pattern Normal

Diagnostic

Warning light is not lit

Warning light lighting circuit troubleGo to Chart B-1

Warning light remains ON

Diagnostic trouble codes are stored. Display diagnostic trouble codes and diagnose on a code basis according to the flow charts.

Warning light is actuated while driving

Diagnostic trouble codes are stored. Display diagnostic trouble codes and diagnose on a code basis according to the flow charts.

Diagnostic Trouble Codes (DTCs)

When the warning light in the meter remains ON, the EHCU stores the fault identification and disables the ABS. 1. How to display and erase DTCs: NOTE: D If DTCs are not displayed, harness C-4 connector terminal 30 and I-10 connector terminal 2 may be disconnected. Repair the harness and try DTC display again.

D DTCs can be displayed also by TECH 2. Select mode F0: Diagnostic Trouble Codes from Application Menu. 1. How to start DTC display: D Confirm that the vehicle has come to a complete stop (with the wheels standing still) and that the brake pedal is not depressed. (Unless these two conditions are satisfied, DTC display cannot be started.) D With IGN OFF, connect #12 terminal with #4 terminal or # 5 terminal (GND) . Then turn IGN ON.

BRAKE CONTROL SYSTEM

The DLC is located behind the driver side kick panel

5A25

350RT001

D Keep #12 terminal connected with #4 terminal or # 5 terminal (GND) during DTC display. (If #12 terminal is separated from #4 terminal or # 5 terminal (GND) during display, display will stop.) 2. DTC display: D DTC is displayed by blinking warning light. D Double-digit display. D First, normal DTC 12 is displayed three times and then any other DTCs are displayed three times. (If no other DTCs have been stored, the display of DTC 12 will be repeated.) 3. How to erase code: D Conduct brake switch ON/OFF operation 6 or more times within 3 seconds of self-diagnosis startup. D The code cannot be erased if more than 3 seconds have passed since self-diagnosis startup, or if self-diagnosis has started with brake switched on (brake pedal depressed).

B05RW005

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BRAKE CONTROL SYSTEM

4. Notes D If the following should occurs during Diagnostic Trouble Code (DTC) display the display will be discontinued. After initial check, the status that is under the control of ABS will be returned : The vehicle starts (The wheels turn) or the brake pedal is depressed. D Up to 3 different codes can be stored. D If the ABS should turn OFF due to an intermittent defect, the system will be restored at the next key cycle, if the initial check finds no abnormality (when IGN is switched from OFF to ON). 5. An example of DTC display Display of DTC 23

B05RW006

After displaying DTC 12 three times, one DTC after another is displayed, starting with the most recent one. (However, display is discontinued after about 5 minutes.)

B05RS005

The DTC 12 is displayed repeatedly. (display is discontinued after about 5 minutes)

BRAKE CONTROL SYSTEM

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Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated.
Step 1 2 Action Is W/L fuse C-10 disconnected? Is W/L burnt out? Yes Replace fuse. Go to Step 5 Replace W/L bulb. Go to Step 5 No Go to Step 2

Go to Step 3

1. 2. 3. 4.

Turn the key off. Disconnect EHCU connector. Turn the key ON. Measure the voltage between EHCU connector terminal 16 and 15. Go to Step 4 Check harness for suspected disconnection. No fault found: Replace EHCU. Go to Step 5 Repeat the Basic diagnostic flow chart.

Is the voltage equal to the battery voltage? 4 Is there continuity between EHCU connector terminals, 12 and 15 and body ground.

Repair harness and connector. Go to Step 5

Repair harness and connector. Go to Step 5

Reconnect all components, ensure all components are properly mounted. Was this step finished?

Go to Step 5

Chart B-2 EHCU Abnormality (DTC 14)

Step 1 Action 1. Turn the key off. 2. Disconnect the EHCU connector. 3. Inspect EHCU ground. Is there resistance between the EHCU connector terminals, 12 and 15 and body ground? 2 1. 2. 3. 4. Turn the key off, connect the EHCU. Erase the trouble code. Turn Ignition off, then on, to perform system self-check. If warning light remains on, display trouble codes once again. Go to Step 2 Yes No

Repair the body ground harness. Go to Step 3 Inspect in accordance with the DTC displayed.

Is the check trouble code 14? 3 1. Reconnect all components and ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished?

Replace EHCU. Go to Step 3 Repeat the Basic diagnostic flow chart.

Go to Step 3

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BRAKE CONTROL SYSTEM

Chart B-3 Power Voltage Drop (DTC 15)

Step 1 Action Is the battery voltage normal? (Battery capacity check) Go to Step 2 2 1. Turn the key off. 2. Disconnect EHCU connector. 3. Turn the key on. Is the voltage between EHCU connector terminals 8 and 15, higher than 10V? Check harness connector for suspected disconnection. Fault found: Repair, and perform system self-check. No fault found: replace EHCU. Go to Step 3 Repeat the Basic diagnostic flow chart. Yes No Charge or replace battery. Go to Step 2

Repair harness or connector. Go to Step 3

1. Reconnect all components, ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished?

Go to Step 3

Chart B-4 CLASS-2 Communication Line Abnormality (DTC 16)

Step 1 Action 1. Turn the key off. 2. Disconnect EHCU and PCM connector. Is there continuity between EHCU connector terminals 25 and ground? 2 1. Connect EHCU connector. 2. Clear diagnostic trouble code. 3. Turn the key on. Is the diagnostic trouble code 16 shown on the displayed? 3 1. Reconnect all components, ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished? Go to Step 2 Check the PCM harness. Refer to 6E section. Go to Step 3 Repeat the Basic diagnostic flow chart. Yes No Repair harness or connector. Go to Step 3

Replace EHCU. Go to Step 3

Go to Step 3

Chart B-5 G-Sensor Circuit (DTC 21)

Step 1 Vehicle placed horizontal. Is the resistance between the G sensor connector terminals 1 and 2 within 4.0-6.0 kW? Action Yes Check harness connector for short. Fault found : Repair , and perform system self-check. No fault found : replace EHCU. Go to Step 3 No

Go to Step 2 Repair or replace bracket. Go to Step 4

Is the bracket installed horizontally? Go to Step 4

BRAKE CONTROL SYSTEM

Step 3 Remove G sensor. Is the resistance between the G sensor connector terminals 1 and 2 within 1.0-2.0 kW when G sensor is horizontal? 4 Measure resistance between G sensor connector terminals 1 and 2 within 4.0-6.0 kW when G sensor tilted to 30 or more? Go to Step 4 Harness between EHCU and G sensor is faulty and short. Repair the harness Go to Step 5 Repeat the Basic diagnostic flow chart. Action Yes No

5A29

Replace G sensor. Go to Step 5

Replace G sensor. Go to Step 5

1. Reconnect all components and ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished?

Go to Step 5

Chart B-6 Abnormal Transmission Input (DTC 23)

Step 1 Action 1. Turn the key off. 2. Disconnect EHCU connector. Is there continuity between EHCU connector terminal 6 to 15 (Gear position-P(A/T), N(M/T))? 2 3 Is the vehicle an A/T model? Turn the key on and measure the voltage between EHCU connector terminal 6 and 15. Is the 6V under when the gear position is L, and R(Battery voltage 12V)? Yes Shorted switch harness. Repair switch or harness. Go to Step 6 Go to Step 3 No

Go to Step 2 Go to Step 4 Transmission SW trouble. Disconnected harness. Repair SW and harness. Go to Step 6 Transmission SW trouble. Disconnected harness. Repair SW and harness. Go to Step 6

Go to Step 5 4 Turn the key on and measure the voltage between EHCU connector terminal 6 and 15. Is the 9.6V over when the gear position is 1, 2, R(Battery voltage 12V)?

Go to Step 5

5A30
Step 5

BRAKE CONTROL SYSTEM

Action Is there 6.6 to 9.0V when the gear position is 3, 4, 5 and N(M/T) or 2,3,D,N and P(A/T)(Battery voltage 12V)? Yes Suspected harness/ connector short power source/GND. Suspected shorted transmission SW. Fault found: repair, and perform system self-check. No fault found: replace EHCU. Go to Step 6 Repeat the Basic diagnostic flow chart. No

Transmission SW trouble. Disconnected harness. Repair SW and harness. Go to Step 6

1. Reconnect all components, ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished?

Go to Step 6

Chart B-7 Transfer Monitor (DTC 24)

Step 1 Action 1. Turn the key off. 2. Disconnect EHCU connector. Is the EHCU connector terminal 9 line normally? 2 Is the TOD ECU or 4WD controler normal? Replace EHCU. Go to Step 3 3 1. Reconnect all components, ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished? Repeat the Basic diagnostic flow chart. Go to Step 2 Yes No Repair Go to Step 3 Repair or replace TOD ECU or 4WD contrder. Go to Step 3

Go to Step 3

Chart B-8 EHCU Pump Motor And Motor Relay Circuit (DTC 32)
Step 1 Action 1. Turn the key off. 2. Disconnect EHCU connector. 3. Measure voltage between EHCU connector terminal 13 and body ground. Is the voltage equal to battery voltage? Go to Step 2 2 Is there continuity between EHCU connector terminal 12 and ground? Yes No Repair fuse/harness between battery and EHCU connector terminal 13. Go to Step 3 Repair between EHCU connector terminal 12 and ground. Go to Step 3

Go to Step 3 3 1. Reconnect all components and ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished? Repeat the Basic diagnostic flow chart.

Go to Step 3

BRAKE CONTROL SYSTEM

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Chart B-9 EHCU Pump Valve And Valve Relay Circuit (DTC 35)
Step 1 Action 1. Turn the key off. 2. Disconnect EHCU connector. 3. Measure voltage between EHCU connector terminal 14 and body ground. Is the voltage equal to battery voltage? 2 1. Reconnect all components and ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished? Replace EHCU. Go to Step 2 Repeat the Basic diagnostic flow chart. Yes No Repair fuse and harness EHCU connector terminal 14 and battery. Go to Step 2

Go to Step 2

Chart B-10 FL Isolation Solenoid Valve Abnormality (DTC 41)

Step 1 Action Was the EHCU Connector Pinout Checks perfomed? Go to Step 2 2 Is the EHCU connector free from damage or corrosion? Yes No Go to EHCU Connector Pin-out Checks. Repair the connector. Repeat the Basic Diagnostic Flow Chart.

Go to Step 3 3 1. Replace the EHCU. 2. Reconnect all component, ensure all component are properly mounted. Was this step finished? Repeat the Basic Diagnostic Flow Chart.

Go to Step 3

Chart B-11 FL Dump Solenoid Valve Abnormality (DTC 42)

Step 1 Action Was the EHCU Connector Pinout Checks perfomed? Go to Step 2 2 Is the EHCU connector free from damage or corrosion? Yes No Go to EHCU Connector Pin-out Checks. Repair the connector. Repeat the Basic Diagnostic Flow Chart.

Go to Step 3 3 1. Replace the EHCU. 2. Reconnect all component, ensure all component are properly mounted. Was this step finished? Repeat the Basic Diagnostic Flow Chart.

Go to Step 3

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BRAKE CONTROL SYSTEM

Chart B-12 FR Isolation Solenoid Valve Abnormality (DTC 43)

Step 1 Action Was the EHCU Connector Pinout Checks perfomed? Go to Step 2 2 Is the EHCU connector free from damage or corrosion? Yes No Go to EHCU Connector Pin-out Checks. Repair the connector. Repeat the Basic Diagnostic Flow Chart.

Go to Step 3 3 1. Replace the EHCU. 2. Reconnect all component, ensure all component are properly mounted. Was this step finished? Repeat the Basic Diagnostic Flow Chart.

Go to Step 3

Chart B-13 FR Dump Solenoid Valve Abnormality (DTC 44)

Step 1 Action Was the EHCU Connector Pinout Checks perfomed? Go to Step 2 2 Is the EHCU connector free from damage or corrosion? Yes No Go to EHCU Connector Pin-out Checks. Repair the connector. Repeat the Basic Diagnostic Flow Chart.

Go to Step 3 3 1. Replace the EHCU. 2. Reconnect all component, ensure all component are properly mounted. Was this step finished? Repeat the Basic Diagnostic Flow Chart.

Go to Step 3

Chart B-14 Rear Isolation Solenoid Valve Abnormality (DTC 45)

Step 1 Action Was the EHCU Connector Pinout Checks perfomed? Go to Step 2 2 Is the EHCU connector free from damage or corrosion? Yes No Go to EHCU Connector Pin-out Checks. Repair the connector. Repeat the Basic Diagnostic Flow Chart.

Go to Step 3 3 1. Replace the EHCU. 2. Reconnect all component, ensure all component are properly mounted. Was this step finished? Repeat the Basic Diagnostic Flow Chart.

Go to Step 3

BRAKE CONTROL SYSTEM

5A33

Chart B-15 Rear Dump Solenoid Valve Abnormality (DTC 46)

Step 1 Action Was the EHCU Connector Pinout Checks perfomed? Go to Step 2 2 Is the EHCU connector free from damage or corrosion? Yes No Go to EHCU Connector Pin-out Checks. Repair the connector. Repeat the Basic Diagnostic Flow Chart.

Go to Step 3 3 1. Replace the EHCU. 2. Reconnect all component, ensure all component are properly mounted. Was this step finished? Repeat the Basic Diagnostic Flow Chart.

Go to Step 3

Chart B-16 FL Speed Sensor Disconnection (DTC 51)

Step 1 Action 1. Turn the key off. 2. Disconnect EHCU connector. 3. Measure the resistance between EHCU connector terminals 20 and 21. Is the resistance between 1.3k and 1.9k ohms? Yes Check for faults in harness between speed sensor and EHCU. Fault found: Repair, and perform system self-check. No fault found: Replace EHCU. Go to Step 3 Repair harness abnormality between sensors and EHCU. Go to Step 3 Repeat the Basic diagnostic flow chart. No

Go to Step 2

Measure the FL speed sensor resistance at the sensor connector. Is the resistance between 1.3k and 1.9k ohms?

Replace sensor. Go to Step 3

1. Reconnect all components, ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished?

Go to Step 3

5A34

BRAKE CONTROL SYSTEM

Chart B-17 FR Speed Sensor Disconnection (DTC 52)

Step 1 Action 1. Turn the key off. 2. Disconnect EHCU connector. 3. Measure the resistance between EHCU connector terminals 4 and 5. Is the resistance between 1.3k and 1.9k ohms? Yes Check for faults in harness between speed sensor and EHCU. Fault found: Repair, and perform system self-check. No fault found: Replace EHCU. Go to Step 3 Repair harness abnormality between sensors and EHCU. Go to Step 3 Repeat the Basic diagnostic flow chart. No

Go to Step 2

Measure the FR speed sensor resistance at the sensor connector. Is the resistance between 1.3k and 1.9k ohms?

Replace sensor. Go to Step 3

1. Reconnect all components and ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished?

Go to Step 3

Chart B-18 RL Speed Sensor Disconnection (DTC 53)

Step 1 Action 1. Turn the key off. 2. Disconnect EHCU connector. 3. Measure the resistance between EHCU connector terminals 22 and 23. Is the resistance between 1.3k and 1.9k ohms? Yes Check for faults in harness between speed sensor and EHCU. Fault found: Repair, and perform system self-check. No fault found: Replace EHCU. Go to Step 3 Repair harness abnormality between sensors and EHCU. Go to Step 3 Repeat the Basic diagnostic flow chart. No

Go to Step 2

Measure the RL speed sensor resistance at the sensor connector. Is the resistance between 1.3k and 1.9k ohms?

Replace sensor. Go to Step 3

1. Reconnect all components and ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished?

Go to Step 3

BRAKE CONTROL SYSTEM

5A35

Chart B-19 RR Speed Sensor Disconnection (DTC 54)

Step 1 Action 1. Turn the key off. 2. Disconnect EHCU connector. 3. Measure the resistance between EHCU connector terminals 2 and 3. Is the resistance between 1.3K and 1.9k ohms? Yes Check for faults in harness between speed sensor and EHCU. Fault found: Repair, and perform system self-check. No fault found: Replace EHCU. Go to Step 3. Repair harness abnormality between sensors and EHUC. Go to Step 3 Repeat the Basic diagnostic flow chart. No

Go to Step 2

Measure the RR speed sensor resistance at the sensor connector. Is the sensor resistance between 1.3k and 1.9k ohms?

Replace sensor. Go to Step 3

1. Reconnect all components and ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished?

Go to Step 3

5A36

BRAKE CONTROL SYSTEM

Chart B-20 FL Speed Sensor Short Circuit (DTC 61)

Step 1 Action 1. Turn the key off. 2. Disconnect EHCU connector 3. Measure the FL speed sensor resistance between EHCU connector terminals 20 and 21. Is the resistance between 1.3k and 1.9k ohms? 2 3 Is there play in the sensor/sensor rotor? Go to Step 4 Measure the FL speed sensor resistance at the sensor connector. Is the resistance between 1.3k and 1.9k ohms? Repair harness abnormality between sensors and EHCU. Go to Step 6 Go to Step 5 5 Is sensor output normal? (Chart C-2 or TC-2) Check for faults in harness between speed sensor and EHCU. Fault found: repair, and perform system self-check. No fault found: replace EHCU. Go to Step 6 Repeat the Basic diagnostic flow chart. Go to Step 2 Go to Step 3 Repair. Go to Step 6 Yes No

Replace sensor. Go to Step 6 Repair. Go to Step 6

Damage and powdered iron sticking to sensor/sensor ring?

Replace sensor. Go to Step 6

1. Reconnect all components and ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished?

Go to Step 6

NOTE: Even after repairing the faulty part the warning light (W/L) does not go out if the vehicle is at a stop. Turn the ignition switch to the ON position and drive the vehicle at 12 km/h or higher to make sure that the warning light goes out.

BRAKE CONTROL SYSTEM

5A37

Chart B-21 FR Speed Sensor Short Circuit (DTC 62)

Step 1 Action 1. Turn the key off. 2. Disconnect EHCU connector. 3. Measure the FR speed sensor resistance between EHCU connector terminals 4 and 5. Is the resistance between 1.3k and 1.9k ohms? 2 3 Is there play in the sensor/sensor rotor? Go to Step 4 Measure the FR speed sensor resistance at the sensor connector. Is the resistance between 1.3k and 1.9k ohms? Repair harness abnormality between sensors and EHCU. Go to Step 6 Go to Step 5 5 Is sensor output normal? (Chart C-2 or TC-2) Check for faults in harness between speed sensor and EHCU. Fault found: repair, and perform system self-check. No fault found: replace EHCU. Go to Step 6 Repeat Basic diagnostic flow chart. Go to Step 2 Go to Step 3 Repair. Go to Step 6 Yes No

Replace sensor. Go to Step 6 Repair. Go to Step 6

Damage and powdered iron sticking to sensor/sensor ring?

Replace sensor. Go to Step 6

1. Reconnect all components and ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished?

Go to Step 6

NOTE: Even after repairing the faulty part the warning light (W/L) does not go out if the vehicle is at a stop. Turn the ignition switch to the ON position and drive the vehicle at 12 km/h or higher to make sure that the warning light goes out.

5A38

BRAKE CONTROL SYSTEM

Chart B-22 RL Speed Sensor Short Circuit (DTC 63)

Step 1 Action 1. Turn the key off. 2. Disconnect EHCU connector 3. Measure the RL speed sensor resistance between EHCU connector terminals 22 and 23. Is the resistance between 1.3k and 1.9k ohms? 2 3 Is there play in the sensor/sensor rotor? Go to Step 4 Measure the RL speed sensor resistance at the sensor connector. Is the resistance between 1.3k and 1.9k ohms? Repair harness abnormality between sensors and EHCU. Go to Step 6 Go to Step 5 5 Is sensor output normal? (Chart C-2 or TC-2)? Check for faults in harness between speed sensor and EHCU. Fault found: repair, and perform system self-check. No fault found: replace EHCU. Go to Step 6 Repeat the Basic diagnostic flow chart. Go to Step 2 Go to Step 3 Repair. Go to Step 6 Yes No

Replace sensor. Go to Step 6 Repair. Go to Step 6

Damage and powdered iron sticking to sensor/sensor ring?

Replace sensor. Go to Step 6

1. Reconnect all components and ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished?

Go to Step 6

NOTE: Even after repairing the faulty part the warning light (W/L) does not go out if the vehicle is at a stop. Turn the ignition switch to the ON position and drive the vehicle at 12 km/h or higher to make sure that the warning light goes out.

BRAKE CONTROL SYSTEM

5A39

Chart B-23 RR Speed Sensor Short Circuit (DTC 64)

Step 1 Action 1. Turn the key off. 2. Disconnect EHCU connector. 3. Measure the RR speed sensor resistance between EHCU connector terminals 2 and 3. Is the resistance between 1.3k and 1.9k ohms? 2 3 Is there play in the sensor/sensor rotor? Go to Step 4 Measure the RR speed sensor resistance at the sensor connector. Is the resistance between 1.3k and 1.9k ohms? Repair harness abnormality between sensors and EHCU. Go to Step 6 Go to Step 5 5 Is sensor output normal? (Chart C-2 or TC-2) Check for faults in harness between speed sensor and EHCU. Fault found: repair, and perform system self-check. No fault found: replace EHCU. Go to Step 6 Repeat Basic diagnostic flow chart. Go to Step 2 Go to Step 3 Repair. Go to Step 6 Yes No

Replace sensor. Go to Step 6 Repair. Go to Step 6

Damage and powdered iron sticking to sensor/sensor ring?

Replace sensor. Go to Step 6

1. Reconnect all components and ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished?

Go to Step 6

NOTE: Even after repairing the faulty part the warning light (W/L) does not go out if the vehicle is at a stop. Turn the ignition switch to the ON position and drive the vehicle at 12 km/h or higher to make sure that the warning light goes out.

5A40

BRAKE CONTROL SYSTEM

Chart B-24 Sensor Signal Input Abnormality (DTC 65)

Step 1 2 Using TECH 2? 1. Connect TECH 2. 2. Select Snap shot manual trigger. 3. With wheel speed data displayed, run the vehicle when speed has arrived at 30 km/h (18 mph). 4. Check speed data on each wheel (refer to the criterion given below). *1 Is the abnormal sensor condition found? 3 4 5 Is there play in sensor/sensor ring? Is there powdered iron sticking to sensor/sensor ring? Is there a broken tooth or indentation in sensor ring? Action Yes Go to Step 2 No Go to Step 3 Go to Step 3 All the sensors should follow the following flowchart (without using TECH 2). Go to Step 4 Go to Step 5

Replace. Go to Step 8 Repair. Go to Step 8 Repair. Go to Step 8 Replace sensor ring. Go to Step 8 Adjust or repair. Go to Step 8

Go to Step 6 Go to Step 7 Repair, and perform system self-check. Go to Step 8

6 7

Is there play in wheel bearing? Is the check wiring between sensor and EHCU normal?

Replace EHCU. Go to Step 8 8 1. Reconnect all components, ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished? Repeat Basic diagnostic flow chart.

Go to Step 8

Sensor Signal Abnormality Criteria using TECH 2

1. While driving, the speed of one or two wheels 25% or more higher than that of the other wheels. 2. The speed of one or two wheels is 10 km/h (6 mph) or more higher than that of the other wheels. 3. During steady driving, wheel speed changes abruptly. *1 The vehicle must run on a level paved road. NOTE: Even after repairing the faulty part the warning light (W/L) does not go out if the vehicle is at a stop. Turn the ignition switch to the ON position and drive the vehicle at 12 km/h or higher to make sure that the warning light goes out. It is important to verify that the correct tires are installed on vehicle.

BRAKE CONTROL SYSTEM

5A41

Unit Inspection Procedure

This section describes the following inspection procedures referred to during SYMPTOM DIAGNOSIS and

DIAGNOSIS BY ABS WARNING LIGHT ILLUMINATION PATTERN :

without TECH 2 Wheel Speed Sensor Output Inspection Transmission SW Inspection Chart C-1-1 to C-1-4 Chart C-2

with TECH 2 Chart TC-1 Chart TC-2

Chart C-1-1 FL Sensor Output Inspection Procedure

Step 1 Action 1. Turn the key off. 2. Disconnect EHCU connector. 3. Jack up the vehicle, With all four wheels off the ground. Measure the AC voltage between EHCU connector terminals while turning FL wheel at a speed of 1 RPS: Is voltage between EHCU connector terminals 20 and 21 under 200 mV? 2 1. Disconnect the wheel speed sensor. 2. Measure resistance between the wheel speed sensor connector terminals 1 and 2. Is resistance between connector (C-13) terminals 1 and 2 within 1.3k - 1.9k ohms? Go to Step 2 Connector is faulty, or open or short circuit in harness between wheel speed sensor connector and EHCU. Inspect and correct the connector or harness Go to Step 3 Repeat the Basic diagnostic flow chart. Ok. Go to Step 3 Yes No

Wheel speed sensor is faulty. Replace the wheel speed sensor. Go to Step 3

Reconnect all components and ensure all components are properly mounted. Was this step finished?

Go to Step 3

5A42

BRAKE CONTROL SYSTEM

Chart C-1-2 FR Sensor Output Inspection Procedure

Step 1 Action 1. Turn the key off. 2. Disconnect EHCU connector. 3. Jack up the vehicle with all four wheels off the ground. Measure the AC voltage between EHCU connector terminals while turning FR wheel at a speed of 1 RPS: Is voltage between EHCU connector terminals 4 and 5 under 200 mV? 2 1. Disconnect the wheel speed sensor. 2. Measure resistance between the wheel speed sensor connector terminals 1 and 2. Is resistance between connector (C-41) terminals 1 and 2 within 1.3k - 1.9k ohms? Go to Step 2 Connector is faulty, or open or short circuit of harness between wheel speed sensor connector and EHCU. Inspect and correct the connector or harness Go to Step 3 Repeat the Basic diagnostic flow chart. Ok. Go to Step 3 Yes No

Wheel speed sensor is faulty. Replace the wheel speed sensor. Go to Step 3

Reconnect all components and ensure all components are properly mounted. Was this step finished?

Go to Step 3

Chart C-1-3 RL Sensor Output Inspection Procedure

Step 1 Action 1. Turn the key off. 2. Disconnect EHCU connector. 3. Jack up the vehicle with all four wheels off the ground. Measure the AC voltage between EHCU connector terminals while turning RL wheel at a speed of 1 RPS: Is voltage between EHCU connector terminals 22 and 23 under 200 mV? 2 1. Disconnect the wheel speed sensor. 2. Measure resistance between the wheel speed sensor connector terminals 1 and 2. Is resistance between connector (F-3) terminals 1 and 2 within 1.3k - 1.9k ohms? Go to Step 2 Connector is faulty, or open or short circuit of harness between wheel speed sensor connector and EHCU. Inspect and correct the connector or harness Go to Step 3 Repeat the Basic diagnostic flow chart. Ok. Go to Step 3 Yes No

Wheel speed sensor is faulty. Replace the wheel speed sensor. Go to Step 3

Reconnect all components and ensure all components are properly mounted. Was this step finished?

Go to Step 3

BRAKE CONTROL SYSTEM

5A43

Chart C-1-4 RR Sensor Output Inspection Procedure

Step 1 Action 1. Turn the key off. 2. Disconnect EHCU connector. 3. Jack up the vehicle with all four wheels off the ground. Measure the AC voltage between EHCU connector terminals while turning RR wheel at a speed of 1 RPS: Is voltage between EHCU connector terminals 2 and 3 under 200 mV? 2 1. Disconnect the wheel speed sensor. 2. Measure resistance between the wheel speed sensor connector terminals 1 and 2. Is resistance between connector (F-2) terminals 1 and 2 within 1.3k - 1.9k ohms? Go to Step 2 Connector is faulty, or open or short circuit of harness between wheel speed sensor connector and EHCU. Inspect and correct the connector or harness Go to Step 3 Repeat the Basic diagnostic flow chart. Ok. Go to Step 3 Yes No

Wheel speed sensor is faulty. Replace the wheel speed sensor. Go to Step 3

Reconnect all components and ensure all components are properly mounted. Was this step finished?

Go to Step 3

Chart TC-1 Sensor Output Inspection Procedure (Use TECH 2)

Step 1 Action 1. Connect TECH 2. 2. While driving the vehicle, check the wheel speed of each sensor by Data List. Is the vehicle speed value is normal? 2 Check the sensor harness for suspected disconnection (Check while shaking harness/connector). Is the sensor harness connection normal? 3 While driving the vehicle, check the wheel speed of each sensor by Data List. Is the vehicle speed value is normal? 4 Check sensor roter. Is the sensor roter normal? 5 While driving the vehicle, check the wheel speed of each sensor by Data List. Is the vehicle speed value is normal? Go to Step 6 6 Reconnect all components, ensure all components are properly mounted. Was this step finished? Repeat the Basic diagnostic flow chart. Go to Step 6 Go to Step 6 Go to Step 4 Replace sensor roter. Go to Step 5 Repair harness or connector between EHCU and speed sensor. Go to Step 6 Go to Step 6 Replace speed sensor. Go to Step 3 Go to Step 2 Repair. Go to Step 6 Yes No

Go to Step 6

5A44

BRAKE CONTROL SYSTEM

Chart C-2 Transmission Input Inspection Procedure

Step 1 Action 1. Turn the key off. 2. Disconnect EHCU connector. Is there continuity between EHCU connector terminals 6 and 15 (Gear position-P(A/T), N(M/T))? 2 3 Is the vehicle an A/T model? Turn the key on and measure voltage between EHCU connector terminals 6 and 15. Is there less than 6V when the gear position is L, and R(Battery voltage 12V)? Yes Shorted switch harness. Repair switch or harness. Go to Step 6 Go to Step 3 No

Go to Step 2 Go to Step 4 Transmission SW trouble. Disconnected harness. Repair SW and harness. Go to Step 6 Transmission SW trouble. Disconnected harness. Repair SW and harness. Go to Step 6 Transmission SW trouble. Disconnected harness. Repair SW and harness. Go to Step 6

Go to Step 5 4 Turn the key on and measure the voltage between EHCU connector terminal 6 and 15. Is there more than 9.6V when the gear position is 1, 2, R(Battery voltage 12V)?

Go to Step 5 5 Measure the voltage between EHCU connector terminals 6 and 15. Is there 6.6 to 9.0V when the gear position is 3, 4, 5 and N(M/T) or 2,3,D,N and P(A/T)(Battery voltage 12V)?

Go to Step 6 6 1. Reconnect all components and ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished? Repeat the Basic diagnostic flow chart.

Go to Step 6

BRAKE CONTROL SYSTEM

5A45

Chart TC-2 Transmission Input Inspection Procedure (Use TECH 2)

Step 1 1. Connect TECH 2. 2. Select Data List. Is this vehicle an A/T model ? 2 3 4 5 6 Is OffRoad Switch(Transmission Input): Active when the shift lever is the L and R? Is OffRoad Switch(Transmission Input): Inactive when the shift lever is other than the L and R? Is OffRoad Switch(Transmission Input): Active when the shift lever is in 1, 2 and R? Is OffRoad Switch(Transmission Input): Inactive when the shift lever is other than the 1, 2 and R? 1. Abnormal T/M SW, inhibitor SW, or harness. 2. Repair T/M SW, inhibitor SW, or harness. Is the T/M SW, inhibitor SW, or harness repaired? 7 Reconnect all components, ensure all components are properly mounted. Was this step finished? Go to Step 7 Repeat the Basic diagnostic flow chart. Go to Step 6 Go to Step 2 Go to Step 3 Go to Step 7 Go to Step 5 Go to Step 7 Go to Step 4 Go to Step 6 Go to Step 6 Go to Step 6 Go to Step 6 Action Yes No

Go to Step 7

5A46

BRAKE CONTROL SYSTEM

Special Tools
ILLUSTRATION TOOL NO. TOOL NAME

J35616 Connector test adapter kit

J39200 High impedance multimeter

7000086ISU Tech 2 Set (1) PCMCIA Card (2) SAE 16/19 Adapter (3) DLC Cable (4) Tech 2

SECTION
ANTILOCK BRAKE SYSTEM
TROOPER

5B1

BRAKES
ANTI-LOCK BRAKE SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . Electronic Hydraulic Control Unit . . . . . . . . . . Electronic Hydraulic Control Unit and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Wheel Speed Sensor . . . . . . . . . . . . . . . 5B1 5B2 5B2 5B2 5B2 5B3 5B3 5B3 5B3 5B4 Front Wheel Speed Sensor and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Wheel Speed Sensor . . . . . . . . . . . . . . . Rear Wheel Speed Sensor and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B4 5B4 5B5 5B5 5B6 5B6 5B6 5B6 5B6

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

5B2

ANTILOCK BRAKE SYSTEM

Electronic Hydraulic Control Unit

Electronic Hydraulic Control Unit and Associated Parts

350RW013

Legend (1) Connector (2) Hydraulic Unit ASM

(3) Bolts (4) Nut (5) Bolt

Removal
1. Remove battery ASM. 2. Remove harness connector. 3. Remove EHCU fixing nuts. 4. Remove brake pipes. D After disconnecting brake pipe, cap or tape the openings of the brake pipe to prevent the entry of foreign matter. 5. Remove hydraulic unit fixing nuts.

Installation
To install, follow the removal steps in the reverse order, noting the following points: Torque Hydraulic unit fixing nuts : 22 Nm (16 lb ft) Ground cable : 14 Nm (10 lb ft) Brake pipe (joint bolts) : 16 Nm (12 lb ft) D After installing the hydraulic unit, bleed brakes completely. See Section 5A Hydraulic Brakes.

ANTILOCK BRAKE SYSTEM

5B3

G-Sensor
Removal Installation
1. Install G-sensor assembly (3). D Care should be taken so that the G-sensor is not installed in the wrong direction. 2. Install G-sensor assembly fixing bolt (2). D Tighten the fixing bolt to the specified torque. Torque : 10 Nm (87 lb in) 3. Install G-sensor wiring connector (1). 4. Install center console. D Refer to Consoles in Body and Accessories section.

350RX001

1. Remove center console. D Refer to Consoles in Body and Accessories section. 2. Remove clip from G-sensor connector, then disconnect connector. 3. Remove G-sensor assembly fixing bolt (2). 4. Remove G-sensor assembly (3).

Inspection and Repair

Refer to Chart B-5 in this Section.

5B4

ANTILOCK BRAKE SYSTEM

Front Wheel Speed Sensor

Front Wheel Speed Sensor and Associated Parts

350RW012

Legend (1) Speed Sensor Connector (2) Sensor Cable Fixing Bolt (Upper side)

(3) Sensor Cable Fixing Bolt (Lower side) (4) Sensor Cable Fixing Bolt (Sensor side) (5) Speed Sensor

Removal
1. Remove speed sensor connector. 2. Remove sensor cable fixing bolt (Upper side). 3. Remove sensor cable fixing bolt (Lower side). 4. Remove the speed sensor cable fixing bolts (1) and caliper fixing bolt (2) from caliper side speed sensor cable bracket (3).

350RW010

5. Remove speed sensor.

ANTILOCK BRAKE SYSTEM

5B5

Inspection and Repair

1. Check the speed sensor pole piece for presence of foreign materials; remove any dirt, etc. 2. Check the pole piece for damage; replace speed sensor if necessary. 3. Check the speed sensor cable for short or open circuit, and replace with a new one if necessary. To check for cable short or open, bend or stretch the cable while checking for continuity. 4. Check the sensor ring for damage including tooth chipping, and if damaged, replace the sensor ring assembly. Refer to removal of the sensor ring in Section 4C Front hub and disc.

NOTE: Confirm that a white line marked on the cable is not twisted when connecting the speed sensor cable. 5. Install speed sensor connector.

Installation
1. Install speed sensor and take care not to hit the speed sensor pole piece during installation. 2. Install speed sensor fixing bolt and tighten the fixing bolt to the specified torque. Torque Sensor side : 8 Nm (69 lb in) Caliper side : 155 Nm (115 lb ft)

350RW011

Legend (1) Caliper Fixing Bolt (2) Bracket (3) Sensor Fixing Bolt (4) Sensor (5) Knuckle (6) Brake Caliper 3. Install speed sensor cable fixing bolt (Lower side) and tighten the fixing bolt to the specified torque. Torque : 24 Nm (18 lb ft) 4. Install speed sensor cable fixing bolt (Upper side) and tighten the fixing bolt to the specified torque. Torque : 6 Nm (52 lb ft)

5B6

ANTILOCK BRAKE SYSTEM

Rear Wheel Speed Sensor

Rear Wheel Speed Sensor and Associated Parts

350RW008

Legend (1) Speed Sensor Connector (2) Sensor Cable Fixing Bolt

(3) Clip (11 pieces) (4) Speed Sensor (5) Sensor Fixing Bolt

Removal
1. Remove speed sensor connector. 2. Remove clip. 3. Remove sensor cable fixing bolt. 4. Remove sensor fixing bolt. 5. Remove speed sensor.

2. Check the pole piece for damage, and replace the speed sensor if necessary. 3. Check the speed sensor cable for a short or an open, and replace with a new one if necessary. To check for cable short or open, bend or stretch the cable while checking for continuity. 4. Check the sensor ring for damage including tooth chipping. If damaged replace the axle shaft assembly. Refer to removal of the sensor ring in Section 4B Rear Axle.

Installation
1. Install the speed sensor and take care not to hit the speed sensor pole piece during installation. 2. Install the sensor fixing bolt and tighten it to the specified torque. Torque : 18 Nm (13 lb ft) 3. Install the sensor cable fixing bolt and tighten it to the specified torque. Torque : 24 Nm (18 lb ft) NOTE: Confirm that the cable is not twisted when connecting the speed sensor cable. 4. Install clip. 5. Install speed sensor connector.

350RS035

Inspection and Repair

1. Check the speed sensor pole piece for presence of foreign materials; remove any dirt, etc.

SECTION
POWER ASSISTED BRAKE SYSTEM
TROOPER

5C1

BRAKES
POWER-ASSISTED BRAKE SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Diagnosis . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Brakes . . . . . . . . . . . . . . . . . . . . . . . . Filling Master Cylinder Reservoir . . . . . . . . Deterioration of Brake Fluid . . . . . . . . . . . . . Leakage of Brake Fluid . . . . . . . . . . . . . . . . . Bleeding Brake Hydraulic System . . . . . . . . Flushing Brake Hydraulic System . . . . . . . . Brake Pipes and Hoses . . . . . . . . . . . . . . . . Brake Hose Inspection . . . . . . . . . . . . . . . . . Front / Rear Caliper Brake Hose . . . . . . . . . . Front / Rear Caliper Brake Hose and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Axle Brake Hose . . . . . . . . . . . . . . . . . . . Rear Axle Brake Hose and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . P & B (Proportioning and Bypass) Valve . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Pedal Height . . . . . . . . . . . . . . . . . Checking Pedal Travel . . . . . . . . . . . . . . . . . Brake Pedal and Associated Parts . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stoplight Switch . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Fluid Reservoir Tank . . . . . . . . . . . . . . . . . . . . . Fluid Reservoir Tank and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Master Cylinder Assembly . . . . . . . . . . . . . . . . 5C2 5C2 5C5 5C6 5C9 5C9 5C9 5C9 5C9 5C10 5C10 5C10 5C11 5C11 5C11 5C11 5C12 5C12 5C12 5C12 5C13 5C13 5C13 5C14 5C14 5C14 5C15 5C16 5C16 5C16 5C17 5C17 5C17 5C18 5C18 5C18 5C19 5C20 5C20 5C20 5C20 5C21 Master Cylinder Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . Vacuum Booster Assembly . . . . . . . . . . . . . . . Vacuum Booster Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exterior Components . . . . . . . . . . . . . . . . . . . . Exterior Components and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vacuum Booster Overhaul . . . . . . . . . . . . . . . . Vacuum Booster . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Disc Brake Pads . . . . . . . . . . . . . . . . . . . Front Disc Brake Pads Inspection . . . . . . . . Front Disc Brake Pads and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Disc Brake Rotor . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Brake Rotors . . . . . . . . . . . . . . . . Refinishing Brake Rotors . . . . . . . . . . . . . . . Front Disc Brake Caliper Assembly . . . . . . . . Front Disc Brake Caliper Assembly and Associated Parts . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Disc Brake Caliper . . . . . . . . . . . . . . . . . Front Disc Brake Caliper Disassembled View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . 5C21 5C21 5C21 5C22 5C23 5C24 5C25 5C25 5C25 5C25 5C26 5C28 5C28 5C28 5C29 5C29 5C29 5C29 5C30 5C31 5C32 5C32 5C32 5C33 5C33 5C35 5C35 5C35 5C35 5C37 5C37 5C37 5C38 5C40 5C40 5C40 5C41 5C41 5C43

5C2

POWER ASSISTED BRAKE SYSTEM

5C44 5C44 5C44 5C45 5C45 5C47 5C47 5C47 5C47 5C48 5C49 Rear Disc Brake Caliper Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Disc Brake Caliper . . . . . . . . . . . . . . . . . . Rear Disc Brake Caliper Disassembled View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . 5C49 5C49 5C50 5C52 5C52 5C52 5C53 5C53 5C55

Rear Disc Brake Pads . . . . . . . . . . . . . . . . . . . Brake Pads Inspection . . . . . . . . . . . . . . . . . Brake Pads and Associated Parts . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Disc Brake Rotor . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Brake Rotors . . . . . . . . . . . . . . . . Refinishing Brake Rotors . . . . . . . . . . . . . . . Rear Drum (In Disc) Inside Diameter Check Rear Disc Brake Caliper Assembly . . . . . . . .

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

General Description
Master Cylinder Assembly

330RW013

The master cylinder contains two pistons that supply the hydraulic pressure for a dualcircuit braking system. The primary piston provides the fluid pressure to the front brakes, while the secondary piston provides the fluid pressure to the rear brakes. If the pressure is lost from either system, the remaining system will function to stop the vehicle.

POWER ASSISTED BRAKE SYSTEM

CAUTION: 1. The master cylinder is not repairable. If found defective, it must be replaced as a complete assembly. 2. If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. (Refer to OnVehicle Service in this section.) 3. The torque values specified un-lubricated fasteners. are

5C3
for dry,

4. Perform service operations on a clean bench free from all mineral oil materials.

Brake Booster

331RS001

This booster is a tandem vacuum unit with a diaphragm effective diameter 205mm + 230mm. In normal operating mode, with the service brakes in the released position, the tandem vacuum booster operates with vacuum on both sides of its diaphragms. When the brakes are applied, air at atmospheric pressure is admitted to one side of each diaphragm to provide the power assist. When the service brake is released, the atmospheric air is shut off from the one side of each diaphragm. The air is then drawn from the booster through the vacuum check valve to the vacuum source. CAUTION: 1. If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. 2. The torque values specified unlubricated fasteners. are for dry,

Disc Brake
The disc brake assembly consists of a caliper, piston, rotor, pad assembly and support bracket. The caliper assembly has a single bore and is mounted to the support bracket with two mounting bolts. The support bracket allows the caliper to move laterally against the rotor. The caliper is a onepiece casting with the inboard side containing the piston bore. A square cut rubber seal is located in a groove in the piston bore which provides the hydraulic seal between the piston and the cylinder wall. NOTE: 1. Replace all components included in repair kits used to service this caliper. 2. Lubricate rubber parts with clean brake fluid to ease assembly. 3. If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. 4. Replace pads in axle sets only.

3. The vacuum booster is not repairable and must be replaced as a complete assembly.

5C4

POWER ASSISTED BRAKE SYSTEM

6. Perform the service operation on a clean bench free from all mineral oil materials.

5. The torque values specified are for dry, unlubricated fasteners. Operation Front Disc Brake

A05RW001

Rear Disc Brake

A05RW002

Hydraulic pressure, created by applying the brake pedal, is converted by the caliper to a stopping force. This force acts equally against the piston and the bottom of the caliper bore to move the piston outward and to move (slide) the caliper inward resulting in a clamping action on the rotor. This clamping action forces the linings against the rotor, creating friction to stop the vehicle.

POWER ASSISTED BRAKE SYSTEM

5C5

Diagnosis
Road Testing The Brakes
Brake Test Brakes should be tested on a dry, clean, reasonably smooth and level roadway. A true test of brake performance cannot be made if the roadway is wet, greasy or covered with loose dirt so that all tires do not grip the road equally. Testing will also be adversely affected if the roadway is crowned so as to throw the weight of the vehicle toward wheels on one side or if the roadway is so rough that wheels tend to bounce. Test the brakes at different vehicle speeds with both light and heavy pedal pressure; however, avoid locking the wheels and sliding the tires. Locked wheels and sliding tires do not indicate brake efficiency, since heavily braked but turning wheels will stop the vehicle in less distance than locked wheels. More tiretoroad friction is present with a heavily braked turning tire then with a sliding tire. The standard brake system is designed and balanced to avoid locking the wheels except at very high deceleration levels. It is designed this way because the shortest stopping distance and best control is achieved without brake lockup. Because of high deceleration capability, a firmer pedal may be felt at higher deceleration levels. External Conditions That Affect Brake Performance 1. Tires: Tires having unequal contact and grip on the road will cause unequal braking. Tires must be equally inflated, identical in size, and the thread pattern of right and left tires must be approximately equal. 2. Vehicle Loading: A heavily loaded vehicle requires more braking effort.

3. Wheel Alignment: Misalignment of the wheels, particularly in regard to excessive camber and caster, will cause the brakes to pull to one side.

Brake Fluid Leaks

With engine running at idle and the transmission in Neutral, depress the brake pedal and hold a constant foot pressure on the pedal. If pedal gradually falls away with the constant pressure, the hydraulic system may be leaking. Check the master cylinder fluid level. While a slight drop in the reservoir level will result from normal lining wear, an abnormally low level in reservoir indicates a leak in the system. The hydraulic system may be leaking internally as well as externally. Refer to Master Cylinder Inspection. Also, the system may appear to pass this test but still have slight leakage. If fluid level is normal, check the vacuum booster push rod length. If an incorrect length push rod is found, adjust or replace the push rod. Check the brake pedal travel and the parking brake adjustment. When checking the fluid level, the master cylinder fluid level may be low from the MAX mark if the front and rear linings are worn. This is not abnormal.

Warning Light Operation

When the ignition switch is in the START position, the BRAKE warning light should turn on and go off when the ignition switch returns to the ON position. The following conditions will turn on the BRAKE light: 1. Parking brake applied. The light should be on whenever the parking brake is applied and the ignition switch is on. 2. Low fluid level. A low fluid level in the master cylinder will turn the BRAKE light on. 3. During engine cranking the BRAKE light should remain on. This notifies the driver that the warning circuit is operating properly.

5C6

POWER ASSISTED BRAKE SYSTEM

General Diagnosis
Condition Brake Pull Possible cause Tire inflation pressure is unequal. Front wheel alignment is incorrect. Unmatched tires on same axle. Adjust Adjust Tires with approx. the same amount of tread should be used on the same axle. Check for soft hoses and damaged lines. Replace with new hoses and new doublewalled steel brake piping. Clean or replace. Replace Replace Grind or replace. Clean or replace. Adjust or replace. Check all suspension mountings. Check and tighten the bolts to specifications. Check per instructions. If not within specifications, replace or machine the rotor. Check per instructions. If not within specifications, replace or machine the rotor. Adjust wheel bearings to correct specifications Replace the brake pad and machine rotor to within specifications. Check the vacuum booster operation and repair, if necessary. Check the front and rear brake system for failure and repair. Also, check the brake warning light. If a failed system is found, the light should indicate failure. Check and replace pads in sets. Remove caliper and rebuild. Remove and replace with original equipment pad or equivalent. Check for ruptured or loose hose. Correct vacuum hose direction. Replace or clean. Correction

Restricted brake pipes or hoses.

Water or oil on the brake pads. Brake pads hardened. Brake pads worn excessively. Brake rotor worn or scored. Disc brake caliper malfunctioning. Front hub bearing preload incorrect. Loose suspension parts. Loose calipers. Brake Roughness (Pulsates) or Chatter Excessive lateral runout.

Parallelism not within specifications.

Wheel bearings not adjusted. Pad reversed (steel against iron). Excessive Pedal Effort Malfunctioning vacuum booster. Partial system failure.

Excessively worn pad. Piston in caliper stuck or sluggish. Fading brakes due to incorrect pad. Vacuum leak to vacuum booster. Check the direction of check valve within vacuum hose. Grease on the brake pads.

POWER ASSISTED BRAKE SYSTEM

Condition Excessive Brake Pedal Travel Possible cause Air in hydraulic circuit. Level of brake fluid in the reservoir too low. Master cylinder push rod clearance excessive. Leakage in hydraulic system. Brake Drag Master cylinder pistons not returning correctly. Restricted brake pipes or hoses. Correction Bleed the hydraulic circuit.

5C7

Replenish brake fluid reservoir to specified level and bleed hydraulic circuit as necessary. Adjust Correct or replace defective parts. Adjust the stop light switch and vacuum booster push rod. If necessary, rebuild. Check for soft hoses or damaged pipes, and replace with new hoses and new doublewalled steel brake piping. Adjust Adjust Adjust the brake pedal height or power cylinder operating rod. Replace Replace piston seals. Clean Replace Overhaul the parking brakes and correct. Adjust or replace. Correct or replace the brake back plate and brake shoe as necessary. Clean Grind or replace. Grind or replace. Grind or replace. Check operation and correct as necessary. Check and lubricate, if necessary. Clean and lubricate. Replace Replace Correct Grind or replace. Replace Adjust or replace. Grind or replace.

Parking brake misadjusted. Parking brake insufficient. lining clearance

Brake pedal free play insufficient. Piston in the master cylinder sticking. Piston in the disc brake caliper sticking. Brake pads sticking in caliper. Return spring weakened. Parking brake binding. Front hub bearing preload incorrect. Parking brake shoes not returning. Obstructions in hydraulic circuit. Brake disc warped excessively. Rear brake drum distorted. Parking cable sticking. Grabbing or Uneven Braking Action (All conditions listed under Pulls) Malfunctioning vacuum booster. Binding brake pedal mechanism. Corroded caliper assembly. Brake Noisy Brake pads are worn. Brake pads are hardened. Brake pads are in poor contact with rotor. Brake disc(s) warped, worn or damaged. Disc brake fatigued. antisqueak shims

Front hub bearings are loose or preload is incorrect. Brake disc is rusted.

5C8

POWER ASSISTED BRAKE SYSTEM

Condition Possible cause Master cylinder faulty. Vacuum booster faulty. Level of brake fluid in reservoir too low. Air in hydraulic circuit. Disc brake caliper faulty. Water or oil on brake pads. Brake pads in poor contact with the brake disc. Brake pads worn. Brake disc rusted. Check valve in vacuum hose faulty. Correction Correct or replace. Correct or replace. Replenish and bleed. Bleed Clean or replace. Clean or replace. Correct Replace Grind or replace. Correct or replace.

Poor Brake Action

POWER ASSISTED BRAKE SYSTEM

5C9

Hydraulic Brakes
Filling Master Cylinder Reservoir
CAUTION: Use only specified brake fluid. Do not use any fluid which contains a petroleum base. Do not use a container which has been used for petroleum based fluids or a container which is wet with water. Petroleum based fluid will cause swelling and distortion of rubber parts in the hydraulic brake system. Water mixed with brake fluid lowers the fluid boiling point. Keep all fluid containers capped to prevent contamination. Always fill the master cylinder reservoir when the engine is cold. Never allow the brake fluid to come in contact with the painted surfaces. The master cylinder reservoir must be kept properly filled to ensure adequate reserve and to prevent air and moisture from entering the hydraulic system. However, because of expansion due to heat absorbed from the brakes and the engine, the reservoir must not be overfilled. The brake fluid reservoir is on the master cylinder, which is located under the hood on the left side of the cowl. Thoroughly clean reservoir cap before removal to avoid getting dirt into reservoir. Remove cup and diaphragm. Add fluid as required to bring level to the MAX mark on the reservoir tank. Use DOT 3 Hydraulic Brake Fluid. If the fluid cap diaphragm is stretched, return it to the original position before installing. cylinder and brakes, then the brake system served by the disconnected pipe must be bled. 1. For 4Wheel Antilock Brake System (ABS) equipped vehicle, be sure to remove the ABS main fuse 40A located at the relay and fuse box before bleeding air. If you attempt to bleed air without removing the main fuse, air cannot be let out thoroughly, and this may cause damage to the hydraulic unit. After bleeding air, be sure to replace the ABS main fuse back to its original position. 2. Set the parking brake completely, then start the engine. NOTE: The vacuum booster will be damaged if the bleeding operation is performed with the engine off. 3. Remove the master cylinder reservoir cap. 4. Fill the master cylinder reservoir with brake fluid. Keep the reservoir at least half full during the air bleeding operation 5. Always use new brake fluid for replenishment. 6. In replenishing brake fluid, take care that air bubbles do not enter the brake fluid. When the master cylinder is replaced or overhauled, first bleed the air from the master cylinder, then from each wheel cylinder and caliper following the procedures described below. Bleeding the Master Cylinder 7. Disconnect the rear wheel brake pipe (1) from the master cylinder. Check the fluid level and replenish as necessary. If replenished, leave the system for at least one minute. 8. Depress the brake pedal slowly once and hold it depressed. 9. Completely seal the delivery port of the master cylinder with your finger, where the pipe was disconnected then release the brake pedal slowly. 10. Release your finger from the delivery port when the brake pedal returns completely. 11. Repeat steps 7 through 9 until the brake fluid comes out of the delivery port during step 7. NOTE: Do not allow the fluid level in the reservoir to go below the halfway mark. 12. Reconnect the brake pipe (1) to the master cylinder and tighten the pipe. 13. Depress the brake pedal slowly once and hold it depressed. 14. Loosen the rear wheel brake pipe (1) at the master cylinder. 15. Retighten the brake pipe, then release the brake pedal slowly.

Deterioration of Brake Fluid

Using any other brake fluid than specified or brake fluid with mineral oil or water mixed in will drop the boiling point of brake fluid. It may, in turn, result in vapor lock or deteriorated rubber parts of the hydraulic system. Be sure to change the brake fluid at specified intervals. If the rubber parts are deteriorated, remove all the system parts and clean them with alcohol. Prior to reassembly, dry the cleaned parts with air to remove the alcohol. Replace all the hoses and rubber parts of the system.

Leakage of Brake Fluid

With engine idling, set shift lever in the neutral position and continue to depress brake pedal at a constant pedal application force. Should the pedal stroke become deeper gradually, a leakage from the hydraulic pressure system is possible. Make sure by visual check that there is no leak.

Bleeding Brake Hydraulic System

A bleeding operation is necessary to remove air from the hydraulic brake system whenever air is introduced into the hydraulic system. It may be necessary to bleed the hydraulic system at all four brakes if air has been introduced through a low fluid level or by disconnecting brake pipes at the master cylinder. If a brake pipe is disconnected at one wheel, only that wheel cylinder/caliper needs to be bled. If the pipes are disconnected at any fitting located between the master

5C10 POWER ASSISTED BRAKE SYSTEM

16. Repeat steps 13 through 15 until no air comes out of the port when the brake pipe is loosened NOTE: Be very careful not to allow the brake fluid to come in contact with painted surfaces. 27. Depress the brake pedal to check if you feel sponginess after the air has been removed from all wheel cylinders and calipers. If the pedal feels spongy, the entire bleeding procedure must be repeated. 28. After the bleeding operation is completed on the each individual wheel, check the level of the brake fluid in the reservoir and replenish up to the MAX level as necessary. 29. Attach the reservoir cap. If the diaphragm inside the cap is deformed, reform it and install. 30. Stop the engine.

Flushing Brake Hydraulic System

It is recommended that the entire hydraulic system be thoroughly flushed with clean brake fluid whenever new parts are installed in the hydraulic system. Approximately one quart of fluid is required to flush the hydraulic system. The system must be flushed if there is any doubt as to the grade of fluid in the system or if fluid has been used when it contains the slightest trace of mineral oil. All rubber parts that have been subjected to a contaminated fluid must be replaced.

330RS023

17. Bleed the air from the front wheel brake pipe connection (2) by repeating steps 7 through 16. Bleeding the Caliper 18. Bleed the air from each wheel in the order listed below: D Right rear caliper D Left rear caliper D Right front caliper D Left front caliper Conduct air bleeding from the wheels in the above order. If no brake fluid comes out, it suggests that air is mixed in the master cylinder. In this case, bleed air from the master cylinder in accordance with steps 7 through 17, and then bleed air from the caliper. 19. Place the proper size box end wrench over the bleeder screw. 20. Cover the bleeder screw with a transparent tube, and submerge the free end of the transparent tube in a transparent container containing brake fluid. 21. Pump the brake pedal slowly three (3) times (once/sec), then hold it depressed. 22. Loosen the bleeder screw until fluid flows through the tube. 23. Retighten the bleeder screw. 24. Release the brake pedal slowly. 25. Repeat steps 21 through 24 until the air is completely removed. It may be necessary to repeat the bleeding procedure 10 or more times for front wheels and 15 or more times for rear wheels. 26. Go to the next wheel in the sequence after each wheel is bled. Be sure to monitor reservoir fluid level.

Brake Pipes and Hoses

The hydraulic brake system components are interconnected by special steel piping and flexible hoses. Flexible hoses are used between the frame and the front calipers, the frame and rear axle case and the rear axle and the rear calipers. When the hydraulic pipes have been disconnected for any reason, the brake system must be bled after reconnecting the pipe. Refer to Bleeding the Brake Hydraulic System in this section.

Brake Hose Inspection

The brake hose should be inspected at least twice a year. The brake hose assembly should be checked for road hazard, cracks and chafing of the outer cover, and for leaks and blisters. Inspect for proper routing and mounting of the hose. A brake hose that rubs on suspension components will wear and eventually fail. A light and mirror may be needed for an adequate inspection. If any of the above conditions are observed on the brake hose, adjust or replace the hose as necessary. CAUTION: Never allow brake components such as calipers to hang from the brake hoses, as damage to the hoses may occur.

POWER ASSISTED BRAKE SYSTEM

5C11

Front / Rear Caliper Brake Hose

Front / Rear Caliper Brake Hose and Associated Parts Installation
To install, follow the removal steps in the reverse order, noting the following points: 1. Tighten the brake pipes to the specified torque Torque: 16 Nm (12 lb ft) 2. Tighten the bolt to the specified torque. Torque: 35 Nm (26 lb ft) NOTE: Always use new gaskets and be sure to put the hooked edge of the flexible hose end into the antirotation cavity. After installing the brake hoses, bleed the brakes as described in this section.

352RW001

Legend (1) Bolt and Gasket (2) Clip (3) Hose (4) Brake Pipe

Removal
1. Raise the vehicle and support it with suitable safety stands. 2. Remove the wheel and tire assembly. 3. Clean dirt, grease, and other foreign material off the hose fittings at both ends. 4. Disconnect brake pipe. 5. Remove clip. 6. Remove bolt and gasket. 7. Remove hose.

5C12 POWER ASSISTED BRAKE SYSTEM

Rear Axle Brake Hose

Rear Axle Brake Hose and Associated Parts Installation
To install, follow the removal steps in the reverse order, noting the following points: 1. Tighten the brake pipes to the specified torque Torque: 16 Nm (12 lb ft) 2. Tighten the bolt to the specified torque. Sems bolts Torque: 13 Nm (113 lb in) Flange bolts Torque: 15 Nm (11 lb ft) After installing the brake hoses, bleed the brakes as described in this section.

352RW002

Legend (1) Brake Pipe (2) Clip (3) Bolt (4) Brake Pipe (5) Hose

Removal
1. Raise the vehicle and support it with suitable safety stands. 2. Remove wheel and tire assembly. 3. Clean dirt, grease, and other foreign material off the hose fittings at both ends. 4. Disconnect brake pipe. 5. Remove clip. 6. Remove brake pipe. 7. Remove bolt. 8. Remove hose.

POWER ASSISTED BRAKE SYSTEM

5C13

Brake Pipe
Removal
1. Raise the vehicle and support it with suitable safety stands. 2. Remove wheel and tire assembly as necessary. 3. Clean dirt, grease, and other foreign material off the pipe fittings at both ends. 4. Remove brake pipe (1).

Installation
To install, follow the removal steps in the reverse order, noting the following points: 1. Tighten the brake pipes to the specified torque. Master cylinder side Torque: 12 Nm (104 lb in) Other Torque: 16 Nm (12 lb ft) After installing the brake pipes, bleed the brakes as described in this section.

330RW001

5. Remove plastic clip (2).

330RW002

5C14 POWER ASSISTED BRAKE SYSTEM

P & B (Proportioning and Bypass) Valve

P & B (Proportioning and Bypass) Valve Sectional View Removal
1. The P&B valve is not repairable and must be replaced as a complete assembly. Care must be taken to prevent brake fluid from contacting any painted surface. 2. Remove hydraulic pipes (1) and plug (1) the pipes to prevent the loss of fluid or the entrance of dirt. 3. Remove bolt (3). 4. Remove P&B valve (2).

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Legend (1) Master Cylinder (Secondary) (2) Master Cylinder (Primary) (3) Rear Brake (4) Front Brake The P&B valve contains two sections, each serving a different function. The proportioning section of the P&B valve proportions outlet pressure to the rear brakes after a predetermined rear input pressure has been reached. This is done to prevent rear wheel lock up on the vehicles with light rear wheel loads. The valve has a pass feature which assures full system pressure to the rear brakes in the event of front brake system malfunction. Also full front pressure is retained in the event of rear brake malfunction. The combination valve has a pressure differential warning switch which is designed to constantly compare front and rear brake pressure from the master cylinder and turn on the brake system warning light on the instrument panel in the event of a front or rear system malfunction. The valve and switch are so designed that the switch will latch in the warning position once a malfunction has occured. The only way the light can be turned off is to repair the malfunction and apply a pedal forced required to developed line pressure. The P&B valve is not repairable and must be replaced as a complete assembly.

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Installation
1. Install P&B valve (2). 2. Install bolt (3) and tighten the bolt to the specified torque. Torque: 13 Nm (113 lb in) 3. Install hydraulic pipes (1) and tighten the bolt to the specified torque. Torque: 16 Nm (12 lb ft) 4. After installing the brake pipes, bleed the brakes refering to Bleeding Brake Hydraulic System in this section.

POWER ASSISTED BRAKE SYSTEM

5C15

Main Data and Specifications

Torque Specifications

E05RW001

5C16 POWER ASSISTED BRAKE SYSTEM

Brake Pedal
Checking Pedal Height
The push rod serves as the brake pedal stopper when the pedal is fully released. Brake pedal height adjustment should be performed as follows:

Adjust Brake Pedal

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NOTE: While adjusting the stoplight switch, make sure that the threaded part of the stoplight switch does not push the brake pedal. h. Tighten the stoplight switch lock nut. i. Connect the stoplight switch connector.
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1. Measure the brake pedal height after making sure the pedal is fully returned by the pedal return spring. Pedal height must be measured after starting the engine and receiving it several times. Pedal Free Play : 6-10 mm (0.23-0.39 in) Pedal Free Play : 208-218 mm (8.19-8.58 in) NOTE: Pedal free play must be measured after turning off the engine and stepping on the brake pedal firmly five times or more. 2. If the measured value is not within the above range, adjust the brake pedal as follows: a. Disconnect the stoplight switch connector. b. Loosen the stoplight switch lock nut (1). c. Rotate the stoplight switch so that is moves away from the brake pedal. d. Loosen the lock nut on the push rod. e. Adjust the brake pedal to the specified height by rotating the push rod in the appropriate direction. f. Tighten the lock nut to the specified torque. Torque: 20 Nm (15 lb ft) g. Adjust the stoplight switch to the specified clearance (between the switch housing and the brake pedal) by rotating the switch housing. Clearance : 00.2 mm (00.008 in)

Checking Pedal Travel

310RW001

1. Pedal height (3) must be measured after starting the engine and revving it several times to apply vacuum to the vacuum booster fully. NOTE: Pedal height (3) must be 100 mm (3.9 in) or more when about 50 kg (110.25 lb) of stepping force is applied. 2. If the measured value is lower than the above range, air existing in the hydraulic system is suspected. Perform the bleeding procedure.

POWER ASSISTED BRAKE SYSTEM

5C17

Brake Pedal and Associated Parts

310RW003

Legend (1) Nut (2) Stoplight Switch Connector (3) Fulcrum Pin (4) Driver Knee Bolster Assembly (5) Lower Cluster Assembly (6) Shift Knob

(7) (8) (9) (10) (11) (12) (13)

Front Console Assembly Instrument Panel Driver Lower Cover Return Spring Brake Pedal Snap Pin Pin Antitheft Controller

Removal
1. Remove shift knob. 2. Remove front console assembly. 3. Remove lower cluster assembly. 4. Remove instrument panel driver lower cover. 5. Remove driver knee bolster assembly. 6. Remove antitheft controller. 7. Remove stoplight switch connector. 8. Remove return spring. 9. Remove snap pin. 10. Remove pin. 11. Remove nut. 12. Remove fulcrum pin. 13. Remove brake pedal.

Installation
1. Install brake pedal. 2. Install fulcrum pin and apply grease to the entire circumference of the fulcrum pin. Torque: 33 Nm (24 lb ft) 3. Install nut and tighten the nut to the specified torque. Torque: 33 Nm (24 lb ft) 4. Install pin and apply grease to the entire circumference of the push rod pin. 5. Install snap pin and adjust the pedal free travel Refer to Brake Pedal Adjustment previously in this section. 6. Install return spring. 7. Connect stoplight switch connector. 8. Connect antitheft connector. 9. Install driver knee bolster assembly. 10. Install instrument panel driver lower cover.

5C18 POWER ASSISTED BRAKE SYSTEM

11. Install lower cluster assembly. 12. Install front console assembly. 13. Install shift knob.

Stoplight Switch
Removal
1. Remove shift knob. 2. Remove front console assembly. 3. Remove lower cluster assembly. 4. Remove instrument panel driver lower cover. 5. Remove driver knee bolster assembly. 6. Remove stoplight switch connector (3). 7. Remove lock nut (1). 8. Remove switch (2).

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2. Install lock nut. 3. Connect stoplight switch connector. 4. Install driver knee bolster assembly. 5. Install instrument panel driver lower cover. 6. Install lower cluster assembly. 7. Install front console assembly. 8. Install shift knob.

310RW004

Installation
1. Install switch and adjust the stoplight switch to the specified clearance (between the switch housing and the brake pedal) by rotating the switch housing. Clearance (1): 0-0.2 mm (0-0.009 in) NOTE: While adjusting the installation of the stoplight switch, make sure that the threaded part of the stoplight switch does not push the brake pedal.

POWER ASSISTED BRAKE SYSTEM

5C19

Main Data and Specifications

General Specifications
Pedal free play Pedal Height 610 mm (0.23 0.39 in) 208218 mm (8198.58 in)

Torque Specifications

E05RW002

5C20 POWER ASSISTED BRAKE SYSTEM

Fluid Reservoir Tank

Fluid Reservoir Tank and Associated Parts

330RW003

Legend (1) Fluid Reservoir (2) Electrical Connector

(3) Oring (4) Retainer

Removal
NOTE: Before removing the fluid reservoir, remove the brake fluid from the fluid reservoir. 1. Disconnect electrical connector. 2. Remove retainer (1).

Installation
To install, follow the removal steps in the reverse order, noting the following points: 1. Oring (1) must be set onto the fluid reservoir (2), before installing fluid reservoir.

330RW005 330RW004

3. Remove fluid reservoir and the fluid lever sensor built into the fluid reservoir . The fluid level sensor cannot be removed for servicing. 4. Remove Oring.

POWER ASSISTED BRAKE SYSTEM

5C21

Master Cylinder Assembly

Master Cylinder Assembly and Associated Parts

330RW006

Legend (1) Electrical Connector (2) Master Cylinder (3) 2 attaching Nuts

(4) P&B Valve and Bracket (5) Brake Pipes (6) Spacer and 2 gaskets

Removal
CAUTION: When removing the master cylinder from the vacuum booster, be sure to get rid of the internal negative pressure of the vacuum booster (by, for instance, disconnecting the vacuum hose) in advance. If any negative pressure remains in the vacuum booster, the piston may possibly come out when the master cylinder is being removed, letting the brake fluid run out. While removing the master cylinder, further, do not hold the piston as it can be easily pulled out. Outside surface of the piston is the surface on which seals are to slide. Care should be taken to keep the surface free of cuts and dents. 1. Disconnect electrical connector. 2. Remove brake pipes after disconnecting the brake pipe, cap or tape the openings of the brake pipe to prevent the entry of foreign matter. 3. Remove 2 attaching nuts.

4. Remove P&B valve and bracket. 5. Remove master cylinder. 6. Remove spacer and the 2 gaskets.

Inspection and Repair

Master Cylinder
The master cylinder is not repairable and must be replaced as a complete assembly if found defective.

Inspection
Excessive brake pedal travel, malfunction or dragging brake suggests that the master cylinder is defective. In such cases perform the following visual check. Visual Check Make parts replacement as required if wear, distortion, nicks, cuts, corrosion, or other abnormal conditions are found through the following parts inspection: D Master cylinder body D Fluid reservoir

5C22 POWER ASSISTED BRAKE SYSTEM

D Oring There should be a pressure increase of 0.5 kg/cm@ or more.

Functional Inspection of Master Cylinder Piston

Push the primary piston (1) with your fingers to check that it travels smoothly. If the motion is questionable, replace the master cylinder as a complete assembly.

330RW009

NOTE: When checking the front (or primary) side, be sure to mount the master cylinder plug in the rear (or secondary) port.
330RW007

0 Line Apply air pressure to the front and rear ports Remarks No pressure rise. Checks port into the atmospheric pressure chamber

5 Line Pressure increase of 0.5 kg/cm@ or more Checks air tightness of the pressure chamber

Functional Inspection of Master Cylinder

Inspect the master cylinder for function as follows. If any abnormal function is found, replace with a new one. (including the master cylinder attachment and master cylinder plug (7)) Install the primary piston holder (3) J39242 onto the master cylinder (4). Make sure the spacer (2) (2 bolts) with its adjusting bolt is screwed in up to the 0 line

NOTE: 1. Do not use an air compressor, as the air from the compressor is mixed with compressor oil. 2. When installing the master cylinder onto the vacuum booster, always adjust the vacuum booster push rod. (Refer to Vacuum Booster in this section). 3. After the master cylinder is installed onto the vehicle, check for leakage, pedal travel and pedal free play.

Installation
1. Install spacer and the 2 gaskets. 2. Install master cylinder, when replacing the master cylinder or vacuum booster or both, always measure the vacuum booster push rod protrusion and adjust it as necessary (Refer to Vacuum Booster in section). 3. Install P&B valve and bracket. 4. Install 2 attaching nuts and tighten the attaching nuts to the specified torque. Torque: 13 Nm (113 lb in)

330RW008

Connect the master cylinder attachment (5) J39242 with the end of the radiator cap tester (6) J2446001, and apply air pressure with the cap tester. Make sure there is no rise in pressure and that with the adjusting bolt further screwed in 5 mm (align the adjusting bolt to the 5 line).

POWER ASSISTED BRAKE SYSTEM

5. Install brake pipes and tighten the brake pipe to the specified torque. Master cylinder side Torque: 12 Nm (104 lb in) Others Torque: 16 Nm (12 lb ft) 6. Connect electrical connector.

5C23

Main Data and Specifications

General Specifications
Type Piston bore diameter Dualcircuit 25.4 mm (1.000 in)

Torque Specifications

E05RW003

5C24 POWER ASSISTED BRAKE SYSTEM

Special Tools
ILLUSTRATION TOOL NO. TOOL NAME

J-39242 Primary Piston Holder (including master cylinder attachment and master cylinder plug

J-24460-01 Radiator Cap Tester

POWER ASSISTED BRAKE SYSTEM

5C25

Vacuum Booster Assembly

Vacuum Booster Assembly and Associated Parts

331RW001

Legend (1) Pin (2) Vacuum Booster Fixing Nut (3) Vacuum Hose

(4) Master Cylinder (5) Vacuum Booster (6) Snap Pin

Removal
1. Before removing the vacuum booster assembly, disconnect and remove the brake pipes. 2. Remove master cylinder, refer to Master Cylinder Removal in this section. CAUTION: When removing the master cylinder from the vacuum booster, be sure to get rid of the internal negative pressure of the vacuum booster (by, for instance, disconnecting the vacuum hose) in advance. If any negative pressure remains in the vacuum booster, the piston may possibly come out when the master cylinder is being removed, letting the brake fluid run out. While removing the master cylinder, further, do not hold the piston as it can be easily pulled out.

Outside surface of the piston is the surface on which seals are to slide. Care should be taken to keep the surface free of cuts and dents. 3. Remove vacuum hose. 4. Disconnect the yoke clevis from the brake pedal. 5. Remove vacuum booster fixing nut. 6. Remove vacuum booster.

Inspection and Repair

Vacuum Hose
1. Inspect the check valve (2), which is installed inside the vacuum hose. 2. Air should pass freely from the vacuum booster (3) to the engine (1).

5C26 POWER ASSISTED BRAKE SYSTEM

3. Air should not pass from the engine (1) to the vacuum booster (3). If it does, the check valve is inoperative and must be replaced. 3. Set push rod gauge J39216 on vacuum booster, and apply negative pressure by means of vacuum pump J23738A so that the pressure in the vacuum booster becomes 500 mm Hg. NOTE: Be sure to apply NEGATIVE pressure after installing a push rod gauge on the vacuum booster.

360RW001

Installation
1. Install vacuum booster and vacuum booster push rod adjustment. NOTE: When replacing either the master cylinder or vacuum booster, be sure to measure push rod, and adjust if required. 2. Remove retainer from vacuum booster front shell using a small screwdriver. Then gently draw plate and seal assembly out of the shell inside.
331RS004

4. Measure dimension (4). Dimension (4) (Standard): 0.10.1 mm (0.00390.0039 in)

331RW002

331RS003

POWER ASSISTED BRAKE SYSTEM

5. If dimension (4) is out of the standard range, adjust push rod using the Push Rod Support J39241.

5C27

331RW003

6. Mount plate and seal assembly in vacuum booster front shell. Then install the retainer. 7. Install vacuum booster fixing nut and tighten the specified torque. Torque: 21 Nm (16 lb ft) 8. Install yoke clevis. 9. Connect vacuum hose and make sure that the arrow on the hose points in the direction of the engine. 10. Install master cylinder, refer to Master Cylinder Installation in this section.

5C28 POWER ASSISTED BRAKE SYSTEM

Exterior Components
Exterior Components and Associated Parts

331RW004

Legend (1) Yoke Clevis (2) Lock Nut (3) Retaining Clip (4) Valve Body Guard (5) Silencer

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

Filter 2 Gaskets and Spacer Vacuum Booster Retainer Plate and Seal Assembly Master Cylinder

Removal
1. Remove master cylinder, refer to Master Cylinder in this section. 2. Remove vacuum booster, refer to Vacuum Booster in this section. 3. Remove yoke clevis. 4. Remove lock nut. 5. Remove retaining clip. 6. Remove valve body guard. 7. Remove silencer. 8. Remove filter. 9. Remove 2 gaskets and spacer. 10. Remove retainer, use a small screwdriver to pry out the retainer. Gently pull out the plate and seal assembly from the shell.
331RS003

POWER ASSISTED BRAKE SYSTEM

11. Remove plate and seal assembly.

5C29

Inspection and Repair

Visual Check
Make necessary parts replacement if cuts, nicks, excessive wear, or other abnormal conditions are found through inspection. Check the following parts: D Yoke clevis D Valve body guard D Silencer D Filter plate and seal assembly

2. Install retainer. 3. Install 2 gaskets and spacer. 4. Install filter. 5. Install silencer. 6. Install valve body guard. 7. Install retainer. 8. Install lock nut and tighten to the specified torque. Torque: 20 Nm (15 lb ft) 9. Install yoke clevis. 10. Install vacuum booster, refer to Vacuum Booster in this section. 11. Install master cylinder, refer to Master Cylinder in this section and after installation, perform brake pedal check and adjustment. Refer to Brake Pedal in this section.

Installation
1. Install plate and seal assembly.

Vacuum Booster Overhaul

Vacuum Booster
The vacuum booster cannot be disassembled for repair. Replace a defective vacuum booster with a new one.

5C30 POWER ASSISTED BRAKE SYSTEM

Main Data and Specifications

General Specifications
Vacuum booster diaphragm diameter (Front) Vacuum booster diaphragm diameter (Rear) Push rod stroke Plunger diameter Push rod diameter 205 mm (8.07 in) 230 mm (9.06 in) More than 32.0 mm (1.26 in) 10.25 mm (0.40 in) 27.4 mm (1.08 in)

Torque Specifications

C05RT003

POWER ASSISTED BRAKE SYSTEM

5C31

Special Tools
ILLUSTRATION TOOL NO. TOOL NAME

J-39216 Push Rod Gauge

J-23738-A Vacuum Pump

J-39241 Push Rod Support

5C32 POWER ASSISTED BRAKE SYSTEM

Front Disc Brake Pads

Front Disc Brake Pads Inspection
Check the outer pad by looking at each caliper from above. Check the thickness on the inner pad by looking down through the inspection hole in the top of the caliper. Whenever the pad is worn to about the thickness of the pad base, the pad should be removed for further measurements. The pad should be replaced anytime the pad thickness (1) is worn to within 1.00 mm (0.039 in) of the pad itself. The disc pads have a wear indicator that makes a noise when the pad wears to where replacement is required. Minimum limit (1): 1.0 mm (0.039 in)

302RS002

Front Disc Brake Pads and Associated Parts

302RW003

Legend (1) Lock Bolt (2) Caliper Assembly

(3) Pad Assembly (4) Clip (5) Outer Side

POWER ASSISTED BRAKE SYSTEM

5C33

Removal
NOTE: If a squealing noise occurs from the front brake while driving, check the pad wear indicator plate. If the indicator plate contacts the rotor, the disc pad assembly should be replaced. D Draw out twothirds of the brake fluid from the reservoir. D Raise the vehicle and support it with suitable safety stands. 1. Remove wheel and tire assembly, refer to Wheels and Tires System in Section 3E. 2. Remove lock bolt (1).

302RS005

2. Install pad assembly with shim and apply special grease (approximately 0.2 g) to both contacting surfaces of the inner shims (2). Wipe off extruded grease after installing.

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3. Remove caliper assembly and support the caliper assembly so that the brake hose is not stretched or damaged. 4. Remove pad assembly with shim. 5. Remove Clip.

Installation
1. Install clip.
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Legend (2) Inner Shim (3) Wear Indicator (4) Inner Side

5C34 POWER ASSISTED BRAKE SYSTEM

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302RW007

3. Install caliper assembly, use adjustable pliers to bottom the piston into the caliper bore. Be careful do not damage the piston boot and do not damage the flexible hose by twisting or pulling it.

5. Install wheel and tire assembly, refer to Wheels and Tires System in Section 3E. 6. Pump the brake pedal several times to make sure that the pedal is firm. Check the brake fluid level in the reservoir after pumping the brakes.

302RS008

4. Install lock bolt (5) and tighten the bolt to the specified torque. Torque: 74 Nm (54 lb ft)

POWER ASSISTED BRAKE SYSTEM

5C35

Front Disc Brake Rotor

Inspection
In the manufacturing of the brake rotor, all the tolerances regarding surface finish, parallelism and lateral runout are held very closely. Maintaining these tolerances provides the surface necessary to assure smooth brake operation. The rotor thickness must not vary more than 0.010 mm (0.0004 in) from point to point. Maximum runout: 0.010 mm (0.0004 in)

Lateral Runout
Lateral runout is the movement of the rotor from side to side as it rotates on the spindle. This could also be referred to as rotor wobble. This movement causes the piston to be knocked back into its bore. This results in additional pedal travel and a vibration during braking.

Checking Lateral Runout

1. Adjust the wheel bearing correctly, refer to Differential in Section 4A. 2. Attach a dial indicator to some portion of the suspension so that the stem contacts the rotor face about 29 mm (1.14 in) from the rotor edge. 3. Move the rotor one complete rotation and the lateral runout should not exceed 0.13 mm (0.005 in). Maximum runout: 0.13 mm (0.005 in)
411RS018

Replacing Brake Rotors

When installing new brake rotors, do not refinish the surfaces. These parts are at the correct level of surface finish.

Refinishing Brake Rotors

Accurate control of the rotor tolerances is necessary for proper performance of the disc brakes. Machining of the rotor should be done only with precision equipment. All brake rotors have a minimum thickness dimension cast into them. This dimension is the minimum wear dimension and not a refinish dimension. The minimum wear dimension is 24.60 mm (0.969 in). The minimum refinish dimension is 24.97 mm (0.983 in). When refinishing rotors, always use sharp cutting tools or bits. Dull or worn tools leave a poor surface finish which will affect initial braking performance. Vibration dampening attachments should always be used when refinishing braking surfaces. These attachments eliminate tool chatter and will result in better surface finish.

411RS019

Parallelism
Parallelism is the measurement of thickness of the rotor at four or more points around the circumference of the rotor. All measurements must be made 29 mm (1.14 in) from the edge of the rotor.

5C36 POWER ASSISTED BRAKE SYSTEM

After refinishing, replace any rotor that does not meet the minimum thickness of 24.97 mm (0.983 in). Do not use a brake rotor that will not meet the specification. Minimum wear dimension: 24.60 mm (0.969 in) Refinish dimension: 24.97 mm (0.983 in)

411RW003

POWER ASSISTED BRAKE SYSTEM

5C37

Front Disc Brake Caliper Assembly

Front Disc Brake Caliper Assembly and Associated Parts

302RW008

Legend (1) Guide Bolt (2) Brake Flexible Hose (3) Lock Bolt

(4) (5) (6) (7)

Caliper Assembly Clip Support Bracket with Pad Assembly Pad Assembly

Removal
1. Raise the vehicle and support with suitable safety stands. 2. Wheel and tire assembly, refer to Wheels and Tires System in Section 3E. 3. Remove the bolt and gaskets, then disconnect the flexible hose from the caliper and after disconnecting the flexible hose (1), cap or tape the openings to prevent entry of foreign material.

302RW009

5C38 POWER ASSISTED BRAKE SYSTEM

4. Since the brake fluid flows out from the connecting coupler, place a drain pan under the vehicle. 5. Remove guide bolt (2). 6. Remove lock bolt (3). 2. Install pad assembly with shim and apply special grease (approximately 0.2 g) to both contacting surfaces of the inner shims (6). Wipe off extruded grease after installing.

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7. Remove caliper assembly. 8. Remove support bracket with pad assembly and take care not to damage the flexible brake hose when removing the support bracket. 9. Remove pad assembly with shim and mark the lining locations if they are to be reinstalled. 10. Remove clip.

Legend (4) Inner Shim (5) Wear Indicator (6) Inner Side 3. Install support bracket and tighten the bolt (7) to the specified torque. Torque: 155 Nm (115 lb ft)

Installation
1. Install clip.

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4. Install caliper assembly.

302RS005

POWER ASSISTED BRAKE SYSTEM

5. Install lock bolt (9) and guide bolt (8) and tighten the bolt to the specified torque. Torque: 74 Nm (54 lb ft)

5C39

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6. Install brake flexible hose, always use new gaskets and be sure to put the hooked edge of the flexible hose end into the antirotation cavity then tighten the Ibolt (10) to the specified torque. Torque: 35 Nm (26 lb ft)

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7. Install wheel and tire assembly, refer to Wheels and Tires System in Section 3E. 8. Bleed brakes. Refer to Hydraulic Brakes in this section.

5C40 POWER ASSISTED BRAKE SYSTEM

Front Disc Brake Caliper

Front Disc Brake Caliper Disassembled View

302RW015

Legend (1) Guide Bolt (2) Lock Bolt (3) Bleeder with Cap (4) Caliper Body

(5) (6) (7) (8) (9)

Dust Boot: Guide Bolt and Lock Bolt Piston Seal Piston Dust Boot: Piston Dust Boot Ring

Disassembly
1. Remove guide bolt. 2. Remove lock bolt. 3. Remove dust boot: guide bolt and lock bolt. 4. Remove dust boot ring, using a small screwdriver, remove the dust boot ring.

302RS016

POWER ASSISTED BRAKE SYSTEM

5. Insert a block of wood into the caliper and force out the piston by blowing compressed air into the caliper at the flexible hose attachment. This procedure must be done prior to removal of the dust boot. WARNING: DO NOT PLACE YOUR FINGERS IN FRONT OF THE PISTON IN AN ATTEMPT TO CATCH OR PROTECT IT WHEN APPLYING COMPRESSED AIR. THIS COULD RESULT IN PERSONAL INJURY. CAUTION: Use just enough air to ease the piston out of the bore. If the piston is blown out, it may be damaged.

5C41

Reassembly
1. Install caliper body. 2. Install bleeder with cap and tighten the cap to the specified torque. Torque: 8 Nm (69 lb in) 3. Install piston seal and apply special rubber grease to the piston seal and cylinder wall, then insert the piston seal into the cylinder. The special rubber grease is included in the repair kit.

302RS018

302RS017

6. Remove dust boot: piston. 7. Remove piston seal. 8. Remove bleeder with cap. 9. Remove caliper body.

4. Install piston. 5. Install piston dust boot; when inserting the piston into the cylinder, use finger pressure only and do not use a mallet or other impact tool, since damage to the cylinder wall or piston seal can result.

Inspection and Repair

Make necessary parts replacement, if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: D Rotor D Cylinder body D Cylinder bore D Piston D Guide bolt, lock bolt D Support bracket NOTE: The piston seal, boot ring and dust boot are to be replaced each time the caliper is overhauled. Discard these used rubber parts and replace them with new ones.
302RS019

5C42 POWER ASSISTED BRAKE SYSTEM

6. Install dust boot ring and apply special grease (approximately 1 g) to the piston and attach the dust boot to the piston and caliper. Insert the dust boot ring into the dust boot.

302RS020

7. Install guide bolt and lock bolt dust boot. 8. Install lock bolt and guide bolt and tighten the bolt to the specified torque. Torque: 74 Nm (54 lb ft) 9. Install the dust boot on the support bracket after applying special grease (approximately 1 g) onto the dust boot inner surface. Apply special grease onto the lock bolt and guide bolt setting hole of the support bracket.

302RS021

POWER ASSISTED BRAKE SYSTEM

5C43

Main Data and Specifications

General Specifications
Type Pad dimension Adjusting method Piston diameter Disc type Disc thickness Disc effective diameter Floating, pin slide 55 cm@ (8.52 in@) Selfadjusting 60.33 mm (2.38 in) Ventilated 26 mm (1.02 in) 222 mm (8.74 in)

Torque Specifications

E05RW004

5C44 POWER ASSISTED BRAKE SYSTEM

Rear Disc Brake Pads

Brake Pads Inspection
Check the outer pads by looking at each caliper from above. Check the thickness on the inner pad by looking down through the inspection hole in the top of the caliper. Whenever the pad is worn to about the thickness of the pad base, the pad should be removed for further measurements. The pad should be replaced anytime the pad thickness (1) is worn to within 1.0 mm (0.039 in) of the pad itself. The disc pads have a wear indicator that makes a noise when the pad wears to where replacement is required. Minimum limit (1): 1.0 mm (0.039 in)

302RW016

Brake Pads and Associated Parts

306RW001

Legend (1) Caliper Assembly (2) Clip

(3) Lock Bolt (4) Pad Assembly

POWER ASSISTED BRAKE SYSTEM

5C45

Removal
NOTE: If a squealing noise occurs from the rear brake while driving, check the pad wear indicator plate. If the indicator plate contacts the rotor, the disc pad assembly should be replaced. D Draw out twothirds of the brake fluid from the reservoir. D Raise the vehicle and support it with suitable safety stands. 1. Remove wheel and tire assembly, refer to Wheels and Tires System in Section 3E. 2. Remove lock bolt (1)

306RW003

2. Install pad assembly with shim and apply special grease (approximately 0.2 g) to both contacting surfaces of the inner shims. Wipe off extruded grease after installing.

306RW002

3. Remove caliper assembly and support the caliper assembly so that the brake hose is not stretched or damaged. 4. Remove pad assembly with shim. 5. Remove clip.

Installation
1. Install clip (2).
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Legend (3) Inner Shim (4) Wear Indicator

5C46 POWER ASSISTED BRAKE SYSTEM

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306RW006

3. Install caliper assembly, use adjustable pliers to bottom the piston into the caliper bore. Be careful not to damage the piston dust boot and do not damage the flexible hose by twisting or pulling it.

302RS008

4. Install lock bolt (5) and tighten the bolt to the specified torque. Torque: 44 Nm (32 lb ft) 5. Install wheel and tire assembly, refer to Wheels and Tires System in Section 3E. 6. Pump the brake pedal several times to make sure that the pedal is firm. Check the brake fluid level in the reservoir after pumping the brakes.

POWER ASSISTED BRAKE SYSTEM

5C47

Rear Disc Brake Rotor

Inspection
In the manufacturing of the brake rotor, all the tolerances regarding surface finish, parallelism and lateral runout are held very closely. Maintaining these tolerances provides the surface necessary to assure smooth brake operation. The rotor thickness must not vary more than 0.010 mm (0.0004 in) from point to point. Maximum parallelism: 0.001 mm (0.0004 in)

Lateral Runout
Lateral runout is the movement of the rotor from side to side as it rotates on the spindle. This could also be referred to as rotor wobble. This movement causes the piston to be knocked back into its bore. This results in additional pedal travel and a vibration during braking.

Checking Lateral Runout

1. Adjust the wheel bearing correctly, refer to Differential in Section 4A. 2. Attach a dial indicator to some portion of the suspension so that the stem contacts the rotor face about 29 mm (1.14 in) from the rotor edge. 3. Move the rotor one complete rotation. 1. The lateral runout should not exceed 0.13 mm (0.005 in) Maximum runout: 0.13 mm (0.005 in)

420RS013

Replacing Brake Rotors

When installing new brake rotors, do not refinish the surfaces. These parts are at the correct level of surface finish.

Refinishing Brake Rotors

Accurate control of the rotor tolerances is necessary for proper performance of the disc brakes. Machining of the rotor should be done only with precision equipment. All brake rotors have a minimum thickness dimension cast into them. This dimension is the minimum wear dimension and not a refinish dimension. The minimum wear dimension is 16.6 mm (0.654 in). The minimum refinish dimension is 16.97 mm (0.668 in). When refinishing rotors, always use sharp cutting tools or bits. Dull or worn tools leave a poor surface finish which will affect initial braking performance. Vibration dampening attachments should always be used when refinishing braking surfaces. These attachments eliminate tool chatter and will result in better surface finish.

411RS019

Parallelism
Parallelism is the measurement of thickness of the rotor at four or more points around the circumference of the rotor. All measurements must be made 22 mm (0.87 in) from the edge of the rotor.

5C48 POWER ASSISTED BRAKE SYSTEM

After refinishing, replace any rotor that does not meet the minimum thickness of 16.97 mm (0.668 in). Do not use a brake rotor that will not meet the specification. Minimum wear dimension: 16.6 mm (0.654 in) Refinish dimension: 16.97 mm (0.668 in)

420RW002

Rear Drum (In Disc) Inside Diameter Check

Check the rear drum inside diameter by measuring at more than two portions as shown in the illustration. If the inside diameter is greater than the limit, replace the rear rotor. Standard: 210.0 mm (8.27 in) Limit: 211.4 mm (8.32 in)

420RS035

POWER ASSISTED BRAKE SYSTEM

5C49

Rear Disc Brake Caliper Assembly

Rear Disc Brake Caliper Assembly and Associated Parts

306RW007

Legend (1) Brake Flexible Hose (2) Clip (3) Lock Bolt

(4) (5) (6) (7)

Support Bracket Guide Bolt Pad Assembly with Shim Caliper Assembly

Removal
1. Raise the vehicle and support with suitable safety stands. 2. Remove wheel and tire assembly, refer to Wheels and Tires System in Section 3E. 3. Remove the bolt and gaskets, then disconnect the flexible hose from the caliper and after disconnecting the flexible hose (1), cap or tape the openings to prevent entry of foreign material.

4. Since the brake fluid flows out from the connecting coupler, place a drain pan under the vehicle. 5. Remove lock bolt (2). 6. Remove guide bolt (3).

306RW009

306RW008

7. Remove caliper assembly. 8. Remove support bracket with pad assembly and take care not to damage the flexible brake hose when removing the support bracket. 9. Remove pad assembly (with shim) and mark the lining locations if they are to be reinstalled.

5C50 POWER ASSISTED BRAKE SYSTEM

10. Remove clip. 3. Install support bracket and tighten the bolt (7) to the specified torque. Torque: 103 Nm (76 lb ft)

Installation
1. Install clip (4).

306RW012

306RW010

2. Install pad assembly (with shim) and apply special grease (approximately 0.2 g) to both contacting surfaces of the inner shims (5). Wipe off extruded grease after installing.

4. Install caliper assembly. 5. Install lock bolt and guide bolt (8) and tighten the bolt to the specified torque. Torque: 44 Nm (32 lb ft)

306RW013 306RW011

Legend (5) Inner Shim (6) Wear indicator

POWER ASSISTED BRAKE SYSTEM

6. Install brake flexible hose, always use new gaskets and be sure to put the hooked edge of the flexible hose end into the antirotation cavity then tighten the Ibolt (9) to the specified torque. Torque: 35 Nm (26 lb ft)

5C51

302RW017

7. Install the wheel and tire assembly, refer to Wheels and Tires System in Section 3E. 8. Bleed brakes. Refer to Hydraulic Brakes in this section.

5C52 POWER ASSISTED BRAKE SYSTEM

Rear Disc Brake Caliper

Rear Disc Brake Caliper Disassembled View

306RW014

Legend (1) Guide Bolt (2) Lock Bolt (3) Bleeder with Cap (4) Caliper Body

(5) (6) (7) (8) (9)

Piston Seal Piston Dust Boot: Piston Dust Boot Ring Dust Boot: Guide Bolt and Lock Bolt

Disassembly
1. Remove guide bolt. 2. Remove lock bolt. 3. Remove dust boot; guide bolt and lock bolt. 4. Remove the dust boot ring using a small screwdriver.

302RS016

POWER ASSISTED BRAKE SYSTEM

5. Insert a block of wood into the caliper and force out the piston by blowing compressed air into the caliper at the flexible hose attachment. This procedure must be done prior to removal of the dust boot. WARNING: DO NOT PLACE YOUR FINGERS IN FRONT OF THE PISTON IN AN ATTEMPT TO CATCH OR PROTECT IT WHEN APPLYING COMPRESSED AIR. THIS COULD RESULT IN PERSONAL INJURY. CAUTION: Use just enough air to ease the piston out of the bore. If the piston is blown out, it may be damaged.

5C53

Reassembly
1. Install caliper body. 2. Install bleeder with cap and tighten the cap to the specified torque. Torque: 8 Nm (69 lb ft) 3. Install piston seal and apply special rubber grease to the piston seal and cylinder wall, then insert the piston seal into the cylinder. The special rubber grease is included in the repair kit.

302RS018

302RS017

6. Remove dust boot: piston. 7. Remove piston seal. 8. Remove bleeder with cap. 9. Remove caliper body.

4. Install piston. 5. Install piston dust boot; when inserting the piston into the cylinder, use finger pressure only and do not use a mallet or other impact tool, since damage to the cylinder wall or piston seal can result.

Inspection and Repair

Make necessary parts replacement, if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: D Rotor D Cylinder body D Cylinder bore D Piston D Guide bolt, lock bolt D Support bracket NOTE: The piston dust seal and dust boot are to be replaced each time the caliper is overhauled. Discard these used rubber parts and replace with new ones.
302RS019

5C54 POWER ASSISTED BRAKE SYSTEM

6. Install dust boot ring and apply special grease (approximately 1g) to the piston and attach the dust boot to the piston and caliper. Insert the dust boot ring into the dust boot.

302RS020

7. Install guide bolt and lock bolt dust boot. 8. Install lock bolt and guide bolt and tighten the bolt to the specified torque. Torque: 74 Nm (54 lb ft) 9. Install the dust boot on the support bracket after applying special grease (Approx. 1g) onto the dust boot inner surface. Also apply special grease onto the lock bolt and guide bolt setting hole of the support bracket.

302RS021

POWER ASSISTED BRAKE SYSTEM

5C55

Main Data and Specifications

General Specifications
Type Pad dimension Adjusting method Piston diameter Disc type Disc thickness Disc effective diameter Floating, pin slide 33 cm@ (5.11 in@) Selfadjusting 41.3 mm (1.63 in) Ventilated 18 mm (0.71 in) 269.2 mm (10.60 in)

Torque Specifications

E05RW005

SECTION
PARKING BRAKE
TROOPER

5D1

BRAKES
PARKING BRAKE SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake Lever and Front Cable . . . . . . Parking Brake Lever, Front Cable and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D1 5D1 5D2 5D3 5D3 5D3 5D4 Parking Brake Rear Cable . . . . . . . . . . . . . . . . Parking Brake Rear Cable and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Parking Brake Adjustment . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . 5D5 5D5 5D5 5D6 5D7 5D7 5D8

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

General Description
Pulling up the parking brake lever by hand will set the parking brake. Once pulled up, the lever is held by a ratchettype lock until it is released. The position of the lever is transmitted through cable/lever systems to the rear wheels. These parts are designed in order to obtain sufficient braking force when parking on slopes. When the parking brake is set, or when the ignition switch is in the ON position, the brake warning light illuminates. The rear wheel parking brake is a duoservo brake (mechanical inside expansion type) built into the rear disc brake. Parking brake adjustment is made through the adjusting hole bored through the back plate. Adjust the parking brake lever stroke to six or seven notches. Refer to Parking Brake Adjustment in this Section.

5D2 PARKING BRAKE

Operation

C05RW003

Legend (1) Strut (2) Fulcrum B (3) Parking Lever (4) Secondary Shoe (5) Adjusting Screw Notch

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

Parking Cable Guide Primary Shoe Parking Brake Cable Guide Adjusting Hole Plug Adjusting Screw Notch Shoe Expanding Direction

When pulled in the direction A, the parking lever presses the secondary shoe against the brake drum using the lever/shoe joint B as a fulcrum and pushes the strut in the direction C. The strut ,in turn, presses the primary shoe against the brake drum. Counter force D to the primary shoe is transmitted again to the secondary shoe through the fulcrum B. The secondary shoe contacts the drum thereby producing braking effect. Clearance which may result from worn parking brake shoe lining can be adjusted by turning the adjusting screw. Refer to Parking Brake Adjustment in this Section.

PARKING BRAKE

5D3

Parking Brake Lever and Front Cable

Parking Brake Lever, Front Cable and Associated Parts

311RW001

Legend (1) Parking Brake Lever (2) Bolt (3) Adjusting Nut

(4) Equalizer (5) Parking Brake Front Cable (6) Switch Connector

Removal
1. Remove adjusting nut (3). 2. Remove equalizer (4).

311RX001

5D4 PARKING BRAKE

3. Remove center console. (Refer to Section 10 Body.) 4. Remove bolts. 5. Disconnect switch connector. 6. Remove parking brake lever. 7. Remove parking brake front cable.

Installation
1. Install parking brake front cable. 2. Install parking brake lever and apply grease (BESCO L2 or equivalent) to front cable contact point. 3. Reconnect switch connector. 4. Install bolts and tighten the parking brake lever fixing bolt to the specified torque. Torque : 15 Nm (11 lb ft) 5. Install center console. (Refer to Section 10 Body.) 6. Install equalizer. 7. Install adjusting nut and adjust the parking brake lever. (See Parking Brake Adjustment in this section.)

PARKING BRAKE

5D5

Parking Brake Rear Cable

Parking Brake Rear Cable and Associated Parts

311RW003

Legend (1) Adjust Nut (2) Back Plate (3) Bolt (4) Holding Spring (5) Return Spring; Upper (6) Shoe Assembly (7) Return Spring; Lower

(8) (9) (10) (11) (12) (13) (14) (15)

Caliper Assembly Rotor (Drum) Rear Wheels Cable Fixing Bolt Clip Clip Clip Rear Cable

Removal
1. Remove adjusting nut. 2. Remove rear wheels.

3. Remove caliper assembly, remove two bolts to remove the caliper assembly from the support bracket. (Refer to Rear Disc Brakes in Disc Brakes in Section 5C). Temporarily hang the caliper with a wire in order to avoid stretching the brake hose. 4. Remove rotor (drum). 5. Remove clip (floor side).

5D6 PARKING BRAKE

6. Remove bolt. 7. Remove back plate. 8. Remove clip (frame side). 9. Remove clip (suspension side). 10. Remove holding spring. 11. Remove return spring; upper. 12. Remove return spring; lower. 13. Remove the brake shoe assembly. Then remove the parking brake cable from the parking brake lever (1).

308RS002

4. Install return spring; lower. 5. Install return spring; upper and the parking brake lever (3) side (secondary side) return spring must be installed on the outer side (2) of the primary side return spring.

308RW001

14. Remove cable fixing bolt. 15. Remove rear cable.

Installation
1. Install rear cable and apply grease (BESCO L2 or equivalent) to the connecting portion of the rear cable and the equalizer. 2. Install cable fixing bolt and tighten the cable fixing bolt to the specified torque. Torque: 6 Nm (52 lb in) 3. Install shoe assembly and after installation of the shoe and cable assembly, apply the special grease included in the repair kit to the portions indicated in the illustration.

308RW002

6. Install holding spring. 7. Install clip (suspension side) and tighten the bolt to the specified torque. Torque: 7.8 Nm (68 lb in) 8. Install clip (frame side) and tighten the bolt to the specified torque. Torque: 15 Nm (11 lb in) 9. Install back plate. 10. Install bolt and tighten the bolt to the specified torque. Torque: 6 Nm (52 lb in) 11. Install clip (floor side) and tighten the bolt to the specified torque. Torque: 15 Nm (11 lb in) 12. Install rotor.

PARKING BRAKE
13. Install caliper assembly. 14. Install rear wheels. 15. Install adjusting nut and apply grease (BESCO L2 or equivalent) to front cable contact point. 16. Tighten the adjusting nut to the specified torque and to adjust the parking brake, refer to Parking Brake Adjustment in this section. Torque: 6 Nm (52 lb in)

5D7

2. Adjustment of parking brake cable a. Turn the equalizer nut so that the parking brake lever travels 6 or 7 notches when pulled up with a force of 30 kg (66 lb). b. Make sure that there is no brake dragging and tighten the cable lock nut. Torque : 6 Nm (52 lb in) 3. Breakin of parking brake shoe D When poor braking is felt, or just after replacement of parking brake shoes, be sure to conduct the breakin procedure by driving the vehicle as follows: a. Forward 50 km/h (30 mph) 400 m (about 30 seconds) with a lever pull force of 15 kg (33 lb). b. Backward 10 km/h (6 mph) 50 m (about 18 seconds) with a lever pull force of 15 kg (33 lb). NOTE: Breakin procedures must be performed under safe conditions and traffic rules. D If the braking effect remains poor after the breakin, wait for some time until parking brake shoe cools down and repeat procedures a. and b. noted above. D On completion of breakin, inspect the parking brake lever stroke, and if the lever does not come within the specified number of notches when pulled up, readjust. D Excessive breakin may cause premature wear of the parking brake lining.

Inspection and Repair

Parking Brake Lining Inspection
Check the shoe assemblies for wear by removing the brake drum rotor. Replace the shoe assemblies if the lining thickness is less than 1.0 mm (0.039 in). Minimum limit: 1.0 m (0.039 in)

308RW003

Parking Brake Rotor (Drum) Inspection

Refer to Rear Disc Brakes in Section 5A2 for the inspection procedure of the rotor (drum).

Parking Brake Adjustment

1. Adjustment of parking brake assembly D Prior to lever stroke adjustment, adjust the rear brake shoe/rotor (drum) gap. Perform this procedure by loosening the adjusting nut of the equalizer. a. Remove the adjusting hole plug (rubber) and turn the shoe adjusting screw downward using a small screwdriver so that the shoes will expand until they get into close contact with the rotor. (Turn down the adjusting screw notch by notch until the rotor does not turn.) b. Turn the adjusting screw in the opposite direction (upward) until the rotor can be turned lightly. Standard number of notches to turn upward: 7 or 8. Turn the rotor in order to ensure that there is no brake dragging.

5D8 PARKING BRAKE

Main Data and Specifications

General Specifications
Rear parking brake Type Lining Dimension Adjusting Method Rotor (Drum) Inside Diameter Parking Brake Lever Stroke Duoservo 121.2 cm@ (18.79 in@) Manual adjusting 210 mm (8.27 in) 67 notches When pulled with a force of 30 kg (66 lb)

Torque Specifications

E05RW006

SECTION
ENGINE MECHANICAL
TROOPER

6A1

ENGINE
CONTENTS
Engine Mechanical . . . . . . . . . . . . . . . . . . . . . . Engine Cooling . . . . . . . . . . . . . . . . . . . . . . . . . Engine Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . . Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . Starting and Charging System . . . . . . . . . . . . 6A 6B 6C 6D1 6D2 6D3 Driveability and Emissions . . . . . . . . . . . . . . . . Engine Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . Engine Speed Control System . . . . . . . . . . . . Inducton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E 6F 6G 6H 6J

ENGINE MECHANICAL
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Engine Diagnosis . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head Cover LH . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head Cover RH . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Common Chamber . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Manifold LH . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Manifold RH . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Stem Oil Controller , Valve Spring and Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston, Piston Ring and Connecting Rod . . . 6A2 6A3 6A4 6A19 6A19 6A20 6A21 6A21 6A21 6A22 6A22 6A22 6A24 6A24 6A24 6A25 6A25 6A25 6A26 6A26 6A26 6A27 6A27 6A28 6A32 6A32 6A32 6A35 6A35 6A35 6A37 6A37 6A37 6A38 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft and Main Bearings . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head and Associated Parts . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Spring, Oil Controller, Valve, Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Clearance Adjustments . . . . . . . . . . . . . Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft and Associated Parts . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft and Associated Parts . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A38 6A39 6A40 6A40 6A41 6A45 6A45 6A45 6A46 6A46 6A47 6A49 6A49 6A50 6A50 6A50 6A51 6A53 6A53 6A53 6A54 6A57 6A58 6A60 6A60 6A60 6A61 6A63 6A66 6A66 6A67 6A67 6A68 6A70

6A2

ENGINE MECHANICAL
6A74 6A74 6A74 6A75 6A79 6A81 Cylinder Block and Associated Parts . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specification . . . . . . . . . . . . . . Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A81 6A81 6A82 6A83 6A86 6A92

Piston and Connecting Rod . . . . . . . . . . . . . . . Piston, Connecting Rod and Associate Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.

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

ENGINE MECHANICAL

6A3

General Description
Engine Cleanliness And Care
An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the thousandths of a millimeter (ten thousandths of an inch). Accordingly, when any internal engine parts are serviced, care and cleanliness are important. Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically stated. D A liberal coating of engine oil should be applied to all friction areas during assembly to protect and lubricate the surfaces on initial operation. D Whenever valve train components, pistons, piston rings, connecting rods, rod bearings, and crankshaft journal bearings are removed for service, they should be retained in order. D At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed. D Battery cables should be disconnected before any major work is performed on the engine. Failure to disconnect cables may result in damage to wire harness or other electrical parts. D The six cylinders of this engine are identified by numbers; Right side cylinders 1, 3 and 5, Left side cylinders 2, 4 and 6, as counted from crankshaft pulley side to flywheel side.

Cylinder Head
The cylinder head, made of aluminum alloy casting employs a pentroof type combustion chamber with a spark plug in the center. The intake and exhaust valves are placed in Vtype design. The ports are crossflow type.

Valve Train
Intake and exhaust camshaft on the both side of banks are driven through an camshaft drive gear by timing belt. The valves are operated by the camshaft and the valve clearance is adjusted to select suitable thickness shim.

Intake Manifold
The intake manifold system is composed of the aluminum cast common chamber and intake manifold attached with six fuel injectors.

Exhaust Manifold
The exhaust manifold is made of nodular cast iron.

Pistons and Connecting Rods

Aluminum pistons are used after selecting the grade that meets the cylinder bore diameter. Each piston has two compression rings and one oil ring. The piston pin is made of chromium steel is offset 1mm toward the thrust side, and the thrust pressure of piston to the cylinder wall varies gradually as the piston travels. The connecting rods are made of forged steel. The connecting rod bearings are graded for correct seze selection.

General Information on Engine Service

The following information on engine service should be noted carefully, as it is important in preventing damage and contributing to reliable engine performance: D When raising or supporting the engine for any reason, do not use a jack under the oil pan. Due to the small clearance between the oil pan and the oil pump strainer, jacking against the oil pan may cause damage to the oil pickup unit. D The 12volt electrical system is capable of damaging circuits. When performing any work where electrical terminals could possibly be grounded, the ground cable of the battery should be disconnected at the battery. D Any time the intake air duct or air cleaner is removed, the intake opening should be covered. This will protect against accidental entrance of foreign material into the cylinder which could cause extensive damage when the engine is started.

Crankshaft and Bearings

The crankshaft is made of Ductile castiron. Pins and journals are graded for correct size selection for their bearing.

Engine Lubrication
The oil discharged by a trochoidtype oil pump driven by the crankshaft is fed through fullflow oil filter and to the oil gallery provided under the crankshaft bearing cap. The oil is then led to the crankshaft journals and cylinder head. The crank pins are lubricated with oil from crankshaft journals through oil holes. Also, an oil jet is fed to each cylinder from crankshaft juornals on the connecting rod for piston cleaning. The oil pan flange is dealed with liquid packing only; do not deform or damage the flange surface during removal or installation.

Cylinder Block
The cylinder block is made of aluminum diecast casting for 75Vtype six cylinders. It has a rear plate integrated structure and employs a deep skint. The cylinder liner is cast and the liner inner diameter and crankshaft journal diameter are classified into grades. The crankshaft is supported by four bearings of which width of No.3 bearing on the body side is different in order to support the thrust bearing. The bearing cap is made of nodular cast iron and each bearing cap uses four bolts and two side bolts.

6A4

ENGINE MECHANICAL

Engine Diagnosis
Hard Starting
1. Starting Motor Does Not Turn Over Troubleshooting Procedure Turn on headlights and starter switch. Condition Headlights go considerably out or dim Possible cause Battery run down or under charged Terminals poorly connected Starting motor coil circuit shorted Starting motor defective Headlights stay bright Starting motor circuit open Starting motor coil open Correction Recharge or replace battery Clean battery posts and terminals and connect properly Overhaul or replace Overhaul or replace Refer to Starting and Charging System Replace

2. Ignition Trouble Starting Motor Turns Over But Engine Does Not Start Spark Test Disconnect an igniton coil from any spark plug. Connect the spark plug tester J26792 (ST125), start the engine, and check if a spark is generated in the spark plug tester. Before starting the engine, make sure that the spark plug tester is properly grounded. To avoid electrical shock, do not touch the part where insulation of the igniton coil is broken while the engine is running. Condition Spark jumps across gap Possible cause Spark plug defective Ignition timing incorrect Fuel not reaching fuel injector(s) or engine Valve timing incorrect Engine lacks compression No sparking takes place Ignition coil disconnected or broken Ion sensing module defective Ion sensing module cable broken or poor connections Poor connections in engine harness Powertrain Control Module cable disconnected or defective Correction Clean or replace Refer to Ignition System Refer to item 3 (Trouble in fuel system) Adjust Refer to item 4 (Engine lacks compression) Connect properly or replace Replace Correct or replace Correct Correct or replace

ENGINE MECHANICAL
3. Trouble In Fuel System Condition Starting motor turns over and spark occurs but engine does not start. Possible cause Fuel tank empty Water in fuel system Fuel filter clogged Fuel pipe clogged Fuel pump defective Fuel pump circuit open Evaporative Emission System circuit clogged Control Fill Clean Replace filter Clean or replace Replace Correct or replace Correct or replace Correction

6A5

Multiport Fuel Injection System faulty 4. Engine Lacks Compression Condition Engine lacks compression Possible cause Spark plug loosely fitted or spark plug gasket defective Valve timing incorrect Cylinder head gasket defective Valve incorrectly seated Valve stem seized Valve spring weakened or broken Cylinder or piston rings worn Piston ring seized

Refer to Driveability and Emissions section

Correction Tighten to specified torque or replace gasket Adjust Replace gasket Lap valve Replace valve and valve guide Replace Overhaul engine Overhaul engine.

Engine Compression Test Procedure

1. Start and run the engine until the engine reaches normal operating temperature. 2. Turn the engine off. 3. Remove all the spark plugs. 4. Remove ignition coil fuse (15A) and disable the ignition system. 5. Remove the fuel pump relay from the relay and fuse box. 6. Engage the starter and check that the cranking speed is approximately 300 rpm. 7. Install cylinder compression gauge into spark plug hole. 8. With the throttle valve opened fully, keep the starter engaged until the compression gage needle reaches the maximum level. Note the reading. 9. Repeat the test with each cylinder. If the compression pressure obtained falls below the limit, engine overhaul is necessary. Limit; 1000 kPa (145 psi)

6A6

ENGINE MECHANICAL

Rough Engine Idling or Engine Stalling

Condition Trouble in fuel injection system Possible cause Throttle valve defective Throttle position sensor circuit open or shorted Fuel injector circuits open or shorted Fuel injectors damaged Fuel pump relay defective Mass Airflow Sensor circuit open or poor connections Mass Airflow Sensor defective Manifold Absolute Pressure Sensor circuit open or poor connections Manifold Absolute Pressure Sensor defective Engine Coolant Temperature Sensor circuit open or poor connections Engine Coolant Temperature Sensor defective Intake Air Temperature sensor circuit open or poor connections Intake Air defective Temperature sensor Correction Correct or replace Correct or replace Correct or replace Replace Replace Correct or replace Replace Correct or replace Replace Correct or replace Replace Correct or replace Replace Correct or replace Replace Correct or replace Replace Replace Correct or replace Replace Correct or replace Replace Refer to Hard Start Refer to Hard Start Lap valve Replace filter element Readjust Replace

Ion sensing module cable broken or poor connections Ion sensing module defective Vehicle Speed Sensor circuit open or shorted Vehicle Speed Sensor defective Trouble in emission control system Powertrain Control Module defective Exhaust Gas Recirculation Valve circuit open or poor connections Exhaust Gas Recirculation Valve faulty Canister purge valve circuit open or poor connections Canister purge valve defective Trouble in ignition system Others Engine lacks compression Valve incorrectly seated Air Cleaner Filter clogged Valve timing incorrect Positive Crankcase Ventilation valve defective or clogged

ENGINE MECHANICAL

6A7

Rough Engine Running

Condition Engine misfires periodically Possible cause Ignition coil layer shorted Spark plugs fouling Spark plug(s) insulator nose leaking Ion sensing module or ION sensing module circuits defective Fuel injector(s) defective Powertrain control module faulty Engine knocks periodically Spark plugs running too hot Powertrain control module faulty Ion sensing module or ION sensing module circuits defective Engine lacks power Spark plugs fouled Fuel injectors defective Mass Airflow Sensor or Intake Airflow Sensor circuit defective Manifold Absolute Pressure (MAP) Sensor or Manifold Absolute Pressure Sensor circuit defective Engine Coolant Temperature Sensor or Engine Coolant Temperature Sensor circuit defective Powertrain Control Module faulty Intake Air Temperature Sensor or Intake Air Temperature Sensor circuit defective Throttle Position Sensor or Throttle Position Sensor circuit defective Ion sensing module or ION sensing module circuits defective Replace Clean or install hotter type plug Replace Correct or replace Replace Replace Install colder type spark plugs Replace Correct or replace Clean Replace Correct or replace Correct or replace Correction

Correct or replace

Replace Correct or replace

Correct circuit or replace throttle valve ASM Correct or replace

6A8

ENGINE MECHANICAL

Hesitation
Condition Hesitation on acceleration Possible cause Throttle Position Sensor adjustment incorrect Throttle Position Sensor circuit open or shorted Mass Airflow Sensor circuit open or poor connections Mass Airflow Sensor defective Manifold Absolute Pressure (MAP) Sensor circuit open or shorted MAP Sensor defective Intake Air Temperature (IAT) Sensor circuit open or shorted Ion sensing module Circuit open or poor connections Ion sensing module defective IAT Sensor defective Hesitation at high speeds (Fuel pressure too low) Fuel tank strainer clogged Fuel pipe clogged Fuel filter clogged Defective fuel pump system Fuel Pressure Control Valve leaking Hesitation at high speeds (Fuel injector not working normally) Power supply or ground circuit for Multiport Fuel Injection System shorted or open Fuel Injector defective Cable of Multiport Fuel Injection System circuit open or poor connections Correction Replace throttle valve assembly Correct or replace Correct or replace Replace Correct or replace Replace Correct or replace Correct or replace Replace Replace Clean or replace Clean or replace Replace Check and replace Replace Check and correct or replace

Replace Correct or replace

ENGINE MECHANICAL
Condition Hesitation at high speeds Possible cause Powertrain Control Module defective Throttle Position Sensor broken or poor connections cable Replace Correction

6A9

Correct cable or replace throttle valve ASM Replace throttle valve ASM Correct or replace Replace Correct or replace Replace Correct or replace Replace Correct or replace Replace Correct or replace Replace Check and correct or replace Replace filter element Check and correct or replace

Throttle Position Sensor defective Engine Coolant Temperature Sensor circuit open or shorted Engine Coolant Temperature Sensor defective Mass Airflow Sensor circuit open or poor connections Mass Airflow Sensor defective MAP Sensor cable broken or poor connections MAP Sensor defective IAT Sensor circuit open or poor connections IAT Sensor defective Ion sensing module circuit open or poor connections Ion sensing module defective Throttle valve not fully opened Air Cleaner Filter clogged Power supply voltage too low

6A10

ENGINE MECHANICAL

Engine Lacks Power

Condition Trouble in fuel system Possible cause Fuel Pressure Control Valve not working normally Fuel injector clogged Fuel pipe clogged Fuel filter clogged or fouled Fuel pump drive circuit not working normally Fuel tank not sufficiently breathing due to clogged Evaporative Emission Control System circuit Water in fuel system Inferior quality fuel in fuel system Powertrain Control Module supplied poor voltage Throttle Position Sensor broken or poor connections cable Replace Clean or replace Clean Replace Correct or replace Clean or replace Correction

Clean Use fuel of specified octane rating Correct circuit Correct or replace Replace Replace Replace Replace Correct or replace Replace Replace Replace filter element Correct or replace Repair Refer to Hard Start Troubleshooting Guide Install spark plugs of adequate heat range Replace

Throttle Position Sensor defective Mass Airflow Sensor not working normally Manifold Absolute Pressure Sensor not working normally Intake Air Temperature Sensor not working normally Engine Coolant Temperature Sensor circuit open or shorted Engine Coolant Temperature Sensor defective Powertrain Control Module defective Trouble in intake or exhaust system Air Cleaner Filter clogged Air duct kinked or flattened TWC defective Ignition failure Heat range of spark plug inadequate Ignition coil defective

ENGINE MECHANICAL 6A11

Condition Engine overheating Possible cause Level of Engine Coolant too low Fan clutch defective Incorrect fan installed Thermostat defective Engine Coolant pump defective Radiator clogged Radiator filler cap defective Level of oil in engine crankcase too low or wrong engine oil Resistance increased in exhaust system Replenish Replace Replace Replace Correct or replace Clean or replace Replace Change or replenish Clean exhaust system or replace defective parts Replace with Throttle Valve ASM Correct or replace Replace Replace (Use a thermostat set to open at 82C (180F)) Refer to Hard Start Adjust to recommended pressures Adjust Adjust or replace Correct level of engine oil Replace Correction

Throttle Position Sensor adjustment incorrect Throttle Position Sensor circuit open or shorted Cylinder head gasket damaged Engine overcooling Engine lacks compression Others Thermostat defective Tire inflation pressure abnormal Brake drag Clutch slipping Level of oil in engine crankcase too high Exhaust Gas Recirculation Valve defective

Engine Noisy
Abnormal engine noise often consists of various noises originating in rotating parts, sliding parts and other moving parts of the engine. It is, therefore, advisable to locate the source of noise systematically. Condition Noise from crank journals or from crank bearings (Faulty crank journals and crank bearings usually make dull noise that becomes more evident when accelerating) Possible cause Oil clearance increased due to worn crank journals or crank bearings Crankshaft out of round Correction Replace crank bearings and crankshaft or regrind crankshaft and install the undersize bearing Replace crank bearings and crankshaft or regrind crankshaft and install the undersize bearing Crank bearing seized. Replace crank bearings and crankshaft or regrind crankshaft and install the undersize bearing

Crank bearing seized

6A12

ENGINE MECHANICAL

Troubleshooting Procedure Short out each spark plug in sequence using insulated spark plug wire removers. Locate cylinder with defective bearing by listening for abnormal noise that stops when spark plug is shorted out. Condition Noise from connecting rods or from connecting rod bearings (Faulty connecting rods or connecting rod bearings usually make an abnormal noise slightly higher than the crank bearing noise, which becomes more evident when engine is accelerated) Possible cause Bearing or crankshaft pin worn Correction Replace connecting rod bearings and crankshaft or regrind crankshaft pin and install the undersize bearing Replace connecting rod bearings and crankshaft or regrind crankshaft pin and install the undersize bearing Correct or replace Replace connecting rod bearings and crankshaft or regrind crankshaft pin and install the undersize bearing

Crankpin out of round

Connecting rod bent Connecting rod bearing seized

Troubleshooting Procedure Abnormal noise stops when the spark plug on the cylinder with defective part is shorted out. Condition Piston and cylinder noise (Faulty piston or cylinder usually makes a combined mechanical thumping noise which increases when engine is suddenly accelerated but diminishes gradually as the engine warms up) Possible cause Piston clearance increased due to cylinder wear Piston seized Piston ring broken Piston defective Correction Replace piston and cylinder body Replace piston and cylinder body Replace piston and cylinder body Replace pistons and others

Troubleshooting Procedure Short out each spark plug and listen for change in engine noise. Condition Piston pin noise (Piston makes noise each time it goes up and down) Possible cause Piston pin or piston pin hole worn Correction Replace piston, piston pin and connecting rod assy

ENGINE MECHANICAL 6A13

Troubleshooting Procedure The slapping sound stops when spark plug on bad cylinder is shorted out. Condition Timing belt noise Possible cause Timing belt tension is incorrect Tensioner bearing defective Timing belt defective Timing pulley defective Timing belt comes in contact with timing cover Valve noise Valve clearance incorrect Valve and valve guide seized Valve spring broken or weakened Valve seat offpositioned Camshaft worn out Crankshaft noise Crankshaft end play excessive (noise occurs when clutch is engaged) Preignition due to use of spark plugs of inadequate heat range Carbon deposits chambers in combustion Correction Replace pusher or adjust the tension pulley or replace timing belt Replace Replace Replace Replace timing belt and timing cover Replace adjusting shim Replace valve and valve guide Replace Correct Replace Replace thrust bearing

Engine knocking

Install Spark Plugs of adequate heat range Clean Replace fuel Refer to Section 6E Caution operator of incorrect gear selection Refer to Engine Lacks Power Replace Repair or Replace Replace auto tentioner or drive belt

Fuel too low in octane rating Wide Open Throttle enrichment system failure Selection incorrect Others of transmission gear

Engine overheating Water pump defective Exhaust system defective Drive belt slipping

6A14

ENGINE MECHANICAL

Abnormal Combustion
Condition Trouble in fuel system Possible cause Fuel pressure control valve defective Fuel filter clogged Fuel pump clogged Fuel tank or fuel pipe clogged Fuel injector clogged Fuel pump relay defective Power supply cable for fuel pump broken or poor connections Mass Airflow (MAF) sensor circuit open or defective MAF Sensor defective Manifold Absolute Pressure Sensor circuit open or shorted Manifold Absolute Pressure Sensor defective Engine Coolant Temperature (ECT) Sensor circuit open or shorted ECT Sensor defective Throttle Position Sensor adjustment incorrect Throttle Position Sensor defective Throttle Position Sensor connector poor connections Vehicle Speed Sensor cable poor connections or defective Vehicle Speed Sensor loosely fixed Vehicle Speed Sensor in wrong contact or defective Powertrain Control Module cable poor connections or defective Trouble in emission control system Heated Oxygen Sensor circuit open Heated Oxygen Sensor defective Signal vacuum hose loosely fitted or defective EGR Valve circuit open or shorted Exhaust Gas Recirculation Valve defective ECT Sensor circuit open or shorted Canister Purge Valve circuit open or shorted Canister Purge Valve defective ECT Sensor defective Positive Crankcase Ventilation (PCV) valve and hose clogged Evaporator system Trouble in ignition system Replace Replace Clean or replace Clean or replace Clean or replace Replace Reconnect, correct or replace Correct or replace Replace Correct or replace Replace Correct or replace Replace Readjust Replace Reconnect Correct or replace Fix tightly Replace Correct or replace Correct or replace Replace Correct or replace Correct or replace Replace Correct or replace Correct or replace Replace Replace Correct or replace Refer to Section 6E Refer to Engine Lacks Power Correction

ENGINE MECHANICAL 6A15

Condition Trouble in cylinder head parts Possible cause Carbon deposits chamber in combustion Correction Remove carbon Remove carbon

Carbon deposit on valve, valve seat and valve guide

6A16

ENGINE MECHANICAL

Engine Oil Consumption Excessive

Condition Oil leaking Possible cause Oil pan drain plug loose Crankcase fixing bolts loosened Oil pan setting bolts loosened Oil pan gasket broken Front cover retaining bolts loose or gasket broken Head cover fixing gasket broken bolts loose or Retighten Retighten Replace gasket Retighten or replace gasket Retighten or replace gasket Replace Retighten or replace oil filter Replace oil seal Retighten or replace Replace hose Clean Replace oil seal Replace Replace valve and valve guide Replace cylinder body assembly and pistons Correct Correct Replace cylinder body assembly and pistons Replace pistons and others Clean piston and replace rings Clean Use oil of recommended S.A.E. viscosity Continuous high speed operation and/or severe usage will normally cause increased oil consumption Correction Retighten or replace gasket

Oil filter adapter cracked Oil filter attaching bolt loose or rubber gasket broken Crankshaft front or rear oil seal defective Oil pressure unit loose or broken Blowby gas hose broken Positive Crankcase Ventilation Valve clogged Engine/Transmission coupling failed Oil leaking into combustion chambers due to poor seal in valve system Oil leaking into combustion chambers due to poor seal in cylinder parts Valve stem oil seal defective Valve stem or valve guide worn Cylinders and excessively Piston ring positioned pistons gaps worn

incorrectly

Piston rings set with wrong side up Piston ring sticking Piston ring and ring groove worn Return ports in oil rings clogged Positive Crankcase System malfunctioning Others Ventilation Positive Crankcase Ventilation Valve clogged Improper oil viscosity Continuous high speed driving and/or severe usage such as trailer towing

ENGINE MECHANICAL 6A17

Fuel Consumption Excessive

Condition Trouble in fuel system Possible cause Mixture too rich or too lean due to trouble in fuel injection system Fuel cut function does not work Trouble in ignition system Others Misfiring or abnormal combustion due to trouble in ignition system Engine idle speed too high Fuel system leakage Clutch slipping Brake drag Selection incorrect of transmission gear Correction Refer to Abnormal Combustion Refer to Abnormal Combustion Refer to Hard Start or Abnormal Combustion Reset Idle Air Control Valve Correct or replace Correct Correct Caution operator of incorrect gear selection Refer to Abnormal Combustion

Excessive Exhaust Gas Recirculation flow due to trouble in Exhaust Gas Recirculation system

Lubrication Problems
Condition Oil pressure too low Possible cause Wrong oil in use Relief valve sticking Oil pump not operating properly Oil pump strainer clogged Oil pump worn Oil pressure gauge defective Crankshaft bearing or connecting rod bearing worn Oil contamination Wrong oil in use Oil filter clogged Cylinder head gasket damage Burned gases leaking Oil not reaching valve system Oil passage in cylinder head or cylinder body clogged Replace Correct or replace Clean or replace strainer Replace Correct or replace Replace Replace with correct engine oil Replace oil filter Replace gasket Replace piston and piston rings or cylinder body assembly Clean or correct Correction Replace with correct engine oil

Engine Oil Pressure Check

1. Check for dirt, gasoline or water in the engine oil. a. Check the viscosity of the oil. b. Change the oil if the viscosity is outside the specified standard. c. Refer to the Maintenance and Lubrication section of this manual. 2. Check the engine oil level. The level should fall somewhere between the ADD and the FULL marks on the oil level dipstick. If the oil level does not reach the ADD mark on the oil level dipstick, engine oil must be added. 3. Remove the oil pressure unit. 4. Install an oil pressure gauge. 5. Start the engine and allow the engine to reach normal operating temperature (About 80C). 6. Measure the oil pressure. Oil pressure should be: 392550 kPa (56.980.4 psi) at 3000 rpm. 7. Stop the engine. 8. Remove the oil pressure gauge. 9. Install the oil pressure unit. 10. Start the engine and check for leaks.

6A18

ENGINE MECHANICAL

Malfunction Indicator Lamp

The instrument panel CHECK ENGINE Malfunction Indicator Lamp (MIL) illuminates by self diagnostic system when the system checks the starting of engine, or senses malfunctions. Condition CHECK ENGINE MIL does not illuminate at the starting of engine Possible cause Bulb defective MIL circuit open Command signal circuit to operate self diagnostic system shorted Engine Control Module (PCM) cable loosely connected, disconnected or defective PCM defective CHECK ENGINE MIL illuminates, and stays on Deterioration of heated sensor internal element oxygen Replace Correct or replace Correct or replace Correct or replace Correction

Replace Replace Reconnect properly Correct Correct or replace Replace Reconnect properly Correct Correct or replace Correct or replace Replace Correct or replace Correct or replace Correct or replace Correct or replace Correct or replace Replace PCM Replace PCM

Heated oxygen sensor connector terminal improper contact Heated oxygen sensor lead wire shorted Heated oxygen sensor circuit open Deterioration of engine coolant temperature sensor internal element Engine coolant temperature sensor connector terminal improper contact Engine coolant temperature sensor lead wire shorted Engine coolant temperature sensor circuit open Throttle position sensor open or shorted circuits Deterioration of crankshaft position sensor Crankshaft position sensor circuit open or shorted Vehicle speed sensor circuit open Manifold absolute pressure sensor circuit open or shorted Intake air temperature sensor circuit open or shorted Fuel injector circuit open or shorted PCM driver transistor defective Malfunctioning of PCM RAM (Random Access Memory) or ROM (Read Only Memory)

ENGINE MECHANICAL 6A19

Cylinder Head Cover LH

Removal
1. Disconnect battery ground cable. 2. Remove engine cover from the dowels on the common chamber. 5. Ignition coil connector and ignition coil. D Disconnect the three connectors from the ignition coils. D Remove harness bracket bolt on cylinder head cover. D Remove fixing bolts on ignition coils.

F06RY001

3. Disconnect positive crankcase ventilation hose. 4. Remove ground cable fixing bolt on cylinder head cover.

060R200199

Legend (1) Ignition Coil Connector (2) Bolt (3) Ignition Coil Assemblies 6. Disconnect fuel injector harness connector then remove fuel injector harness bracket bolt. 7. Remove eight fixing bolts, then the cylinder head cover.

010R200001

6A20

ENGINE MECHANICAL

Installation
1. Install cylinder head cover. D Clean the sealing surface of cylinder head and cylinder head cover to remove oil and sealing materials completely. D Apply sealant (TB-1207B or equivalent) of bead diameter 2-3 mm at eight place of arched area of camshaft bearing cap on front and rear sides. D The cylinder head cover must be installed with in 5 minutes after sealant application to prevent hardning of sealant. D Tighten bolts to the specified torque. Torque : 9 Nm (78 lb in)

060R200199

Legend (1) Ignition Coil Connector (2) Bolt (3) Ignition Coil Assembly CAUTION: Ignition coil assembly #6 is different from ignition coil assembly from #1 to #5. Ignition coil assembly #6 is short type. So, note it when installing ignition coil assembly of #6.

010R200002

2. Install fuel injection harness bracket and tighten bolt to the specified torque. Torque : 9 Nm (78 lb in) 3. Connect ignition coil connector and ignition coil, then tighten bolt to the specified torque. Torque : 4 Nm (35 lb in)

060RY00002

Legend (1) Long Type Ignition Coil Assemblies (# 1 # 5) (2) Short Type Ignition Coil Assembly (# 6) 4. Connect ground cable and tighten bolts to the specified torque. Torque : 9 Nm (78 lb in) 5. Install positive crankcase ventilation hose. 6. Install engine cover mating with the dowels.

ENGINE MECHANICAL 6A21

Cylinder Head Cover RH

Removal
1. Disconnect battery ground cable. 2. Remove engine cover from the dowels on the common chamber.

Installation
1. Install cylinder head cover. D Clean the sealing surface of cylinder head and cylinder head cover to remove oil and sealing materials completely. Apply sealant (TB-1207B or equivalent) bead (diameter 2-3 mm) at eight places of arched areas of camshaft bracket on front and rear sides. D The cylinder head cover must be installed within 5 minutes after sealant application to prevent premature hardening of sealant. D Tighten bolts to the specified torque. Torque : 9 Nm (78 lb in)

F06RY001

3. Disconnect ventilation hose from cylinder head cover. 4. Disconnect three ignition coil connectors from ignition coils and remove harness bracket bolts on cylinder head cover then remove ignition coil fixing bolts on ignition coils and remove ignition coils. 5. Disconnect fuel injector harness connector then remove fuel injector harness bracket bolt. 6. Remove eight fixing bolts then the cylinder head cover.
014RW019

2. Tighten fuel injector harness bracket bolts to specified torque then reconnect fuel injector harness connector. Torque : 9 Nm (78 lb ft) 3. Connect ignition coil connector and tighten ignition coil fixing bolts to specified torque. Torque : 4 Nm (35 lb in) 4. Connect ventilation hose to cylinder head. 5. Install engine cover mating with the dowels.

010RW002

6A22

ENGINE MECHANICAL

Common Chamber
Removal
1. Disconnect battery ground cable. 2. Remove air cleaner duct assembly. 10. Remove common chamber four bolts and four nuts then remove the common chamber.

025R200001

013RY00001

Legend (1) Positive Crankcase Ventilation Hose Connector (2) Intake Air Temperature Sensor (3) Air Cleaner Duct Assembly (4) Air Flow Sensor 3. Disconnect vacuum booster hose from common chamber. 4. Disconnect connector from manifold absolute pressure sensor, ion sensing module, throttle position sensor, solenoid valve, electric vacuum sensing valve, and EGR valve. 5. Disconnect vacuum hose on canister VSV and positive crankcase ventilation hose, fuel rail assembly with pressure control valve bracket. 6. Remove ventilation hose from throttle valve and intake duct and remove water hose. 7. Remove the four throttle body fixing bolts. 8. Remove exhaust gas recirculation valve assembly fixing bolt and nut on common chamber and remove EGR valve assembly. 9. Remove two bolts from common chamber rear side for remove fuel hose bracket.

Legend (1) Common Chamber (2) Throttle Valve Assembly (3) Bolt

Installation
1. Install common chamber and tighten bolts and nuts to the specified torque. Torque : Bolt : 25 Nm (18 lb ft) Nut : 25 Nm (18 lb ft) 2. Install fuel hose bracket and tighten bolts to specified torque. Torque : 10 Nm (87 lb in) 3. Install exhaust gas recirculation valve assembly and tighten bolt and nut to the specified torque. Torque : 25 Nm (18 lb ft) 4. Install throttle body and tighten bolts to the specified torque. Torque : 25 Nm (18 lb ft) 5. Install ventilating hose to throttle valve and intake duct. 6. Connect vacuum hoses on canister VSV and positive crankcase ventilation hose. Tighten bolts for fuel rail assembly with pressure control valve bracket. Torque : 25 Nm (18 lb ft) 7. Connect each connector without fail. 8. Connect vacuum booster hose.

ENGINE MECHANICAL 6A23

9. Connect the ion sensing module connectors as shown in the illustration.

060RY00111

Legend (1) Green Connector (2) Blue Connector (3) Identification Mark (6VE1 Engine Only) 10. Install air cleaner duct assembly.

013RY00001

Legend (1) Positive Crankcase Ventilation Hose Connector (2) Intake Air Temperature Sensor (3) Air Cleaner Duct Assembly (4) Mass Air Flow Sensor

6A24

ENGINE MECHANICAL

Exhaust Manifold LH
Removal
1. Disconnect battery ground cable. 2. Remove transfer case skid plate. 3. Remove 3rd crossmember. 4. Disconnect Heated oxygen (O2) sensor connector. 5. Remove the three stud nuts from the front exhaust pipe flange and two nuts from the rear exhaust pipe flange.

Installation
1. Install exhaust manifold and gasket and tighten exhaust manifold fixing nuts to the specified torque with new nuts. Torque: 52 Nm (38 lb ft) 2. Install heat protector. 3. Install exhaust front pipes three stud nuts and rear pipes two nuts to the specified torque. Torque : Stud nuts: 67 Nm (49 lb ft) Nuts (Exhaust front pipe LHRH): 57 Nm (42 lb ft) Nuts (Exhaust front pipe silencer): 43 Nm (32 lb ft) 4. Set A/C compressor to normal position and tighten two bolts to the specified torque. Torque : 40 Nm (30 lb ft) 5. Reconnect O2 sensor connectors. 6. Install 3rd crossmember. 7. Install transfer case skid plate.

035RX015

Legend (1) O2 Sensors (2) Exhaust Front Pipe LH (3) Transfer Case Skid Plate (4) 3rd Crossmember 6. Remove heat protector two fixing bolts then the heat protector. 7. Remove a bolt on engine LH side for air conditioner (A/C) compressor bracket and loosen two bolts for A/C compressor then move A/C compressor to front side. 8. Remove exhaust manifold eight fixing nuts and remove exhaust manifold from the engine.

ENGINE MECHANICAL 6A25

Exhaust Manifold RH
Removal

035RX016

Legend (1) Exhaust Front Pipe RH (2) O2 Sensors (3) Torsion Bar

(4) Front Propeller Shaft (5) Transfer Case Skid Plate (6) 3rd Crossmember

1. Disconnect battery ground cable. 2. Remove transfer case skid plate. 3. Remove 3rd crossmember. 4. Remove torsion bar and front propeller shaft. Refer to removal procedure in Front Suspension section. 5. Disconnect front Heated oxygen (O2) sensor connectors. 6. Remove front exhaust flange pipe three stud nuts and two rear flange nuts then disconnect exhaust pipe. 7. Remove heat protector two fixing bolts then the heat protector. 8. Remove exhaust gas recirculation (EGR) pipe fixing bolt and nut from exhaust manifold, remove a nut from EGR valve and a bolt from rear side of cylinder head for bracket of EGR pipe then remove the EGR pipe. 9. Remove exhaust manifolds eight fixing nuts and the exhaust manifold.

Installation
1. Install exhaust manifold and tighten bolts to the specified torque. Torque : 52 Nm (38 lb ft) 2. Install the EGR pipe, tighten bolt and nut on exhaust manifold to specified torque. Torque : 28 Nm (21 lb ft) Tighten nut to EGR valve to the specified torque. Torque : 44 Nm (33 lb ft) Tighten the bolt for EGR pipe bracket to specified torque. Torque : 25 Nm (18 lb ft) 3. Install heat protector

6A26

ENGINE MECHANICAL
7. Install front propeller shaft. Refer to installation procedue in Front suspension section. 8. Install 3rd crossmember. 9. Install transfer case skid plate.

4. Install front exhaust flange pipe and tighten three stud nuts and rear two nuts to the specified torque. Torque: Stud nuts: 67 Nm (49 lb ft) Nuts: 57 Nm (42 lb ft) 5. Reconnect O2 Sensor harness connector. 6. Install the torsion bar and readjust the vehicle height. Refer to installation and vehicle height adjustment procedure for Front Suspension.

Crankshaft Pulley
Removal
1. Disconnect battery ground cable. 2. Remove air cleaner assembly. 4. Move serpentine belt tensioner to loose side using wrench then remove serpentine belt.

850RW001

013RY00001

Legend (1) Positive Crankcase Ventilation Hose Connector (2) Intake Air Temperature Sensor (3) Air Cleaner Duct Assembly (4) Mass Air Flow Sensor 3. Remove radiator upper fan shroud from radiator.

Legend (1) Crankshaft Pulley (2) Cooling Fan Pulley (3) Tensioner (4) Generator (5) Air Conditioner Compressor (6) Power Steering Oil Pump (7) Idle Pulley (8) Driver Belt 5. Remove cooling fan assembly four fixing nuts, then the cooling fan assembly. 6. Remove crankshaft pulley assembly using J-8614-01 crankshaft holder, hold crankshaft pulley then remove center bolt and pulley.

Installation
1. Install crankshaft pulley using J-8614-01 crankshaft holder, hold the crankshaft pulley and tighten center bolt to the specified torque. Torque : 167 Nm (123 lb ft)

ENGINE MECHANICAL 6A27

2. Install cooling fan assembly and tighten bolts/nuts to the specified torque. Torque : 22 Nm (16 lb ft) for fan pulley and fan bracket. Torque : 10 Nm (87 lb in) for fan and clutch assembly. 3. Move serpentine belt tensioner to loose side using wrench, then install serpentine belt to normal position. 4. Install radiator upper fan shroud. 5. Install air cleaner assembly.

Timing Belt
Removal
1. Disconnect battery ground cable. 2. Remove air cleaner assembly. 3. Remove radiator upper fan shroud from radiator. 4. Move drive belt tensioner to loose side using wrench then remove drive belt. 11. Remove right side timing belt cover then left side timing belt cover. 12. Remove lower timing belt cover 13. Remove pusher. CAUTION: The pusher prevents air from entering the oil chamber. Its rod must always be facing upward.

850RW001 014RW011

Legend (1) Crankshaft Pulley (2) Cooling Fan Pulley (3) Tensioner (4) Generator (5) Air Conditioner Compressor (6) Power Steering Oil Pump (7) Idle Pulley (8) Drive Belt 5. Remove cooling fan assembly four nuts, then the cooling fan assembly. 6. Remove cooling fan drive pulley assembly. 7. Remove idle pulley assembly. 8. Remove serpentine belt tensioner assembly. 9. Remove power steering pump assembly. 10. Remove crankshaft pulley assembly using J-8614-01 crankshaft holder, hold crankshaft pulley remove center bolt, then the pulley.

Legend (1) Up Side (2) Down Side (3) Direction For Installation (4) Locking Pin 14. Remove timing belt. CAUTION: 1. Do not bend or twist the belt, otherwise its core could be damaged. The belt should not be bent at a radius less than 30 mm. 2. Do not allow oil or other chemical substances to come in contact with the belt. They will shorten the life. 3. Do not attempt to pry or stretch the belt with a screw driver or any other tool during installation. 4. Store timing belt in a cool and dark place. Never expose the belt direct sunlight or heat.

6A28

ENGINE MECHANICAL
1. Install timing belt. 1. Align groove of crankshaft timing pulley (2) with mark on oil pump (1). Align the mark on the crankshaft timing pulley (3) with alignment mark (white dotted line) on the timing belt (4). Secure the belt with a double clip or equivalent clip. NOTE: When timing marks are aligned, No.2 piston will be on Top Dead Center.

Installation
NOTE: For correct belt installation, the letter on the belt must be able to be read as viewed from the front of the vehicle.

014RW005

Legend (1) Crankshaft Timing Pulley (2) RH Bank Camshaft Drive Gear Pulley (3) Water Pump Pulley (4) Idle Pulley (5) LH Bank Camshaft Drive Gear Pulley (6) Tension Pulley (7) Alignment Mark on Oil Pump. (8) Alignment Mark on Timing Belt

014RW003

Legend (1) Alignment Mark on Oil Pump (2) Groove on Crankshaft Timing Pulley (3) Alignment Mark on Crankshaft Timing Pulley (4) Alignment Mark on Timing Belt

014RW006

Legend (1) Timing Belt (2) Engine Rotation Direction (3) Cylinder Head Side

ENGINE MECHANICAL 6A29

2. Align the alignment mark on the RH bank camshaft drive gear pulley (2) to the alignment mark of the cylinder head cover RH (3). 3. Align the alignment mark (white line) on the timing belt (1) with alignment mark on the RH bank camshaft drive gear pulley (2) (on the left side as viewed from the front of the vehicle) and put the timing belt on the camshaft drive gear pulley. Secure the belt with a double clip or equivalent clip. NOTE: It is recommended for easy installation that the belt be secured with a double clip or equivalent clip after it is installed to each pulley.

014RW00005

014RW00004

Legend (1) Alignment Mark on Timing Belt (White line). (2) Alignment Mark on Camshaft Drive Gear Pulley. (3) Alignemnt Mark on Cylinder Head Cover RH. 4. Align the alignment mark on the LH bank camshaft drive gear pulley (2) to the alignment mark of the cylinder head cover LH (3). 5. Align the alignment mark (white line) on the timing belt (1) with the alignment mark on the LH bank camshaft drive gear pulley (2). When aligning the timing marks, use a wrench to turn the camshaft drive gear pulley, then set the timing mark between timing belt and camshaft drive gear pulley and put the timing belt on the camshaft drive gear pulley. Secure the belt with a double clip or equivalent clip.

6. Install crankshaft pulley temporarily and tighten center bolt by hand (do not use a wrench). Turn the crankshaft pulley clockwise to give some belt slack between the crankshaft timing pulley and the RH bank camshaft drive gear pulley. 2. Install pusher and tighten bolt to the specified torque. 1. Install the pusher while pushing the tension pulley to the belt. 2. Pull out pin from the pusher. NOTE: When reusing the pusher, press the pusher with approximately 100Kg to retract the rod, and insert a pin (1.4 mm piano wire).

6A30

ENGINE MECHANICAL

014RW011

020RW003

Legend (1) Up Side (2) Down Side (3) Direction for Installation (4) Locking Pin 3. Remove double clips or equivalent clips from timing belt pulleys. Turn the crankshaft pulley clockwise by two turns. Torque : 25 Nm (18 lb ft) 3. Install timing belt cover. Remove crankshaft pulley that was installed in step 1 item 5. Tighten bolts to the specified torque. Torque: 19 Nm (14 lb ft)

Legend (1) Timing Belt Cover (2) Rubber Bushing (3) Sealing Rubber (4) Cylinder Body 4. Install crankshaft pulley using J-8614-01, hold the crankshaft pulley and tighten center bolt to the specified torque. Torque : 167 Nm (123 lb ft) 5. Install fan pulley bracket and tighten fixing bolts to the specified torque. Torque : 22 Nm (16 lb ft) 6. Install power steering pump assembly and tighten to the specified torque. Torque : M8 bolt : 22 Nm (16 lb ft) M10 bolt : 46 Nm (34 lb ft) 7. Install cooling fan assembly and tighten bolts/nuts to the specified torque. Torque : 22 Nm (16 lb ft) for fan pulley and fan bracket. Torque : 10 Nm (87 lb in) for fan and clutch assembly.

020RW004

Legend (1) Timing Belt Cover RH (2) Timing Belt Cover LH (3) Timing Belt Cover Lower

ENGINE MECHANICAL 6A31

8. Move drive belt tensioner to loose side using wrench, then install drive belt to normal position.

850RW001

Legend (1) Crankshaft Pulley (2) Cooling Fan Pulley (3) Auto Tensioner (4) Generator (5) Air Conditioner Compressor (6) Power Steering Oil Pump (7) Idle Pulley (8) Drive Belt 9. Install radiator upper fan shroud. 10. Install air cleaner assembly.

6A32

ENGINE MECHANICAL

Camshaft
Removal
1. Disconnect battery ground cable. 2. Remove crankshaft pulley. D Refer to removal procedure for Crankshaft Pulley in this manual. 3. Remove timing belt. D Refer to removal procedure for Timing Belt in this manual. 4. Remove cylinder head cover LH. D Refer to removal procedure for Cylinder Head Cover LH in this manual. 5. Remove cylinder head cover RH. D Refer to removal procedure for Cylinder Head Cover RH in this manual. 6. Remove twenty fixing bolts from inlet and exhaust camshaft bearing cap on one side bank, then camshaft bearing caps. 9. Remove three fixing bolts from camshaft drive gear retainer, then camshaft drive gear assembly.

014RW026

Legend (1) Right Bank (2) Left Bank (3) Timing Mark on Retainer

Installation
1. Install camshaft drive gear assembly and tighten three bolts to the specified torque. Torque : 10 Nm (87 lb in) 2. Tighten bolt for camshaft drive gear assembly pulley to the specified torque. Torque : 98 Nm (72 lb ft)
014RW027

7. Remove camshaft assembly. 8. Remove fixing bolt for camshaft drive gear pulley.

3. Tighten sub gear setting bolt. 1. Use the J42686 gear spring lever to turn sub gear to right direction until it aligns with the M5 bolt hole between camshaft driven gear and sub gear. 2. Tighten the M5 bolt to a suitable torque to prevent the sub gear from moving.

ENGINE MECHANICAL 6A33

014RW041

014RW023

4. Install camshaft assembly and camshaft bearing caps, tighten twenty bolts on one side bank to the specified torque. 1. Apply engine oil to camshaft journal and bearing surface of camshaft bearing cap. 2. Align timing mark on intake camshaft (one dot for right bank, two dots for left bank) and exhaust camshaft (one dot for right bank, two dots for left bank) to timing mark on camshaft drive gear (one dot).

Legend (1) Right Bank Camshaft Drive Gear (2) Left Bank Camshaft Drive Gear (3) Timing Mark on Drive Gear (4) Dowel Pin

014RW020

Legend (1) Intake Camshaft Timing Gear for Right Bank (2) Intake Camshaft Timing Gear for Left Bank (3) Exhaust Camshaft Timing Gear (4) Discrimination Mark (LI: Left bank intake, RI: Right bank intake) (LE: Left bank exhaust, RE: Right bank exhaust)

6A34

ENGINE MECHANICAL

014RW024

Legend (1) Right Bank (2) Left Bank

(3) Alignment Mark on Camshaft Drive Gear (4) Alignment Mark on Camshaft (5) Alignment Mark on Retainer

3. Tighten twenty bolts on numerical order an one side bank as shown in the illustration. Torque : 10 Nm (87 lb in)

5. Install cylinder head cover RH. D Refer to installation procedure for CYLINDER HEAD COVER RH in this manual. 6. Install cylinder head cover LH. D Refer to installation procedure for CYLINDER HEAD COVER LH in this manual. 7. Install timing belt. D Refer to installation procedure for TIMING BELT in this manual. 8. Install crankshaft pulley. D Refer to installation procedure for CRANKSHAFT PULLEY in this manual.

014RW031

ENGINE MECHANICAL 6A35

Cylinder Head
Removal
1. Remove engine hood. 2. Disconnect battery ground cable. 3. Drain radiator coolant. 4. Drain engine oil. 5. Remove crankshaft pulley. D Refer to removal procedure for Crankshaft Pulley in this manual. 6. Remove timing belt. D Refer to removal procedure for Timing Belt in this manual. 7. Remove cylinder head cover LH. D Refer to removal procedure for Cylinder Head Cover LH in this manual. 8. Remove cylinder head cover RH. D Refer to removal procedure for Cylinder Head Cover RH in this manual. 9. Remove common chamber. D Refer to removal procedure for Common Chamber in this manual. 10. Remove cylinder head assembly. A. Loosen head bolts in reverse of tightening sequence. B. Remove cylinder head assembly.

Installation
1. Install cylinder head assembly to cylinder block. A. Put cylinder head gasket on the cylinder block. NOTE: There is discrimination mark R for right bank and L for left bank on the cylinder head gasket as shown in the illustration. Do not reuse cylinder head gasket.

011RW005

B. Align dowel pin hole to dowel pin on the cylinder block. C. Position cylinder head on the cylinder block. D. Tighten two bolts temporarily by hand to prevent the cylinder head assembly from moving. E. Using J-24239-01 cylinder head bolt wrench, tighten bolts in numerical order as shown in the illustration to the specified torque.

014RW028

Legend (1) Cylinder Head (2) Cylinder Head Bolt (3) Camshaft

6A36

ENGINE MECHANICAL

NOTE: Do not reuse cylinder head bolts. Do not apply any lubricant to the cylinder head bolts. Torque : Temporary : 29 Nm (22 lb ft) Final : 64 Nm (47 lb ft)

014RW029

2. Install common chamber. D Refer to installation procedure for Common Chamber in this manual. 3. Install cylinder head cover RH. D Refer to installation procedure for Cylinder Head Cover RH in this manual. 4. Install cylinder head cover LH. D Refer to installation procedure for Cylinder Head Cover LH in this manual. 5. Install timing belt. D Refer to installation procedure for Timing Belt in this manual. 6. Install crankshaft pulley. D Refer to installation procedure for Crankshaft Pulley in this manual.

ENGINE MECHANICAL 6A37

Valve Stem Oil Controller , Valve Spring and Valve Guide

Removal
1. Disconnect battery ground cable. 2. Drain engine oil. D Drain engine coolant. 3. Remove cylinder head assembly. D Refer to removal procedure for Cylinder Head in this manual. 4. Remove camshaft. D Refer to removal procedure for Camshaft in this manual. 5. Remove tappets with shim. NOTE: Do not damage shim surface. 6. Remove valve springs using J8062 valve spring compressor and J42898 valve spring compressor adapter then remove upper valve spring seat and lower seat.

Installation
1. Install valve guide using J42899 valve guide installer. 2. Install oil controller using J38537 oil controller installer. 3. Install lower valve spring seat, valve spring and upper valve spring seat then put split collars on the upper spring seat, using J8062 valve spring compressor and J42898 valve spring compressor adapter to install the split collars.

014RW042

014RW042

7. Remove oil controller using J37281 oil controller remover, remove each valve stem oil controller. 8. Remove valve guide using J37985 valve guide replacer.

4. Install tappet with shim. 5. Install camshaft assembly. D Refer to installation procedure for Camshaft in this manual. 6. Install cylinder head assembly. D Refer to installation procedure for Cylinder Head in this manual. 7. Fill engine oil until full level. 8. Fill engine coolant.

6A38

ENGINE MECHANICAL

Piston, Piston Ring and Connecting Rod

Removal

F06RW011

Legend (1) Cylinder Head (2) Crankcase with Oil Pan (3) Oil Pipe

(4) Oil Strainer (5) Oil Gallery (6) Piston with Connecting Rod Assembly

1. Remove cylinder head assembly. D Refer to removal procedure for Cylinder Head in this manual. 2. Remove crankcase with Oil Pan. D Refer to removal procedure for Oil Pan and Crankcase in this manual.

ENGINE MECHANICAL 6A39

3. Remove oil strainer fixing bolts, remove oil strainer assembly with O-ring.

015RW003

050RW002

Legend (1) Oil Pump (2) Oil Strainer (3) Oil Gallery (4) From Oil Filter (5) To Oil Filter 4. Remove three fixing bolts, oil pipe with O-ring. 5. Remove eight fixing bolts, oil gallery. 6. Remove piston with connecting rod assembly. (before removing the bearing cap, remove carbon on the top of cylinder bore and push piston with connecting rod out from the top of cylinder bore.)

Legend (1) Piston Front Mark (2) Piston Grade (3) Connecting Rod Front Mark 2. Install oil gallery and tighten the bolts in two steps, in the order shown in illustration. Torque : 1st step : 29 Nm (22 lb ft) 2nd step : 5565

Installation
1. Install piston with connecting rod assembly. D Apply engine oil to cylinder bore, connecting rod bearing and crank pin. When installing the piston, its front mark must face the engine front side. D The bearing cap number must be the same as connecting rod number. D Apply engine oil to the thread and seating surface of each nut. D Tighten nuts to the specified torque. Torque : 54 Nm (40 lb ft) D After tightening the nuts, make sure that the crankshaft rotates smoothly. NOTE: Do not apply engine oil to the bearing back faces and connecting rod bearing fitting surfaces. 3. Install oil pipe with O-ring. Torque : 10 Nm (87 lb in) 4. Install oil strainer assembly with O-ring. Torque : 25 Nm (18 lb ft) 5. Install crankcase with Oil Pan. D Refer to installation procedure for Oil Pan and Crankcase in this manual. 6. Install cylinder head assembly. D Refer to installation procedure for Cylinder Head in this manual.
051RS009

6A40

ENGINE MECHANICAL

Crankshaft and Main Bearings

Removal

F06RY002

Legend (1) Engine Assembly (2) Crankshaft Pulley (3) Timing Belt Cover (4) Timing Belt (5) Crankcase with Oil Pan (6) Oil Pipe (7) Oil Strainer

(8) (9) (10) (11) (12) (13) (14) (15)

Oil Pump Assembly Cylinder Body Side Bolt Oil Gallery Flywheel Rear Oil Seal Retainer Connecting Rod Cap Crankshaft Main Bearing Cap Crankshaft and Main Bearing

1. Remove engine assembly. D Refer to removal procedure for Engine Assembly in this manual. 2. Remove timing belt. D Refer to removal procedure for Timing Belt in this manual.

3. Remove oil pan and crankcase. D Refer to removal procedure for Oil Pan and Crankcase in this manual. 4. Remove oil pipe with O-ring. 5. Remove oil strainer assembly with O-ring.

ENGINE MECHANICAL 6A41

6. Remove oil pump assembly. D Refer to removal procedure for Oil Pump in this manual. 7. Remove cylinder body side bolts. 8. Remove oil gallery. 9. Remove flywheel. 10. Remove rear oil seal retainer. D Refer to removal procedure for Rear Oil Seal in this manual. 11. Remove connecting rod caps. 12. Remove crankshaft main bearing caps. 13. Remove crankshaft and main bearings.

Installation
1. Install crankshaft and main bearings. D Install main bearing in the cylinder block and main bearing cap respectively. Apply new engine oil to upper and lower main bearings. NOTE: D D D D D D Do not apply engine oil to the bearing back faces. Make sure that main bearings are in correct position. Install crankshaft with care. Apply engine oil to the thrust washer. Install thrust washer on No.3 journal. Oil grooves in thrust washer must face the crankshaft.
015RS013

2. Install crankshaft main bearing caps. D Apply engine oil to the thread and seating surface of each bearing cap fixing bolt. NOTE: D Do not apply engine oil to the bearing back faces. D Install bearing caps, starting with cylinder block front side. D Tighten main bearing fixing bolts to the specified torque. Torque : 39 Nm (29 lb ft) D After tightening the bolts, make sure that the crankshaft rotates smoothly. 3. Install connecting rod caps. D The cap number must be same as connecting rod number. D Apply engine oil to the thread and seating surface of each nut. D Tighten nuts to the specified torque. Torque : 54 Nm (40 lb ft) D After tightening the nuts, make sure that the crankshaft rotates smoothly. 4. Install rear oil seal retainer. D Remove oil on cylinder block and retainer fitting surface. D Apply sealant (TB1207B or equivalent) to retainer fitting surface as shown in illustration.

015RS012

6A42

ENGINE MECHANICAL
D Tighten fixing bolts to the specified torque. Torque : 54 Nm (40 lb ft)

D The oil seal retainer must be installed within 5 minutes after sealant application before the sealant hardens.

015RS018 015RW002

Legend (1) Around Bolt Holes (2) Around Dowel Pin D Apply engine oil to oil seal lip and align a dowel pin hole in the cylinder block with that in the retainer. D Tighten retainer fixing bolts to the specified torque. Torque : 18 Nm (13 lb ft)

6. Install oil gallery. D Clean contact surface of oil gallery and main bearing cap. Apply engine oil to oil gallery fixing bolts and tighten the bolts in two steps, in the order shown in illustration. Torque : 1st step : 29 Nm (22 lb ft) 2nd step : 5565 7. Install cylinder body side bolts and tighten bolts in order to the specified torque. Torque : 39 Nm (29 lb ft) NOTE: Do not apply the oil to the bolts.

015RW001

5. Install flywheel. D Clean tapped holes in the crankshaft. D Remove oil on crankshaft and flywheel fitting surface. NOTE: D Do not reuse the bolts. D Do not apply oil or thread lock to the bolts.
012RS007

8. Install oil pump assembly. D Remove oil on cylinder block and oil pump mounting surface.

ENGINE MECHANICAL 6A43

D Apply sealant (TB1207B or equivalent) to the oil pump mounting surface. D The oil pump assembly must be installed within 5 minutes after sealant application before the sealant hardens. D Apply engine oil to oil seal lip. D Install oil pump in the cylinder block and tighten fixing bolts to the specified torque. Torque : 25 Nm (18 lb ft) 11. Install crankcase. D Remove oil on crankcase mounting surface and dry the surface. D Properly apply a 4.5 mm (0.7 in) wide bead of sealant (TB1207C or equivalent) to the crankcase mounting surface. The bead must be continuous. D The crankcase must be installed within 5 minutes after sealant application before the sealant hardens. D Tighten fixing bolts to the specified torque. Torque : 10 Nm (87 lb in)

051RW002

Legend (1) Around Bolt Holes (2) Around Dowel Pin

013RW010

013RW004

051RW001

9. Install oil strainer with O-ring, tighten to the specified torque. Torque : 25 Nm (18 lb ft) 10. Install oil pipe with O-ring, tighten fixing bolts to the specified torque. Torque : 25 Nm (18 lb ft)

12. Install oil pan D Remove oil on oil pan mounting surface and dry the surface. D Properly apply a 4.5 mm (0.7 in) wide bead of sealant (TB1207C or equivalent) to the oil pan mounting surface. The bead must be continuous. D The oil pan must be installed within 5 minutes after sealant application to prevent premature hardening of sealant.

6A44

ENGINE MECHANICAL

D Tighten fixing bolts to the specified torque. Torque : 25 Nm (18 lb ft)

013RW003

013RW002

13. Install timing belt. D Refer to installation procedure for Timing Belt in this manual. 14. Install engine assembly. D Refer to installation procedure for Engine in this manual.

ENGINE MECHANICAL 6A45

Rear Oil Seal

Removal
1. Remove transmission assembly. D Refer to removal procedure for Transmission section in this manual. 2. Remove flywheel. 3. Remove rear oil seal using a seal remover. NOTE: Take care not to damage the crankshaft or oil seal retainer when removing oil seal.

Installation
1. Apply engine oil to oil seal lip and install oil seal using J-39201.

015RS018

3. Install transmission. D See Transmission section in this manual. CAUTION: When assembling the engine and transmission, confirm that dowels have been mounted in the specified positions at the engine side. NOTE: Take care that dowel positions are different between the manual transmission and the automatic transmission. Otherwise, the transmission may be damaged.

015RS017

2. Install flywheel. D Clean tapped holes in the crankshaft. D Remove oil on the crankshaft and flywheel mounting surface. D Tighten fixing bolts to the specified torque. NOTE: Do not reuse the bolts and do not apply oil or thread lock to the bolts. Torque : 54 Nm (40 lb ft)

012RS009

6A46

ENGINE MECHANICAL

Engine Assembly
Removal

035RY00001

1. Disconnect battery ground and positive cable. 2. Remove battery. 3. Make alignment mark on the engine hood and hinges before removal in order to return the hood to original position exactly. 4. Remove engine hood. 5. Drain radiator coolant. 6. Disconnect ion sensing module harness connectors, and manifold absolute pressure sensor harness connectors from sensors on common chamber. 7. Disconnect throttle position sensor harness connectors from throttle body. 8. Disconnect air duct with air cleaner cover. 9. Remove air cleaner assembly. 10. Disconnect canister vacuum hose. 11. Disconnect vacuum booster hose. 12. Disconnect three engine harness connectors. 13. Disconnect harness connector to transmission (left front side of engine compartment), disconnect shift on the fly harness connector from front side of front axle and remove transmission harness bracket from engine left side. 14. Disconnect ground cable between engine and frame. 15. Disconnect bonding cable connector on the back of right dash panel. 16. Disconnect bonding cable terminal on the left bank. 17. Disconnect starter harness connector from starter. 18. Disconnect generator harness connector from generator. 19. Disconnect coolant reserve tank hose from radiator. 20. Remove radiator upper and lower hoses. 21. Remove upper fan shroud.

22. Remove cooling fan assembly four fixing nuts, then the cooling fan assembly. 23. Move drive belt tensioner to loose side using wrench then remove drive belt. 24. Remove power steering pump fixing bolts, then power steering pump. Place the power steering pump along with piping on the body side. 25. Remove air conditioning compressor fixing bolts from bracket and place the compressor along with piping on the body side. 26. Remove four O2 sensor harness connectors (two each bank) from exhaust front pipe. 27. Remove three exhaust pipe fixing nuts from each bank. 28. Remove two exhaust pipe fixing nuts from each exhaust pipe, then move exhaust pipe to rear side of vehicle. 29. Remove flywheel dust covers. 30. Disconnect two heater hoses from engine. 31. Disconnect fuel hoses from right side of transmission. CAUTION: Plug fuel pipes on engine side and fuel hoses from fuel tank. 32. Remove transmission assembly. Refer to Transmission section in this manual. 33. Support the engine by engine hoist. 34. Remove two left side engine mount fixing bolts from engine mount on chassis side. 35. Remove two right side engine mount fixing bolts from engine mount on chassis side. 36. Remove engine assembly.

ENGINE MECHANICAL 6A47

Installation
CAUTION: When assembling the engine and transmission, confirm that dowels have been mounted in the specified positions at the engine side. NOTE: Take care that dowel positions are different between the manual transmission and the automatic transmission. If the engine is assembled in the condition that the dowels have not been mounted in the specified positions, the transmission may be damaged the transmission.

035RW005

Legend (1) Exhaust Front Pipe RH (2) O2 Sensor

012RS009

1. Install engine assembly. Tighten engine mount fixing bolts to frame to the specified torque. Torque: 41 Nm (30 lb ft) 2. Reconnect fuel hose to fuel pipe on engine. 3. Install transmission assembly. Refer to Transmission section in this manual. 4. Reconnect two heater hoses to engine. 5. Install flywheel dust covers. 6. Install exhaust pipe and temporally tighten two (each bank) rear exhaust flange nuts then tighten three stud nuts (each bank) between exhaust manifold and exhaust pipe, finally tighten rear side nuts to the specified torque. Torque: Nuts (Exhaust front pipe LHRH): 57 Nm (42 lb ft) Nuts (Exhaust front pipe silencer): 43 Nm (32 lb ft)

035RW016

Legend (1) O2 Sensor (2) Exhaust Front Pipe LH 7. Reconnect O2 sensor connector. 8. Install cooling fan assembly and tighten bolts/nuts to the specified torque. Torque : 22 Nm (16 lb ft) for fan pulley and fan bracket. Torque : 10 Nm (87 lb in) for fan and clutch assembly. 9. Install air conditioner compressor to engine and tighten to the specified torque. Torque : M8 bolts : 22 Nm (16 lb ft)

6A48

ENGINE MECHANICAL
26. Reconnect connector. throttle position sensor harness

M10 bolts : 43 Nm (32 lb ft) 10. Install power steering pump, tighten fixing bolt to the specified torque. Torque : M8 bolts : 22Nm (16 lb ft) M10 bolts : 46 Nm (34 lb ft) 11. Move drive belt tensioner to loose side using wrench, then install drive belt to normal position.

035R200004

Legend (1) Throttle Position Sensor Connector (2) Throttle Valve Assembly 27. Reconnect manifold absolute pressure sensor harness connectors. 28. Reconnect ion sensing module connectors as shown in the illustration.

850RW001

Legend (1) Crankshaft Pulley (2) Cooling Fan Pulley (3) Tensioner (4) Generator (5) Air Conditioner Compressor (6) Power Steering Oil Pump (7) Idle Pulley (8) Drive Belt 12. Install upper fan shroud. 13. Reconnect radiator upper and lower hoses. 14. Reconnect coolant reserve tank hose to radiator. 15. Reconnect generator harness connector. 16. Reconnect starter harness connector. 17. Reconnect bonding cable terminal on left bank 18. Reconnect bonding cable terminal on the back of right dash panel. 19. Reconnect ground cable between engine and chassis. 20. Reconnect harness connector to transmission and install transmission harness bracket on engine left side. 21. Reconnect three engine harness connectors. 22. Reconnect vacuum booster hose. 23. Reconnect canister vacuum hose. 24. Install air cleaner assembly. 25. Reconnect air duct.

060RY00111

Legend (1) Green Connector (2) Blue Connector (3) Identification Mark (6VE1 Engine Only) 29. Install engine hood to the original position. D Refer to installation procedure for Body section in this manual.

ENGINE MECHANICAL 6A49

Cylinder Head
Cylinder Head and Associated Parts

011RW008

Legend (1) Spark Plug (2) Cylinder Head Bolt (3) Camshaft Drive Gear Pulley Fixing Bolt (4) Camshaft Drive Gear Pulley (5) Camshaft Bearing Cap Fixing Bolt (6) Camshaft Bearing Cap (7) Camshaft Exhaust

(8) (9) (10) (11) (12) (13) (14)

Camshaft Intake Retainer Fixing Bolt Retainer Assembly Tappet with Shim Split Collar Valve Spring and Spring Upper Seat Valve

6A50

ENGINE MECHANICAL

Disassembly
NOTE: D During disassembly, be sure that the valve train components are kept together and identified so that they can be reinstalled in their original locations. D Before removing the cylinder head from the engine and before disassembling the valve mechanism, perform a compression test and note the results. 1. Remove camshaft drive gear pulley fixing bolt (3), then pulley (4). 2. Remove camshaft bearing cap fixing bolt (5), camshaft bearing cap (6), then camshaft exhaust (7), and intake side (8). 3. Remove tappet with shim (11). 4. Use the J8062 valve spring compressor and J42898 valve spring compressor adapter to remove the split collar (12), valve spring with upper seat (13) and valve (14).

Inspection and Repair

1. Cylinder head gasket and mating surfaces for leaks, corrosion and blowby. If the gasket has failed, determine the cause. Insufficient torque on head bolts. Improper installation Loose or warped cylinder head Missing dowel pins Warped case surface 2. Cylinder head for cracks, especially between valve seats and in the exhaust ports. 3. Cylinder head deck for corrosion, sand particles in head and porosity. CAUTION: D Do not attempt to weld the cylinder head. Replace it. D Do not reuse cylinder head bolts. 4. Cylinder head deck, common chamber and exhaust manifold mating surfaces for flatness. These surfaces may be reconditioned by milling. If the surfaces are out of flat by more than specification, the surface should be ground to within specifications. Replace the head if it requires machining beyond the repairable limit. Head surface and manifold surface Standard: 0.05 mm (0.002 in) or less Warpage limit: 0.2 mm (0.0079 in) Maximum Repairable limit: 0.2 mm (0.0079 in) Head height Standard height : 133.2 mm (5.2441 in) Warpage limit : 0.2 mm (0.0079 in) Maximum Repairable limit : 133.0 mm (5.2362 in)

014RW042

5. Remove spark plug (1). CAUTION: Do not remove the spark plugs when the head and plugs are hot. Clean dirt and debris from spark plug recess areas before removal.

Clean
Cylinder head
Carefully remove all varnish, soot and carbon from the bare metal. Do not use a motorized wire brush on any gasket sealing surface.

011RW019

5. Water jacket sealing plugs seating surfaces.

ENGINE MECHANICAL 6A51

Reassembly
1. Install Spark plug and tighten all the spark plugs to specified torque. Torque: 18 Nm (13 lb ft) 2. Tighten sub gear setting bolt. 1. Use J(42686 gear spring lever) to turn sub gear to right direction until the M5 bolt aligns with the hole between camshaft driven gear and sub gear. 2. Tighten the M5 bolt to a suitable torque to prevent the sub gear from moving .

014RW020

Legend (1) Intake Camshaft Timing Gear for Right Bank (2) Intake Camshaft Timing Gear for Left Bank (3) Exhaust Camshaft Timing Gear (4) Discrimination Mark LI: Left Bank Intake RI: Right Bank Intake LE: Left Bank Exhaust RE: Right Bank Exhaust
014RW025

3. Install camshaft drive gear assembly and tighten three bolts to the specified torque. Torque: 10 Nm (87 lb in) 4. Install camshaft assembly and camshaft bearing cap, tighten twenty bolts on one side bank to the specified torque. 1. Apply engine oil to camshaft journal and bearing surface of camshaft bearing cap. 2. Align timing mark on intake camshaft (one dot for right bank, two dots for left bank) and exhaust camshaft (one dot for right bank, two dots for left bank) to timing mark on camshaft drive gear (one dot).

014RW023

Legend (1) Right Bank Camshaft Drive Gear (2) Left Bank Camshaft Drive Gear (3) Timing Mark on Drive Gear (4) Dowel Pin

6A52

ENGINE MECHANICAL

014RW024

Legend (1) Right Bank (2) Left Bank

(3) Alignment Mark on Camshaft Drive Gear (4) Alignment Mark on Camshaft (5) Alignment Mark on Retainer

3. Tighten twenty bolts in numerical order on one side bank as shown in the illustration. Torque: 10 Nm (87 lb in)

014RW031

5. Tighten bolt for camshaft drive gear assembly pulley to the specified torque. Torque: 98 Nm (72 lb ft)

ENGINE MECHANICAL 6A53

Valve Spring, Oil Controller, Valve, Valve Guide

Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts

014RW039

Legend (1) Camshaft Bearing Cap Fixing Bolts (2) Camshaft Assembly Inlet (3) Camshaft Assembly Exhaust (4) Shim (5) Tappet (6) Split Collar

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

Spring Upper Seat Valve Spring Oil Controller Spring Lower Seat Valve Guide Valve

Disassembly
1. Remove camshaft bearing cap fixing bolts (1). 2. Remove camshaft assembly (intake).

3. Remove camshaft assembly (Exhaust side). 4. Remove shim (4) and tappet (5).

6A54

ENGINE MECHANICAL
2. Measure the valve spring squareness with a steel square and replace the valve springs if the measured value exceeds the specified limit. Limit : 2 mm (0.0787 in)

5. Use J8062 valve spring compressor and J42898 valve spring compressor adapter to remove split collar.

014RW042

6. Remove valve spring. 7. Remove valve. 8. Remove oil controller and spring lower seat. 9. Remove the valve guide using the J42899 valve guide replacer.

014RS005

Inspection and Repair

Valve Spring
CAUTION: Visually inspect the valve springs and replace them if damage or abnormal wear is evident. 1. Measure the free height of the springs. The springs must be replaced if the free height is below the specified limit. Standard : 44.6 mm (1.7559 in) Limit : 43.6 mm (1.7165 in)

3. Using a spring tester to compress the springs to the installed height, measure the compressed spring tension, and replace the springs if the measured tension is below the specified limit. At installed height: 35.0 mm (1.38 in) Standard: 196 N (44 lb) Limit: Less than 181 N (41 lb)

014RS006

Valve Guide
CAUTION: Take care not to damage the valve seat contact surface, when removing carbon adhering to the valve head. Carefully inspect the valve stem for scratchs or abnormal wear. If these conditions are present, the valve and the valve guide must be replaced as a set.
014RS004

ENGINE MECHANICAL 6A55

1. Measure the valve stem diameter with a micrometer. If the valve stem diameter is less than the specified limit, the valve and the valve guide must be replaced as a set. Diameter of Valve Stem Intake Standard : 5.977 mm5.959 mm (0.2353 in0.2346 in) Limit : 5.90 mm (0.2323 in) Exhaust Standard : 5.952 mm5.970 mm (0.2343 in0.2350 in) Limit : 5.90 mm (0.2323 in)

014RS008

2. Apply engine oil to the outside of the valve guide. Using valve guide replacer J42899, drive in a new valve guide from the camshaft side, and check the valve guide height. Valve guide upper end height: 13.0 mm (0.5118 in) (Measured from the cylinder head upper face)

014RS007

2. Measure the inside diameter of the valve guide with a micrometer. Subtract the measured outer diameter of the valve stem from the measured inner diameter of the valve guide. If the value exceeds the specified limit, the valve and the valve guide must be replaced as a set. Inside Diameter of the Vale Guide Inlet clearance Standard : 0.023 mm0.056 mm (0.0009 in0.0002 in) Limit : 0.20 mm (0.00787 in) Exhaust clearance Standard : 0.030 mm0.063 mm (0.0012 in0.0025 in) Limit : 0.20 mm (0.00787 in)
014RW046

3. Check the clearance. If the clearance is less than the specified value, ream the inside diameter of valve guide. Using a sharp 6 mm reamer, ream the valve guide to obtain the specified clearance.

Valve Guide Replacement

1. Using Valve guide replacer: J42899, drive out the valve guide from the combustion chamber side.

Valve Seat
1. Measure the protrusion of the valve stem when a new valve is installed in the cylinder head. If the protrusion of the valve stem exceeds the limit, replace the valve seat insert or the cylinder head assembly. Protrusion of valve stem Intake Standard: 39.32 mm (1.5480 in)

6A56

ENGINE MECHANICAL
2. If the measured value exceeds the limit, replace valve, valve guide and valve seat as a set. Valve contact surface angle: 45

Limit: 39.47 mm (1.5539 in) Exhaust Standard: 39.30 mm (1.5472 in) Limit: 39.45 mm (1.5531 in)

014RS012

014RW047

2. Measure the valve seat contact width. Make the necessary corrections if the seat contact surface is damaged or rough or if the contact width wear exceeds the limit. Valve seat contact width Standard: 1.1 mm (0.0433 in) Limit: 1.7 mm (0.0669 in)

Valve Seat Insert Correction

1. Remove the carbon from the valve seat insert surface. 2. Use a valve cutter to minimize scratches and other rough areas. This will bring the contact width back to the standard value. Remove only the scratches and rough areas. Do not cut away too much. Take care not to cut away unblemished areas of the valve seat surface. Valve seat angle degree: 90

014RS011

Contact Surface Angle on Valve Seat on Valve

1. Measure contact surface angle on valve seat.

014RW059

3. Apply abrasive compound to the valve seat insert surface. 4. Insert the valve into the valve guide. 5. Turn the valve while lapping it to fit the valve seat insert. 6. Check that the valve contact width is correct.

ENGINE MECHANICAL 6A57

7. Check that the valve seat insert surface is in contact with the entire circumference of the valve. 7. After insertion, use a seat grinder to grind finish the seating face. Carefully note the seating angle, the contact width, and the depression. 8. Lap the valve and the seat.

Reassembly
1. Install valve guide (1) to cylinder head. Apply engine oil to the outside of the valve guide. Using valve guide replacer J42899, drive in a new valve guide from the camshaft side. 2. Install oil controller (3) and spring lower seat (2). Using oil controller replacer J37281, drive in a new oil controller.

014RS014

Valve Seat Insert Replacement

1. Arc weld the rod at several points. Be careful not to damage the aluminum section. 2. Allow the rod to cool for a few minutes. This will cause the valve seat to shrink. 3. Strike the rod and pull it out.

014RW058

3. Install valve to valve guide. Before install valve guide apply engine oil to the outside of the valve stem. 4. Install valve spring to cylinder head. Attach the valve spring to the lower spring seat. The painted area of the valve spring should be facing downward.

014RS015

4. Carefully clean the valve seat pressfit section on the cylinder head side. 5. Heat the pressfit section with steam or some other means to cause expansion. Cool the valve seat with dry ice or some other means. 6. Insert the pressfit section into the valve seat horizontally. Standard fitting interference: 0.14 mm0.09 mm (0.0055 in0.0035 in)
014RS020

6A58

ENGINE MECHANICAL

5. Install lower valve spring seat, valve spring and upper valve spring seat then put split collars on the upper spring seat, using the J8062 valve spring compressor and J42898 valve spring compressor adapter to install the split collars.

Valve Clearance Adjustments

NOTE: To adjust valve clearance, apply engine oil to the cam as well as to the adjusting shim (2) with the cylinder head built on the cylinder block, give a few turns to the camshaft by means of timing pulley tightening bolt, and measure valve clearance when the nose of cam is just opposite to maximum cam lift (1) as shown in illistration below.

014RW042

6. Install tappet with shim. 7. Install camshaft assembly. D Refer to installation procedure for Camshaft in this manual. Legend (1) Cam (2) Shim (3) Tappet

014RW081

Valve Clearance Standard Value (cold)

Intake: 0.23 mm0.33 mm (0.0091 in0.0130 in) Exhaust: 0.25 mm0.35 mm (0.0098 in0.0138 in)

Selection of Adjusting Shim

Shim to be selected = (Thickness of removed shim) + (Valve clearance measurement Standard valve) Based on the above formula, the best suited shim should be selected from 41 sorts of shim (differently thick at 0.02mm (0.0008 in) intervals from 2.40mm (0.0945 in) through 3.2mm (0.1260 in) thick). Install the shim and check valve clearance.

ENGINE MECHANICAL 6A59

Replacement of Shim
Let the cam push down the edge of tappet by using J42689 valve clearance adjusting tool and push out the shim with a flat blade screw driver as shown in illustrations below.

014RW084

014RW082

014RW083

6A60

ENGINE MECHANICAL

Camshaft
Camshaft and Associated Parts

014RW040

Legend (1) Camshaft Bearing Cap Fixing Bolt (2) Camshaft Bearing Cap (3) Camshaft Assembly Intake (4) Camshaft Assembly Exhaust (5) Pulley Fixing Bolt

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

Camshaft Drive Gear Pulley Retainer Fixing Bolt Retainer Camshaft Drive Gear Oil Seal

Disassembly
1. Remove fixing bolt (5) for camshaft drive gear pulley using the J43041 universal holder.

014RW060

ENGINE MECHANICAL 6A61

2. Remove twenty fixing bolts from inlet and exhaust camshaft bearing cap on one side bank, then camshaft bearing cap (2). 2. Use a micrometer to measure the diameter and the uneven wear of the camshaft journals. Replace the camshaft if the diameter or the uneven wear exceeds the specified limit. Journal Diameter Standard : 25.972 mm25.993 mm (1.0225 in1.0233 in) Limit : 25.8 mm (1.0157 in) Uneven wear : 0.05 mm (0.0020 in)

014RW027

3. Remove camshaft assembly (3), (4). 4. Remove three fixing bolts (7) from camshaft drive gear retainer (8), then camshaft drive gear assembly.

Inspection and Repair

1. Use a micrometer to measure the cam lobe height and uneven wear. Replace the camshaft if either the lobe height or the uneven wear exceeds the specified limit. Lobe height : 44.709 mm (1.7602 in) Uneven wear : 0.05 mm (0.0020 in)
014RS023

3. Place the camshaft on Vblocks. Slowly rotate the camshaft and measure the runout with a dial indicator. Replace the camshaft if the runout exceeds the specified limit. Runout Limit : 0.1 mm (0.0039 in)

014RW043

014RW044

6A62

ENGINE MECHANICAL
5. Replace the cylinder head and/or camshaft if the measured oil clearance exceeds the specified limit. 1. Carefully clean the camshaft journal, the camshaft bracket, and the cylinder head. 2. Install camshaft assembly and camshaft bearing cap (2), tighten twenty bolts (1) on one side bank to the specified torque. Torque: 10 Nm (87 lb in)

4. Measure the camshaft journal oil clearance. 1. Measure the camshaft bearing cap housing inside diameter. NOTE: Tighten camshaft bearing cap (2) to specified torque before measuring the camshaft bearing cap inside diameter. Torque : 10 Nm (87 lb in)

014RW031

2. Subtract the camshaft outside diameter from the camshaft bearing cap housing inside diameter. Oil Clearance Standard : 0.027 mm0.078 mm (0.0011 in0.0031 in) Limit : 0.11 mm (0.0043 in)

014RW031

3. Measure the camshaft thrust clearance with a dial indicator. Replace the camshaft and/or the cylinder head if the camshaft thrust clearance exceeds the specified limit. Camshaft thrust Clearance Standard : 0.03 mm0.08 mm (0.0012 in.0.0031 in.) Limit : 0.12 mm (0.0047 mm)

014RW037

014RW035

ENGINE MECHANICAL 6A63

Reassembly
1. Install camshaft drive gear assembly and tighten three bolts to specified torque. Torque: 10 Nm (87 lb in) 2. Tighten sub gear setting bolt. 1. Use J42686 to turn sub gear to right direction until the M5 bolt hole aligns between camshaft driven gear and sub gear. 2. Tighten M5 bolt suitable torque for prevent moving the sub gear.

014RW020

Legend (1) Intake Camshaft Timing Gear for Right Bank (2) Intake Camshaft Timing Gear for Left Bank (3) Exhaust Camshaft Timing Gear (4) Discerning Mark LI: Left Bank Intake RI: Right Bank Intake LE: Left Bank Exhaust RE: Right Bank Exhaust
014RW041

3. Install camshaft assembly and camshaft bearing caps, tighten twenty bolts on one side bank to the specified torque. 1. Apply engine oil to camshaft journal and bearing surface of camshaft bearing cap. 2. Align timing mark on intake camshaft (one dot for right bank, two dots for left bank) and exhaust camshaft (one dot for right bank, two dots for left bank) to timing mark on camshaft drive gear (one dot).

014RW023

Legend (1) Right Bank Camshaft Drive Gear (2) Left Bank Camshaft Drive Gear (3) Timing Mark on Drive Gear (4) Dowel Pin

6A64

ENGINE MECHANICAL

014RW024

Legend (1) Right Bank (2) Left Bank

(3) Alignment Mark on Camshaft Drive Gear (4) Alignment Mark on Camshaft (5) Alignment Mark on Retainer

3. Tighten twenty bolts in numerical order on one side bank as shown in the illustration. Torque: 10 Nm (87 lb in)

4. If the oil seal requires replacement, use the J42985 to install the oil seal.

014RW034

014RW031

ENGINE MECHANICAL 6A65

5. Tighten bolt for camshaft drive gear pulley to the specified torque using the J43041 universal holder. Torque: 98 Nm (72 lb ft)

014RW060

6A66

ENGINE MECHANICAL

Crankshaft
Crankshaft and Associated Parts

013RW009

Legend (1) Cylinder Head Assembly (2) Crankcase with Oil Pan (3) Oil Pipe and O-Ring (4) Oil Strainer and O-Ring (5) Oil Pump Assembly (6) Cylinder Block Side Bolts (7) Oil Gallery

(8) (9) (10) (11) (12) (13) (14)

Piston and Connecting Rod Assembly Flywheel Rear Oil Seal Retainer and Oil Seal Main Bearing Cap Crankshaft Main Bearing Cap Fixing Bolts Oil Gallery Fixing Bolts

ENGINE MECHANICAL 6A67

Disassembly
1. Remove cylinder head assembly (1). Refer to Cylinder Head in this manual. 2. Remove crankcase with oil pan (2). Refer to Oil Pan and Crankcase in this manual. CAUTION: Take care not to damage or deform the sealing flange surface of crankcase. 3. Remove oil pipe and O-ring (3). 4. Remove oil strainer and O-ring (4). 5. Remove oil pump assembly (5). 6. Remove crankcase side bolts (6). 7. Remove oil gallery (7). 8. Remove piston and connecting rod assembly (8). Refer to Piston, Piston Ring and Connecting Rod in this manual. 9. Remove flywheel (9). 10. Remove rear oil seal retainer (10). 11. Remove main bearing cap (11). 12. Remove crankshaft (12).

2. Remove the main bearing cap fixing bolts in the sequence shown in the illustration. Arrange the removed main bearing caps in the cylinder number order. Remove the main bearings.

Inspection and Repair

015RS004

1. Crankshaft Set the dial indicator as shown in the illustration and measure the crankshaft thrust clearance. If the thrust clearance exceeds the specified limit, replace the thrust bearings as a set. Thrust Clearance Standard : 0.06 mm0.24 mm (0.0024 in0.0094 in) Limit : 0.30 mm (0.0118 in)

3. Remove the crankshaft. Remove the main bearings. 4. Clean the upper and lower bearings as well as the crankshaft main journal. 5. Check the bearings for damage or excessive wear. The bearings must be replaced as a set if damage or excessive wear is discovered during inspection. 6. Set the upper bearings and the thrust washers to their original positions. Carefully install the crankshaft. 7. Set the lower bearings to the bearing cap original position. 8. Apply plastigage to the crankshaft journal unit as shown in the illustration. NOTE: Do not set the plastigage on the oil hole.

015RS003

Main Bearing Clearance

1. Remove the bearing caps and measure the oil clearance.

015RS005

6A68

ENGINE MECHANICAL
Standard : 0.019 mm0.043 mm (0.0007 in0.0017 in) Limit : 0.08 mm (0.0031 in)

9. Install main bearing caps, oil gallery and crank case bolts in the order shown, and tighten each bolt to the specified torque. NOTE: Do not apply engine oil to the crank case side bolts. Main bearing cap bolts. Torque: 39 Nm (29lb ft) Oil gallery fixing bolts. Torque: 1st step: 29 Nm (21 lb ft) 2nd step 55 65 Crank case side bolts Torque : 39 Nm (29lb ft) NOTE: Do not allow the crankshaft to rotate.

015RS008

12. Clean the plastigage from the bearings and the crankshaft. Remove the crankshaft and the bearings.

Crankshaft (12) Inspection

Inspect the surface of the crankshaft journal and crank pins for excessive wear and damage. Inspect the oil seal fitting surfaces for excessive wear and damage. Inspect the oil ports for obstructions.

Inspection and Repair

015RS006

10. Remove the main bearing caps in the sequence shown in the illustration.

1. Carefully set the crankshaft on the Vblocks. Slowly rotate the crankshaft and measure the runout. If the crankshaft runout exceeds the specified limit, the crankshaft must be replaced. Runout : 0.04 mm (0.0016 in)

015RS004

11. Measure the plastigage width and determine the oil clearance. If the oil clearance exceeds the specified limit, replace the main bearings as a set and/or replace the crankshaft.

015RS007

ENGINE MECHANICAL 6A69

2. Measure the diameter and the uneven wear of main journal and crank pin. If the crankshaft wear exceeds the specified limit, crankshaft must be replaced. Main journal diameter : 63.918 mm63.933 mm (2.5165 in2.5170 in) Crank pin diameter : 53.922 mm53.937 mm (2.1229 in.2.1235 in.) Uneven wear limit : 0.005 mm (0.0002 in) 2. Crankshaft journal diameter grade mark. The diameter size marks (1) are stamped on the No.1 crankshaft balancer (2) as shown in the illustration.

015R200005

NOTE: Take care to ensure the bearings are positioned correctly.

015RS009

Crankshaft Bearing Selection

When installing new crankshaft bearings or replacing bearings, refer to the selection table below. Select and install the new crankshaft bearings, paying close attention to the cylinder block journal bore diameter grade mark and the crankshaft journal diameter grade mark. 1. Cylinder block journal bore diameter grade (1).

015R200006

Legend (1) Number 1 and 4 main bearing upper and lower (2) Number 2 and 3 main bearing upper (3) Number 2 and 3 main bearing lower (4) Size mark paint (5) Tab

015RS010

6A70
Size Mark (Cylinder block)

ENGINE MECHANICAL
Crank Shaft Main Journal Diameter 63.918-63.925 (2.5165-2.5167) 63.926-63.933 (2.5168-2.5170) 63.918-63.925 (2.5165-2.5167) 63.926-63.933 (2.5168-2.5170) 63.918-63.925 (2.5165-2.5167) 63.926-63.933 (2.5168-2.5170) Size Mark (Crankshaft) 2 1 Brown 2 1 Green 2 1 Yellow Crank Shaft Bearing Size Mark paint Blue Crank Shaft Bearing Thickness 2.527-2.530 (0.0995-0.0996) 2.524-2.527 (0.0994-0.0995) 0.019-0.043 (0.0007-0.0017) 2.521-2.524 (0.0993-0.0994) 2.518-2.521 (0.0991-0.0993)

Main Bearing Bore Diameter

Oil Clearance (Reference)

68.994-69.000 (2.7163-2.7165)

68.987-68.993 (2.7160-2.7163)

68.980-68.986 (2.7157-2.7160)

Reassembly
1. Crankshaft (12) D Install the main bearings to the cylinder block and the main bearing caps. D Be sure that they are positioned correctly. D Apply new engine oil to the upper and lower main bearing faces. NOTE: Do not apply engine oil to the main bearing back faces.

D Carefully mount the crankshaft. D Apply engine oil to the thrust washer. D Assemble the thrust washer to the No.3 bearing journal. The oil grooves must face the crankshaft.

015RS013

2. Rear oil seal (10) D Remove the oil from the cylinder block and the retainer mounting surface. D Apply sealant (TB1207B or equivalent) to the retainer mounting surface, following the pattern shown in the illustration. The retainer must be installed within 5 minutes after sealant application befor the sealant hardens.

015RS012

Legend (1) Number 1 and 4 main bearing upper and lower (2) Number 2 and 3 main bearing upper (3) Number 2 and 3 main bearing lower

ENGINE MECHANICAL 6A71

015RW002

015RS017

Legend (1) Around Bolt Holes (2) Around Dowel Pin D Apply engine oil to the oil seal lip. D Align the cylinder block dowel pin holes with the rear retainer dowel pins. D Tighten the rear retainer fixing bolts. New bolts should be used when installing rear retainer. Torque: 18 Nm (13 lb ft) NOTE: Be very careful not to disengage the oil seal garter spring during installation of the rear retainer. If the seal was removed from retainer for replacement, apply engine oil to the oil seal lip and install the oil seal using J39201 oil seal installer.

3. Flywheel (9) 1. Thoroughly clean and remove the oil from the threads of crankshaft. 2. Remove the oil from the crankshaft and flywheel mounting faces. 3. Mount the flywheel on the crankshaft and then install the washer. 4. Hold the crankshaft to prevent from rotating then install the bolts in the order shown to the specified torque. Torque: 54 Nm (40 lb ft) NOTE: Do not reuse the bolt and do not apply oil or thread lock to the bolt.

015RS018

015RW001

6A72

ENGINE MECHANICAL

4. Piston and connecting rod assembly (8) D Apply engine oil to the cylinder bores, the connecting rod bearings and the crankshaft pins. Check to see that the piston ring end gaps are correctly positioned.

015RS020

5. Install oil gallery (7) and tighten the bolts in 2 steps, in the order shown. 1st step: 29 Nm (22 lb ft) 2nd step: 55 65
015RS019

Legend (1) No.1 Compression Ring (2) No.2 Compression Ring (3) Oil Ring Side Rail Upper (4) Oil Ring Side Rail Lower (5) Piston Front Mark D Insert the piston/connecting rod assemblies into each cylinder with the piston ring compressor. The front marks must be facing the front of the engine. D Match the numbered caps with the numbers on the connecting rods. Align the punched marks on the connecting rods and caps. D Apply engine oil to the threads and seating faces of the nuts. D Tighten the nuts. Torque: 54 Nm (40 lb ft) After tightening the cap nuts, check to see that the crankshaft rotates smoothly. NOTE: Do not apply engine oil to the bearing back faces.
051RS009

6. Cylinder block side bolts (6) D Tighten all the bolts to the specified torque in the order shown. NOTE: Do not apply engine oil to the crank case side bolts. Torque: 39 Nm (29 lb ft)

ENGINE MECHANICAL 6A73

012RS001

013RW010

7. Install oil pump assembly (5), refer to Oil pump in this manual. 8. Install oil strainer and O-ring (4). 9. Install oil pipe and O-ring (3) and tighten the bolts. Torque: 25 Nm (18 lb ft) 10. Install crankcase with oil pan (2). 1. Completely remove all residual sealant, lubricant and moisture from the sealing surfaces. The surfaces must be perfectly dry. 2. Apply a correct width bead of sealant (TB 1207C or its equivalent) to the contact surfaces of the oil pan. There must be no gaps in the bead. 3. The crankcase assembly must be installed within 5 minutes after sealant application to prevent premature hardening of the sealant. 4. Tighten the bolts and nuts to the specified torque. Torque : 10 Nm (87 lb in)

Legend (1) Portion Between Bolt Holes (2) Bolt Hole Portion 11. Install cylinder head assembly, refer to Cylinder head in this manual.

6A74

ENGINE MECHANICAL

Piston and Connecting Rod

Piston, Connecting Rod and Associate Parts

015RW019

Legend (1) Cylinder Head Assembly (2) Cylinder Head Gasket (3) Crankcase with Oil Pan (4) Oil Pipe and O-Ring (5) Oil Strainer and O-Ring (6) Oil Gallery

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

Piston and Connecting Rod Assembly Piston Ring Piston Pin Piston Connecting Rod Connecting Rod Cap

Disassembly
1. Remove cylinder head assembly (1). Refer to Cylinder Head Removal in this manual. 2. Remove cylinder head gasket (2). 3. Remove crankcase with oil pan (3). Refer toOil Pan and Crankcase in this manual. 4. Remove oil pipe and O-ring (4).

5. Remove oil strainer and O-ring (5). 6. Remove oil gallery (6). 7. Remove connecting rod cap with connecting rod lower bearing (12). 8. Remove piston and connecting rod assembly (7). NOTE: Before removing piston and connecting rod assembly, measure thrust clearance.

ENGINE MECHANICAL 6A75

015RS031

015RS023

D Remove any ridge or carbon build up from the top end of the cylinder. 9. Remove the piston rings (8) with a piston ring expander. Arrange the removed piston rings in the cylinder number order.

Legend (1) Press Ram (2) Piston (3) Connecting Rod (4) Piston Pin 11. Piston (10) 12. Connecting rod (11)

Inspection and Repair

Pistons (10)
Carefully clean away all the carbon adhering to the piston head and the piston ring grooves. NOTE: Never use a wire brush to clean the pistons. Damage will result. Visually check each piston for cracking, scoring, and other signs of excessive wear. If any of the above conditions are found, the piston must be replaced.

Piston Diameter
015RS022

10. Remove the piston pin (9) using J24086C piston pin service set and piston support with a press. NOTE: Keep the parts removed from each cylinder separate. All parts must be reinstalled in their original positions. Heating the connecting rod will permit easy removal of the piston pin.

1. Measure the piston outside diameter with micrometer at the piston grading position and a right angle to the piston pin. Piston grading position (from piston head) Piston grading position : 43.0 mm (1.6929 in)

6A76

ENGINE MECHANICAL

015RV014

012RS002

The size mark (1) for piston outside diameter is represented as shown in illustration below. Outside Diameter Size Mark A : 93.360 mm93.370 mm (3.6756 in3.6760 in) Size Mark B : 93.371 mm93.380 mm (3.6760 in3.6764 in) Size Mark C : 93.381 mm93.390 mm (3.6764 in3.6768 in)

Piston Rings (8)

Any worn or damaged part discovered during engine overhaul must be replaced with a new one. 1. Ring end gap measurement D Insert the piston ring into the bore. D Push the ring by the piston, at a right angle to the wall, into the point at which the cylinder bore diameter is the smallest. D Measure the ring end gap. Compression Ring 1st ring Standard: Limit: 2nd ring Standard: Limit: Oil ring Standard: Limit: 0.150 mm0.450 mm (0.0059 in0.0177 in) 1.05 mm (0.0413 in) 0.450 mm0.600 mm (0.0177 in0.0236 in) 1.2 mm (0.0472 in) 0.300 mm0.400 mm (0.0118 in0.0157 in) 1.0 mm (0.0394 in)

015RS025

Measure the cylinder bore inside diameter (refer to Cylinder Block in this manual).

ENGINE MECHANICAL 6A77

015RS026

015RS028

D Positioning mark (1) is painted as shown in the illustration. Marked T : No.1 Compression ring Marked T2 : No.2 Compression ring

Piston Pin (9)

NOTE: Do not reuse the old piston pin. 1. Use a micrometer to measure the new piston pin outside diameter in both directions at three different positions. 2. Measure the inside diameter of the connecting rod small end. If the fitting interference between the small end and pin does not conform to the specified value, the connecting rod must be replaced. Standard : 0.023 mm0.038 mm (0.0009 in0.0015 in)

015RS027

2. Measure the clearance between the piston ring groove and the piston ring with a feeler gauge. If the piston ring groove / piston ring clearance exceeds the specified limit, the piston must be replaced. Compression Ring Clearance Standard : 0.016 mm0.038 mm (0.0006 in.0.0015 in) Limit : 0.15mm (0.0059 in)
015RS029

6A78

ENGINE MECHANICAL

3. Insert the new pin into the piston and rotate it. If the pin rotates smoothly with no backlash, the clearance is normal. If there is backlash or roughness, measure the clearance. If the clearance exceeds the specified limit, the piston must be replaced. Clearance Standard : 0.010 mm0.017 mm (0.0004 in.0.0007 in) Limit : 0.040 mm (0.0016 in)

Connecting Rods (11)

1. Check the connecting rod alignment If either the bend or the twist exceeds the specified limit, the connecting rod must be replaced. Bend per 100 mm (3.937 in) Limit: 0.15 (0.0059) Twist per 100 mm (3.937 in) Limit: 0.20 (0.0078)

015RS031

3. Measure the oil clearance between the connecting rod and the crankshaft. 1. Remove the connecting rod cap nuts and the rod caps (12). Arrange the removed rod caps in the cylinder number order. 2. Clean the rod bearings and the crankshaft pins. 3. Carefully check the rod bearings. If even one bearing is found to be damaged or badly worn, the entire bearing assembly must be replaced as a set. Reinstall the bearings in their original positions. Apply plastigage to the crank pin.

015RS030

2. Measure the connecting rod thrust clearance. Use a feeler gauge to measure the thrust clearance at the large end of the connecting rod If the clearance exceeds the specified limit, the connecting rod must be replaced. Standard : 0.16 mm0.35 mm (0.0063 in.0.0138 in) Limit : 0.40 mm (0.0157 in)

015RS032

4. Reinstall the rod caps (12) to their original positions. Tighten the rod cap nuts. Torque: 54 Nm (40 lb ft) NOTE: Do not allow the crankshaft to rotate.

ENGINE MECHANICAL 6A79

5. Remove the rod caps. 6. Measure the width of the plastigage and determine the oil clearance. If the oil clearance exceeds the limit, replace the rod bearing as a set. Standard : 0.019 mm0.043 mm (0.0007 in0.0017 in) Limit : 0.08 mm (0.003 in) 7. Clean the plastigage from the bearings and the crankshaft pins.

Conrod Bearing Selection

Select and install the new connecting rod bearings, paying close attention to the connecting rod big end diameter size mark (1). NOTE: Take care not to confuse the alignment mark (2) and the size mark (1) during the installation procedure.

015RS008 015RS034

1 Size Mark A B C

Big end Bore Diameter 56.994-57.000 (2.2439-2.2441) 56.988-56.994 (2.2436-2.2439) 56.982-56.988 (2.2434-2.2436)

Crankshaft Pin Diameter

Connecting Rod Bearing Thickness (Reference) 1.512-1.516 (0.0595-0.0597)

Color of Size Mark Yellow Green Pink

Oil Clearance (Reference) 0.025-0.054 (0.0010-0.0021) 0.027-0.056 (0.0011-0.0022) 0.029-0.058 (0.0011-0.0023)

53.922-53.937 (2.1229-2.1235)

1.508-1.512 (0.0594-0.0595) 1.504-1.508 (0.0592-0.0594)

Reassembly
1. Install connecting rod 2. Install piston 3. Install piston pin D Apply a thin coat of engine oil to the piston pin. Try to insert the piston pin into the piston pin hole with normal finger pressure. NOTE: When changing piston / connecting rod combinations, do not change the piston / piston pin combination and do not reuse the old piston pin. D Attach the piston to the connecting rod with the piston front mark and the connecting rod front mark on the same side.

015RS036

6A80

ENGINE MECHANICAL
D Install piston rings in the following sequence. 1. Oil ring 1. Expander ring 2. Upper side rail 3. Lower side rail 2. 2nd compression ring 3. 1st compression ring D The compression rings must be set with the T or T2 mark facing up. Marked T : No.1 Compression ring Marked T2 : No.2 Compression ring D After installation, apply engine oil to the entire circumference of the piston rings. Check to see that all the rings rotate smoothly.

D With J24086C Piston pin service set and a press, press fit the piston pin. NOTE: Heat the connecting rod small end to a suitable temperature to ensure smooth installation.

015RS037

Legend (1) Press Ram (2) Piston (3) Connecting Rod (4) Piston Pin 4. Install piston ring with the piston ring expander. The compression ring must be set with the T mark (1) facing up. Marked T : No.1 Compression ring Marked T2 : No.2 Compression ring
015RS038

5. Install piston and connecting rod assembly. D Insert the bearings into the connecting rods and caps. Apply new engine oil to the bearing faces and nuts. D Tighten the connecting rod cap nuts Torque : 54 Nm (40 lb ft) NOTE: Do not apply engine oil to the bearing back faces. 6. Oil gallery, refer to Crankshaft and main bearing in this manual. 7. Oil strainer and O-ring. 8. Oil pipe and O-ring. 9. Install crankcase with oil pan, refer to Oil pan and Crankcase in this manual. 10. Install cylinder head gasket. 11. Install Cylinder head assembly. D Refer to Cylinder head in this manual.
015RS027

ENGINE MECHANICAL 6A81

Cylinder Block
Cylinder Block and Associated Parts

012R200002

Legend (1) Cylinder Head Assembly (2) Cylinder Head Gasket (3) Crankcase with Oil Pan (4) Oil Pipe and O-Ring (5) Oil Strainer and O-Ring (6) Oil Pump Assembly (7) Cylinder Block Side Bolts

(8) (9) (10) (11) (12) (13) (14)

Oil Gallery Piston and Connecting Rod Assembly Flywheel Rear Oil Seal Retainer Assembly Main Bearing Cap Crankshaft Cylinder Block

Disassembly
1. Remove cylinder head assembly. 2. Remove cylinder head gasket. 3. Remove crankcase with oil pan. 4. Remove oil pipe and O-ring.

5. Remove oil strainer and O-ring. 6. Remove oil pump assembly. 7. Remove crankcase side bolts. 8. Remove oil gallery. 9. Remove piston and connecting rod assembly. 10. Remove flywheel.

6A82

ENGINE MECHANICAL

11. Remove rear oil seal retainer assembly. 12. Remove main bearing cap. 13. Remove crankshaft. 14. Remove cylinder block.

Cylinder Bore
Use a cylinder gauge to measure the cylinder bore diameter in both the axial and thrust directions. Each measurement should be made at six points. CAUTION: Be very careful not to allow any material to accidentally drop into the upper surface of the cylinder block. Be very careful not to scratch the upper surface of the cylinder block. Cylinder Bore Inside Diameter Limit : 93.530 (3.6823) If the measurement exceed the specified limit, the cylinder block must be replaced. Diameter Grade A : 93.400 mm93.410 mm (3.6772 in3.6776 in) Grade B : 93.411 mm93.420 mm (3.6776 in3.6779 in) Grade C : 93.421 mm93.430 mm (3.6780 in3.6783 in)

Inspection and Repair

1. Remove the cylinder head gasket and any other material adhering to the upper surface of the cylinder block. Be very careful not to allow any material to accidentally drop into the cylinder block. Be very careful not to scratch the cylinder block. 2. Carefully remove the oil pump, rear oil seal retainer, and crankcase assembly installation surface seal. 3. Wipe the cylinder block clean. 4. Visually inspect the cylinder block. If necessary, use a flaw detector to perform a dye penetrate and hydraulic (or air pressure) test. If cracking or other damage is discovered, the cylinder block must either be repaired or replaced.

Flatness
1. Using a straightedge and feeler gauge, check that the upper surface of the cylinder block is not warped. CAUTION: Be very careful not to allow any material to accidentally drop into the upper surface of the cylinder block. Be very careful not to scratch the upper surface of the cylinder block. 2. The cylinder block must be reground or replaced if the warpage exceeds the limit. Warpage Limit : 0.15 mm (0.0059 in) Maximum repairable limit: 0.15 mm (0.0059 in)

012RS005

NOTE: For information on piston diameter, please refer to the section Inspection of the Piston and Connecting Rod Assembly in this manual.

012RS004

ENGINE MECHANICAL 6A83

D The Grade mark (1) is stamped at the position illustrated. D Carefully mount the crankshaft. D Apply engine oil to the thrust washer. D Assemble the thrust washer to the No. 3 bearing journal. The oil grooves must face the crankshaft.

012RS006

Reassembly
015RS013

1. Install cylinder block. 2. Install crankshaft. D Install the main bearings to the cylinder block and the main bearing caps. D Be sure that they are positioned correctly. D Apply new engine oil to the upper and lower main bearing faces. NOTE: Do not apply engine oil to the bearing back faces.

3. Install rear oil seal retainer. D Remove oil on cylinder block and retainer fitting surface. D Apply sealant (TB1207B or equivalent) to retainer fitting surface as shown in illustration. D The oil seal retainer must be installed within 5 minutes after sealant application before the sealant hardens.

015RW002 015RS012

Legend (1) Number 1 and 4 main bearing upper and lower. (2) Number 2 and 3 main bearing upper. (3) Number 2 and 3 main bearing lower.

Legend (1) Around Bolt Holes (2) Around Dowel Pin

6A84

ENGINE MECHANICAL
5. Install piston and connecting rod assembly. D Apply engine oil to the cylinder bores, the connecting rod bearings and the crankshaft pins. NOTE: Do not apply engine oil to the bearing back faces. D Check to see that the piston ring end gaps are correctly positioned.

D Apply engine oil to oil seal lip and align a dowel pin hole in the cylinder block with that in the retainer. D Tighten retainer fixing bolts to the specified torque. Torque: 25 Nm (18 lb ft)

015RW001

4. Install flywheel 1. Thoroughly clean and remove the oil from the threads of crankshaft. 2. Remove the oil from the crankshaft and flywheel mounting faces. 3. Mount the flywheel on the crankshaft and then install the washer. 4. Holding the crankshaft stationary, tighten the flywheel bolts in the order shown. Torque: 54 Nm (40 lb ft) NOTE: Do not reuse the bolts and do not apply oil or thread lock to the bolts.

015RS019

Legend (1) No.1 Compression Ring (2) No.2 Compression Ring (3) Oil Ring Side Rail Upper (4) Oil Ring Side Rail Lower (5) Piston Front Mark D Insert the piston/connecting rod assemblies into each cylinder with the piston ring compressor. D The front marks (1) must be facing the front of the engine.

015RS018

015RS020

ENGINE MECHANICAL 6A85

6. Install oil gallery and tighten the bolts in 2 steps in the order shown. 1st step : 29 Nm (22 lb ft) 2nd step : 55 65 8. Install oil pump assembly. Refer to Oil Pump in this manual. 9. Install oil strainer and O-ring. 10. Install oil pipe and O-ring. 11. Install crankcase with oil pan. 1. Completely remove all residual sealant, lubricant and moisture from the sealing surfaces. The surfaces must be perfectly dry. 2. Apply a correct width bead of sealant (TB 1207C or its equivalent) to the contact surfaces of the crankcase. There must be no gaps in the bead. 3. The oil pan must be installed within 5 minutes after sealant application to prevent premature hardening of sealant. 4. Tighten the bolts and nuts to the specified torque. Torque : 10 Nm (87 lb in)

012RS007

7. Install cylinder block side bolts (1) and tighten crankcase bolts in sequence shown in the illustration. Torque : 39 Nm (29 lb ft)

013RW010

Legend (1) Portion Between Both Holes (2) Bolt Hole Portions 12. Install cylinder head gasket. 13. Install cylinder head assembly. Refer to Cylinder Head in this manual.
012RW005

6A86

ENGINE MECHANICAL

Main Data and Specification

General Specification
Item Engine type, number of cylinders and arrangement Form of combustion chamber Valve mechanism Cylinder liner type Total piston displacement Cylinder bore x stroke Compression ratio Compression pressure at 300rpm Engine idling speed (rpm) Valve clearance Oil capacity Ignition timing Spark plug Plug gap Specifications 6VE1 Water cooled, four cycle V6 Pent roof type 4-Cams, 4-Valves, DOHC Gear & Belt Drive Casted in cylinder drive 3494 cc 93.4mm x 85.0mm (3.677 in x 3.346 in) 9.1 : 1 1370 kPa (199 psi) Non adjustable (750) Intake: 0.28 mm (0.11 in) Exhaust: 0.30mm (0.12in) 5.3 liters (5.6 U.S. q.t.) Non adjustable (20 BTDC at idle rpm) K16PRP11, PK16PR11, RC10PYP4 1.0 mm1.1 mm(0.0394 in 0.0433 in)

ENGINE MECHANICAL 6A87

Torque Specifications
Ignition coil, Spark plug, Crankshaft position sensor and Under cover

E06RY001

6A88

ENGINE MECHANICAL

Cylinder head cover, Cylinder head, Camshaft bearing cap, Common chamber, EGR valve and EGR pipe, Ion sensing module

E06R200002

ENGINE MECHANICAL 6A89

Crankshaft main bearing, Flywheel, Crankcase, Oil pan, Timing belt tensioner, Timing pulley, Timing belt cover, Oil pump, Oil gallery, Oil strainer and Water pump

E06R200010

6A90

ENGINE MECHANICAL

Connecting rod and Water pump

E06RW011

ENGINE MECHANICAL 6A91

Engine mount

E06RW003

6A92

ENGINE MECHANICAL

Special Tool
ILLUSTRATION TOOL NO. TOOL NAME ILLUSTRATION TOOL NO. TOOL NAME

J2168702 Remover; tie rod end

J861401 Holder; Crankshaft

J8062 Compressor; Valve spring (1) J42898 Adapter; Compressor, Valve spring (2)

J37228 Seal cutter

J37281 Remover; Oil controller

J39201 Installer; Real oil seal

J38537 Installer; Oil controller

J242391 Cylinder head bolt wrench

J42985 Installer; Camshaft oil seal

J42899 Replacer; Valve guide (1, 2) J42687 Installer; Valve guide (1) J379851 Remover; Valve guide (2)

J39206 Installer; Pilot bearing

J42689 Adjusting Tool: Valve clearance

ENGINE MECHANICAL 6A93

ILLUSTRATION TOOL NO. TOOL NAME

J42686 Lever; Gear spring

J43041 Holder; Universal

SECTION
ENGINE COOLING
TROOPER

6B1

ENGINE
ENGINE COOLING
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Draining and Refilling Cooling System . . . . . Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Pump and Associated Parts . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostat and Associated Parts . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B1 6B2 6B5 6B6 6B7 6B7 6B7 6B7 6B7 6B8 6B8 6B8 6B8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator and Associated Parts . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Belt and Cooling Fan . . . . . . . . . . . . . . . Drive Belt and Associated Parts . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B8 6B9 6B9 6B9 6B10 6B11 6B12 6B12 6B12 6B12 6B13 6B14

Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.

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

6B2

ENGINE COOLING

General Description

030RW001

Legend (1) Water Pump (2) Thermostat (3) Radiator (4) Reserve Tank (5) Cooling Fan (6) Cylinder Block

(7) (8) (9) (10) (11) (12) (13)

Cylinder Head Right Bank Throttle Body Cylinder Block Cylinder Head Left Bank Heater

The cooling system is a pressurized Engine Coolant (EC) forced circulation type which consists of a water pump, thermostat cooling fan, radiator and other components. The automatic transmission fluid is cooled by the EC in radiator.

Water Pump
The EC pump is a centrifugal impeller type and is driven by a timing belt.

030RS001

ENGINE COOLING

6B3

Thermostat
The thermostat is a wax pellet type with a air hole(1) and is installed in the thermostat housing.

Anti Freeze Solution

D Relation between the mixing ratio and freezing temperature of the EC varies with the ratio of antifreeze solution in water. Proper mixing ratio can be determined by referring to the chart. Supplemental inhibitors or additives claiming to increase cooling capability that have not been specifically approved by Isuzu are not recommended for addition to the cooling system. D Calculating mixing ratio

031RW002

Radiator
The radiator is a tube type with corrugated fins. In order to raise the boiling point of the coolant, the radiator is fitted with a cap in which the valve is operated at 88.2 117.6 kPa (12.8 17.0 psi) pressure. (No oil cooler provided for M/T)

F06RW005

NOTE: Antifreeze solution + Water = Total cooling system capacity. D Total Cooling System Capacity D M/T 8.8Lit (2.32Us gal) D A/T 8.4Lit (2.22Us gal)

110RS001

6B4

ENGINE COOLING

B06RW002

B06RW003

D Mixing ratio Check the specific gravity of engine coolant in the cooling system temperature ranges from 0C to 50C using a suction type hydrometer, then determine the density of the engine coolant by referring to the table. NOTE: 1. Even in the areas where the atmospheric temperature is higher than 0C, be sure not to use antifreeze solution at a mixing ratio lower than 20% so that the inside of the engine may not be corroded. 2. If antifreeze solution is used at a mixing ratio higher than 60%, the specific heat of the coolant falls and the engine may be overheated. Moreover, antifreeze performance drop and the coolant may be frozen. The density of the solution must be adjusted as occasion calls. Antifreeze solution lower than 20% may not have sufficient anticorrosive performance, and therefore, please never fail to adjust as occasion demands within the range of 20% to 60%.

ENGINE COOLING

6B5

Diagnosis
Engine Cooling Trouble
Condition Engine overheating Possible cause Low Engine Coolant level Incorrect fan installed Thermo meter unit faulty Faulty thermostat Faulty Engine Coolant temperature sensor Clogged radiator Faulty radiator cap Low engine oil level or use of improper engine oil Clogged exhaust system Faulty Throttle Position sensor Open or shorted Throttle Position sensor circuit Damaged cylinder head gasket Engine overcooling Engine slow to warmup Faulty thermostat Faulty thermostat Thermo unit faulty Replenish Replace Replace Replace Repair or replace Clean or replace Replace Replenish or change oil Clean exhaust system or replace faulty parts Replace throttle valve assembly Repair or replace Replace Replace Replace Replace Correction

6B6

ENGINE COOLING
9. After the engine has cooled, replenish with EC up to the MAX line of the reserve tank. 10. Start the engine. With the engine running at 3,000 rpm, make sure there is no running water sound from the heater core (behind the center console). 11. If the running water sound is heard, repeat steps 8 to 10.

Draining and Refilling Cooling System

Before draining the cooling system, inspect the system and perform any necessary service to ensure that it is clean, does not leak and is in proper working order. The engine coolant (EC) level should be between the MIN and MAX lines of reserve tank when the engine is cold. If low, check for leakage and add EC up to the MAX line. There should not be any excessive deposit of rust or scales around the radiator cap or radiator filler hole, and the EC should also be free from oil. Replace the EC if excessively dirty. 1. Completely drain the cooling system by opening the drain plug (2) at the bottom of the radiator.

110RW002

2. Remove the radiator cap. WARNING: TO AVOID THE DANGER OF BEING BURNED, DO NOT REMOVE THE CAP WHILE THE ENGINE AND RADIATOR ARE STILL HOT. SCALDING FLUID AND STEAM CAN BE BLOWN OUT UNDER PRESSURE. 3. Disconnect all hoses from the EC reserve tank. Scrub and clean the inside of the reserve tank with soap and water. Flush it well with clean water, then drain it. Install the reserve tank and hoses. 4. Refill the cooling system with the EC using a solution that is at least 50 percent antifreeze but no more than 70 percent antifreeze. 5. Fill the radiator to the base of the filler neck. Fill the EC reserve tank to MAX line when the engine is cold. 6. Block the drive wheels and firmly apply the parking brake. Shift an automatic transmission to P (Park) or a manual transmission to neutral. 7. Remove the radiator cap. Start the engine and warm it up at 2,500 3,000 rpm for about 30 minutes. 8. When the air comes out from the radiator filler neck and the EC level has gone down, replenish with the EC. Repeat this procedure until the EC level does not go down. Then stop the engine and install the radiator cap. Let the engine cool down.

ENGINE COOLING

6B7

Water Pump
Water Pump and Associated Parts

014R200005

Legend (1) Timing Belt (2) Idle Pulley

(3) Water Pump Assembly (4) Gasket

Removal
1. Disconnect battery ground cable. 2. Drain coolant. 3. Radiator hose (on inlet pipe side). 4. Remove timing belt. Refer to Timing Belt in this manual. 5. Remove Idle pulley. 6. Remove water pump assembly. 7. Remove gasket.

2. Install water pump assembly and tighten bolts to the specified torque. Torque: 25 Nm (18 lb ft) D Tightening order The tightening order are in the illustrate. NOTE: To prevent the oil leakage, apply the LOCTITE 262 or an equivalent, to the arrow marked fixing bolt thread.

Inspection
Make necessary repair and parts replacement if extreme wear or damage is found during inspection. Should any of the following problems occur, the entire water pump assembly must be replaced: D Crack in the water pump body D EC leakage from the seal unit D Play or abnormal noise in the bearing D Cracks or corrosion in the impeller.

Installation
1. Install gasket, clean the mating surface of gasket before installation.
030RW008

6B8

ENGINE COOLING
4. Timing belt D Install timing belt. Refer to timing belt installation step in Timing Belt in this manual. 5. Connect radiator inlet hose and replenish EC. 6. Connect battery ground cable.

3. Idle pulley D Install idle pulley and tighten bolt to the specified torque. Torque: 52 Nm (38 lb ft)

Thermostat
Thermostat and Associated Parts Inspection
Suspend the thermostat in a waterfilled container using thin wire. Place a thermometer next to the thermostat. Do not directly heat the thermostat. Gradually increase the water temperature. Stir the water so that the entire water is same temperature.

031RW001

Legend (1) Thermostat Housing (2) Thermostat (3) Outlet Pipe

031RS003

Removal
1. Disconnect battery ground cable. 2. Drain engine coolant from the radiator and engine. 3. Disconnect radiator hose from the inlet pipe. 4. Remove thermostat housing. 5. Remove thermostat(2).

Confirm the temperature when the valve first begins to open. Valve opening temperature 74.5C 78.5C (166.1F 173.3F) Confirm the temperature when the valve is fully opened. Valve full open temperature and lift More than 8.5mm (0.33 in) at 90C (194F) Make necessary repair and parts replacement if extreme wear or damage is found during inspection.

Installation
1. Install thermostat into the outlet pipe(4) making sure that the air hole is in the up position. 2. Install thermostat housing and tighten bolts to the specified torque. Torque: 25 Nm (18 lb ft) 3. Installation rubber hose. 4. Replenish engine coolant (EC). 5. Start engine and check for EC leakage.

ENGINE COOLING

6B9

Radiator
Radiator and Associated Parts

110RW003

Legend (1) Oil Cooler Hose For Automatic Transmission (2) Radiator Hose (3) Fan Guide, Lower

(4) (5) (6) (7)

Reserve Tank Hose Bracket Radiator Assembly Reserve Tank

Removal
1. Disconnect battery ground cable. 2. Loosen a drain plug(2) to drain EC. 3. Disconnect oil cooler hose(1) on automatic transmission (A/T). 4. Disconnect radiator inlet hose and outlet hose from the engine.

5. Remove fan guide(1), clips(3) on both sides and the bottom lock, then remove lower fan guide(3) with fan shroud(4).

110RW001

110RW002

6B10

ENGINE COOLING
Valve opening vacuum kPa (psi) 1.96 4.91 (0.28 0.71)

6. Disconnect the reserve tank hose(4) from radiator. 7. Remove bracket(5).

110RW004

110RS006

8. Lift up and remove the radiator assembly with hose, taking care not to damage the radiator core with a fan blade. 9. Remove rubber cushions on both sides at the bottom.

Radiator Core
1. A bent fin may result in reduced ventilation and overheating may occur. All bent fins must be straightened. Pay close attention to the base of the fin when it is being straightened. 2. Remove all dust, bugs and other foreign material.

Inspection
Radiator Cap
Measure the valve opening pressure of the pressurizing valve with a radiator filler cap tester. Replace the cap if the valve opening pressure is outside the standard range. Valve opening pressure kPa (psi) 88.3 117.7 (12.8 17.1) Cap tester: J2446001 Adapter: J33984A Check the condition of the vacuum valve in the center of the valve seat side of the cap. If considerable rust or dirt is found, or if the valve seat cannot be moved by hand, clean or replace the cap.

Flushing the Radiator

Thoroughly wash the inside of the radiator and the engine coolant passages with cold water and mild detergent. Remove all signs of scale and rust.

Cooling System Leakage Check

Use a radiator cap tester to force air into the radiator through the filler neck at the specified pressure of 196 kPa (28.5 psi) with a cap tester: D Leakage from the radiator D Leakage from the coolant pump D Leakage from the water hoses D Check the rubber hoses for swelling.

ENGINE COOLING 6B11

Cap tester: J2446001 Adapter: J33984A 8. Connect battery ground cable. 9. Pour engine coolant up to filler neck of radiator, and up to MAX mark of reserve tank.

110RS005

111RS001

Installation
1. Install rubber cushions on both sides of radiator bottom. 2. Install radiator assembly with hose, taking care not to damage the radiator core with a fan blade. 3. Install bracket (6) and support the radiator upper tank with the bracket (5) and secure the radiator. 4. Connect reserve tank hose (4). 5. Install lower fan guide (3). 6. Connect radiator inlet hose and outlet hose to the engine. 7. Connect oil cooler hose (1) to automatic transmission.

Important operation (in case of 100% engine coolant change) procedure for filling with engine coolant.

Engine Coolant Filling Up Procedure

1. Make sure that the engine is cool. WARNING: WHEN THE COOLANT IS HEATED TO A HIGH TEMPERATURE, BE SURE NOT TO LOOSEN OR REMOVE THE RADIATOR CAP. OTHERWISE YOU MIGHT GET SCALDED BY HOT VAPOR OR BOILING WATER. TO OPEN THE RADIATOR CAP, PUT A PIECE OF THICK CLOTH ON THE CAP AND LOOSEN THE CAP SLOWLY TO REDUCE THE PRESSURE WHEN THE COOLANT HAS BECOME COOLER. 2. Open radiator cap pour coolant up to filler neck. 3. Pour coolant into reservoir tank up to MAX line. 4. Tighten radiator cap and start the engine. After idling for 2 to 3 minutes, stop the engine and reopen radiator cap. If the water level is lower, replenish. 5. After replenish the coolant tighten radiator cap, warm up the engine at about 2000 rpm. Set heater adjustment to the highest temperature position, and let the coolant circulate also into heater water system. 6. Check to see the thermometer, continuously idling 5 minutes and stop the engine. 7. When the engine has been cooled, check filler neck for water level and replenish if required. Should extreme shortage of coolant is found, check the coolant system and reservoir tank hose for leakage. 8. Pour coolant into the reservoir tank up to MAX line.

110RW004

6B12

ENGINE COOLING

Drive Belt and Cooling Fan

Drive Belt and Associated Parts

015RW005

Legend (1) Crankshaft Pulley (2) Generator (3) Power Steering Pump

(4) (5) (6) (7)

Water Pump and Cooling Fan Pulley Idle Pulley Tension Pulley Drive Belt

The drive belt adjustment is not required as automatic drive belt tensioner is equipped.

Installation
Install cooling fan assembly and tighten bolts/nuts to the specified torque. Torque : 22 Nm (16 lb ft) for fan pulley and fan bracket. Torque : 10 Nm (87 lb in) for fan and clutch assembly. NOTE: Fan belts for 6VE1 Gasoline Engine mounted on 98MY Trooper (UX) have been brought into one. As a result, the rotating direction of a fan belt is opposite to the direction of cooling fan for 92 to 97MY 6VD1 with no interchangeability. Therefore, incorrect installation of a fan may cause the air for cooling to flow in the opposite direction, this resulting in the poor performance of the air-conditioner and a rise temperature in engine cooling water.

Inspection
Check drive belt for wear or damage, and replace with a new one as necessary.

ENGINE COOLING 6B13

Main Data and Specifications

General Specifications
M/T Cooling system Radiator Heat radiation capacity Heat radiation area Radiator front area Radiator dry weight Radiator cap valve opening pressure Radiator coolant capacity Engine coolant pump Delivery Pump speed Thermostat Valve opening temperature Engine coolant total capacity 39N (8.8lb) 2.5lit (2.6U.S q.t.) A/T Engine coolant forced circulation (1 tube in row) Tube type corrugated (2 tube in row) 68,000 kcal/h 9.445m@ (0.878ft@) 0.302m@ (0.028ft@) 44N (9.9lb) 2.4lit (2.5U.S q.t.) 93.3 122.7kpa (13.5 17.8psi) Centrifugal impeller type 300 lit (79 U.S. gal)/min or more 5000 50 rpm Wax pellet type with air hole 74.5 78.5C (166.1 173.3F) 10.4lit (11.0U.S qt) 10.5lit (11.1U.S qt) 77,000 kcal/h 11.21m@ (1.04ft@)

Torque Specifications

E06R200009

6B14

ENGINE COOLING

Special Tool
ILLUSTRATION TOOL NO. TOOL NAME

J2446001 Tester; radiator cap

J33984A Adapter; radiator cap

SECTION
ENGINE FUEL
TROOPER

6C1

ENGINE
ENGINE FUEL
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Fuel Metering . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Filter and Associated Parts . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . InTank Fuel Filter . . . . . . . . . . . . . . . . . . . . . Fuel Pump Flow Test . . . . . . . . . . . . . . . . . . . Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Pump and Associated Parts . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C1 6C2 6C3 6C4 6C4 6C4 6C4 6C4 6C5 6C5 6C5 6C6 6C6 6C6 6C6 6C6 6C6 6C7 Fuel Tank and Associated Parts . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Tube / Quick Connect Fittings . . . . . . . Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . Cautions During Work . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reuse of QuickConnector . . . . . . . . . . . . . . . Assembling Advice . . . . . . . . . . . . . . . . . . . . . . Fuel Gauge Unit . . . . . . . . . . . . . . . . . . . . . . . . Fuel Gauge Unit and Associated Parts . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Filler Cap . . . . . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . 6C7 6C7 6C7 6C8 6C8 6C8 6C8 6C9 6C10 6C11 6C11 6C11 6C11 6C12 6C12 6C12 6C13

Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.

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

6C2

ENGINE FUEL

General Description

140RY00002

Legend (1) Fuel Filler Cap (2) Fuel Tank (3) Rollover Valve (4) Fuel Pump (Fuel Level Sending Unit/Fuel Tank Pressure Sensor) (5) Fuel Filter (6) Fuel Rail Right (7) Right Bank

(8) (9) (10) (11) (12) (13) (14) (15) (16)

Fuel Rail Left Left Bank Fuel Pressure Control Valve Common Chamber Duty Solenoid Valve Throttle Valve Canister Evaporation Shut Off Valve Vent Solenoid Cut Valve

When working on the fuel system, there are several things to keep in mind: D Any time the fuel system is being worked on, disconnect the negative battery cable except for those tests where battery voltage is required. D Always keep a dry chemical (Class B) fire extinguisher near the work area.

D Replace all pipes with the same pipe and fittings that were removed. D Clean and inspect O rings. Replace if required. D Always relieve the line pressure before servicing any fuel system components. D Do not attempt repairs on the fuel system until you have read the instructions and checked the pictures relating to that repair.

ENGINE FUEL
D Adhere to all Notices and Cautions. All gasoline engines are designed to use only unleaded gasoline. Unleaded gasoline must be used for proper emission control system operation. Its use will also minimize spark plug fouling and extend engine oil life. Using leaded gasoline can damage the emission control system and could result in loss of emission warranty coverage. All cars are equipped with an Evaporative Emission Control System. The purpose of the system is to minimize the escape of fuel vapors to the atmosphere.

6C3

Fuel Metering
The Engine Control Module (ECM) is in complete control of this fuel delivery system during normal driving conditions. The intake manifold function, like that of a diesel, is used only to let air into the engine. The fuel is injected by separate injectors that are mounted over the intake manifold. The Manifold Absolute Pressure (MAP) sensor measures the changes in the intake manifold pressure which result from engine load and speed changes, which the MAP sensor converts to a voltage output. This sensor generates the voltage to change corresponding to the flow of the air drawn into the engine. The changing voltage is transformed into an electric signal and provided to the ECM. With receipt of the signals sent from the MAP sensor, Intake Air Temperature sensor and others, the ECM determines an appropriate fuel injection pulse width feeding such information to the fuel injector valves to effect an appropriate air/fuel ratio. The Multiport Fuel Injection system utilizes an injection system where the injectors turn on at every crankshaft revolution. The ECM controls the injector on time so that the correct amount of fuel is metered depending on driving conditions. Two interchangeable O rings are used on the injector that must be replaced when the injectors are removed. The fuel rail is attached to the top of the intake manifold and supplies fuel to all the injectors. Fuel is recirculated through the rail continually while the engine is running. This removes air and vapors from the fuel as well as keeping the fuel cool during hot weather operation. The fuel pressure control valve that is mounted on the fuel rail maintains a pressure differential across the injectors under all operating conditions. It is accomplished by controlling the amount of fuel that is recirculated back to the fuel tank based on engine demand. See Section Driveability and Emission for more information and diagnosis.

6C4

ENGINE FUEL

Fuel Filter
Fuel Filter and Associated Parts

041RW014

Legend (1) Fuel Filler Cap (2) Fuel Hose

(3) Fuel Filter Fixing Bolt (4) Fuel Filter

Removal
CAUTION: When repair to the fuel system has been completed, start engine and check the fuel system for loose connection or leakage. For the fuel system diagnosis, see Section Driveability and Emission. 1. Disconnect battery ground cable. 2. Remove Fuel filler cap(1). 3. Disconnect fuel hoses(2) from fuel filter on both engine side and fuel tank side. 4. Fuel filter fixing bolt(3). D Remove the fuel filter fixing bolt(3) on fuel filter holder. 5. Remove fuel filter(4).

Inspection
1. Replace the fuel filter if the fuel leaks from fuel filter body or if the fuel filter body itself is damaged. 2. Replace the filter if it is clogged with dirt or sediment. 3. Check the drain of receive rubber and if it is clogged with dust, clean it up with air.

Installation
1. Install the fuel filter in the proper direction. 2. Install fuel filter holder fixing bolt.

ENGINE FUEL
3. Connect fuel hoses on engine side(1) and fuel tank side(2).

6C5

4. Connect the pump relay terminals with a jumper wire(1) as shown and start the fuel pump to measure delivery.

041RW001

4. Install fuel filler cap 5. Connect the battery ground cable.

140RW002

CAUTION: Never generate sparks when connecting a jumper wire. Delivery 15 seconds Delivery 0.38 liters minimum

Inspection
After installation, start engine and check for fuel leakage.

InTank Fuel Filter

The filter is located on the lower end of fuel pickup tube in the fuel tank. It prevents dirt from entering the fuel pipe and also stops water unless the filter is completely submerged in the water. It is a self cleaning type, not requiring scheduled maintenance. Excess water and sediment in the tank restricts fuel supply to the engine, resulting in engine stoppage. In such a case, the tank must be cleaned thoroughly.

If the measure value is out of standard, conduct the pressure test.

Pressure test
For the pressure test to the fuel system, see Section 6E Fuel System Electrical Test.

Fuel Pump Flow Test

If reduction of fuel supply is suspected, perform the following checks: 1. Make sure that there is fuel in the tank. 2. With the engine running, check the fuel feed pipe and hose from fuel tank to injector for evidence of leakage. Retighten, if pipe or hose connection is loose. Also, check pipes and hoses for squashing or clogging. 3. Insert the hose from fuel feed pipe into a clean container, and check for fuel pump flow rate.

6C6

ENGINE FUEL

Fuel Pump
Fuel Pump and Associated Parts

035RW030

Removal
CAUTION: When repair to the fuel system has been completed, start engine and check the fuel system for loose connection or leakage. For the fuel system diagnosis, see Section Driveability and Emission. 1. Disconnect battery ground cable. 2. Loosen fuel filler cap. 3. Drain fuel. Tighten drain plug to the specified torque after draining fuel. Torque: 20 Nm (14 lb ft) M8 4. Remove fuel tank assembly(1). Refer to Fuel Tank Removal in this section. 5. Remove fuel pump (FP) assembly(2) fixing screws and remove the FP assembly. NOTE: After removing FP, cover fuel tank to prevent any dust entering.

Installation
1. Install FP assembly(2). 2. Install fuel tank assembly(1). Refer to Fuel Tank Installation. 3. Fill the tank with fuel and tighten fuel filler cap. 4. Connect battery ground cable.

Fuel Pump Relay

General Description
In order to control the FP operation, the FP relay is provided. When the starter switch is turned to ON position, the FP relay operates the FP for 2 seconds. When it is turned to START position, the Power Train Control Module (PCM) receives the reference pulse from the Ignition Control Module and it operates the relay, again causing the FP to feed fuel.

ENGINE FUEL

6C7

Fuel Tank
Fuel Tank and Associated Parts

035RW032

Legend (1) Fender Liner (2) Fuel Filler Hose and Air Breather Hose and Evapo Hose (3) Undercover

(4) Fuel Tank Wiring Connector (5) Evapo Fuel Hose (6) Fuel Feed Tube and Fuel Return Tube/QuickConnect Fittings (7) Fuel Tank

Removal
CAUTION: When repair to the fuel system has been completed, start engine and check the fuel system for loose connection or leakage. For the fuel system diagnosis, see Section Driveability and Emission. 1. Disconnect battery ground cable. 2. Loosen fuel filler cap. 3. Drain fuel. Tighten drain plug to the specified torque after draining fuel. Torque: 20 Nm (14 lb ft) M8 4. Remove fender liner (1) of wheel well on rear right side. 5. Fuel filler hose, air breather hose and evapo hose (2). 6. Remove undercover fixing bolts on both sides and remove under cover(3). 7. Disconnect two fuel tank wiring connectors(4) on front right side of tank.

8. Disconnect evapo fuel hose(5). 9. Disconnect fuel feed tube and fuel return tube(6). NOTE: Handling of the fuel tube, be sure to refer Fuel Tube/QuickConnect Fittings in this section. 10. Remove fuel tank fixing bolts on both sides and remove fuel tank(7).

Installation
1. Install fuel tank(7). D Place a flange on right side of tank on the bracket. D Install a flange on left side on the bracket from the bottom, and tighten bolts to the specified torque. Torque: 36 Nm (27 lb ft) 2. Connect fuel feed tube and fuel return tube(6). 3. Connect evapo fuel hose(5). 4. Connect fuel tank wiring connector(4). 5. Install undercover(3).

6C8

ENGINE FUEL
D Fill the tank with fuel and tighten fuel filler cap. D Connect battery ground cable.

6. Connect fuel filler hose, air breather hose and evapo hose(2). 7. Install fender liner(1). D Mount fender liner to the wheel well.

Fuel Tube / Quick Connect Fittings

Precautions
D Lighting of Fires Prohibited. D Keep flames away from your work area to prevent the inflammable from catching fire. D Disconnect the battery negative cable to prevent shorting during work. D When welding or conducting other heat-generating work on other parts, be sure to provide pretreatment to protect the piping system from thermal damage or spattering. 2. For removal of the delivery pipe (feeding fuel to the engine), hold the connector in one hand, and hold the retainer tab with the other hand and pull out the connector, as illustrated. The pipe can be removed with the retainer attached.

Cautions During Work

Do not expose the assembly to battery electrolyte or do not wipe the assembly with a cloth used to wipe off spilt battery electorolyte. The piping wet with battery electrolyte cannot be used. Be careful not to give a bending or twisting force to the piping during the work. If deformed, replace with a new piping.

Removal
1. Open the fuel cap to relieve the fuel pressure in the tank. If the fuel quick-connect fittings are dusty, clean with an air blower, etc. and then remove it.
141RW019

3. For removal of the return pipe (returnig fuel to the tank), hold the pipe in one hand, and pull out the connentor with the other hand while pressing the square relieve button of the retainer, as illustrated.

141RW016

As some pressure may remain in the piping, cover the connector with a cloth, etc. to prevent the splashing of fuel in the first disconnection of the piping.

141RW020

NOTE: This work should be done by hands. Do not use any tools. Should the pipe can hardly be removed from

ENGINE FUEL
the connector, use a lubricant (light oil) and/or push and pull the connector longitudinally until the pipe is removed.

6C9

D If the retainer removed according to the removal step above is attached to the pipe, clean and insert it straight into the quick-connector till it clicks. After it clicks, try pulling it out to make sure that it is not drawn and is securely locked. NOTE: The retainer, once removed from the pipe, cannot be reused. Just replace with a new retainer. Insert the new retainer into the connector side until it clicks, and connect the pipe as inserting it into the retainer until it clicks.

141RW021

When reusing the delivery pipe retainer, reuse without removing the retainer from the pipe. If the retainer is damaged or deformed, however, replace with a new retainer. Cover the connectors removed with a plastic bag, etc. to prevent the entry of dust or rain water.
141RW018

(Return Pipe) D Replace the pipe and connector if scratch, dent or crack is found. D Remove mud or dust from the pipe and make sure that the end including spool is free from defects, such as scratch, rust, and dent, which may cause poor sealability. If defective, replace with a new pipe. D After cleaning the pipe, insert it straight into the connector until it clicks. After it clicks, try pulling it out to make sure that it is not drawn and is securely locked.

141RW022

Reuse of QuickConnector
(Delivery Pipe) D Replace the pipe and connector if scratch, dent or crack is found. D Remove mud and dust from the pipe and make sure that the end including spool is free of defects, such as scratch, rust, and dent, which may cause poor sealability. If defective, replace with a new pipe.

141RW017

6C10

ENGINE FUEL

Assembling Advice
Application of engine oil or light oil to the pipe facilitates connecting work. The work should be started immediately after lubrication, since dust may stick to the pipe surface to cause poor sealability if a long time passes after lubrication. Test/Inspection After Assembling 1. Reconnect the battery negative cable. 2. Turn the ignition key to the ON position and check pump startup sound. As the pump is actuated to raise fuel pressure, check and see fuel leak from the piping system. 3. Make sure of no fuel leakage by conducting the above fuel leak check a few times. 4. Start the engine and make sure of stable idling speed and normal vehicle run.The entry of dust during the work may sometimes affect the fuel injection system.

ENGINE FUEL 6C11

Fuel Gauge Unit

Fuel Gauge Unit and Associated Parts

140RS004

Legend (1) Wiring Connector (2) Fuel Gauge Unit

Removal
CAUTION: When repair to the fuel system has been completed, start engine and check the fuel system for loose connection or leakage. For the fuel system diagnosis, see Section Driveability and Emission. 1. Disconnect battery ground cable. 2. Loosen fuel filler cap. 3. Drain fuel. Tighten drain plug to the specified torque after draining fuel. Torque: 20 Nm (14 lb ft) M8 4. Wiring connector D Disconnect wiring connector(1) from the unit. 5. Fuel gauge unit D Remove the fixing screws, then the fuel gauge unit(2). NOTE: After removing fuel gauge unit, cover fuel tank to prevent any dust entering

Installation
1. Fuel gauge unit(2). 2. Wiring connector(1). D Connect the wiring connector to the fuel gauge unit. D Fill the tank with fuel and tighten fuel filler cap. D Connect battery ground cable.

6C12

ENGINE FUEL

Fuel Filler Cap

General Description
Fuel filler cap includes vacuum valve and pressure valve. In case any high vacuum and any high pressure happen in tank, each valve works to adjust the pressure to prevent the tank from being damaged.

140R200028

Legend (1) Vacuum Valve (2) Pressure Valve (3) Seal Ring

Inspection
Check the seal ring in the filler cap for presence of any abnormality and for seal condition. Replace the filler cap, if abnormal. CAUTION: The fuel filler cap valves have characteristics. A defective valve, no valve at all or a valve with the wrong characteristics will do a lot of harm to engine operating characteristics; be sure to use the same fuel filler cap as installed in this vehicle.

ENGINE FUEL 6C13

Main Data and Specifications

Torque Specification

035RW031

SECTION
ENGINE ELECTRICAL
TROOPER

6D11

ENGINE
ENGINE ELECTRICAL
CONTENTS
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Charging . . . . . . . . . . . . . . . . . . . . . . 6D11 6D11 6D11 6D12 Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . Battery Removal . . . . . . . . . . . . . . . . . . . . . . Battery Installation . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . 6D12 6D13 6D13 6D14

Battery
General Description
There are six battery fluid caps on top of the battery. These are covered by a paper label. The battery is completely sealed except for the six small vent holes on the side. These vent holes permit the escape of small amounts of gas generated by the battery. This type of battery has the following advantages over conventional batteries: 1. There is no need to add water during the entire service life of the battery. 2. The battery protects itself against overcharging. The battery will refuse to accept an extensive charge. (A conventional battery will accept an excessive charge, resulting in gassing and loss of battery fluid.) 3. The battery is much less vulnerable to self discharge than a conventional type battery.

Diagnosis
061RW001

1. Visual Inspection
Inspect the battery for obvious physical damage, such as a cracked or broken case, which would permit electrolyte loss. Replace the battery if obvious physical damage is discovered during inspection. Check for any other physical damage and correct it as necessary.

2. Hydrometer Check
There is a builtin hydrometer (Charge test indicator(1)) at the top of the battery. It is designed to be used during diagnostic procedures. Before trying to read the hydrometer, carefully clean the upper battery surface. If your work area is poorly lit, additional light may be necessary to read the hydrometer. a. BLUE RING OR DOT VISIBLE(5) Go to Step 4. b. BLUE RING OR DOT NOT VISIBLE(4) Go to Step 3.

6D12

ENGINE ELECTRICAL
a. VOLTAGE DOES NOT DROP BELOW THE MINIMUM LISTED IN THE TABLE The battery is good and should be returned to service. b. VOLTAGE IS LESS THAN MINIMUM LISTED Replace battery. ESTIMATED TEMPERATURE F 70 60 50 40 30 20 10 0 C 21 16 10 4 1 7 12 18 MINIMUM VOLTAGE V 9.6 9.5 9.4 9.3 9.1 8.9 8.7 8.5

3. Fluid Level Check

The fluid level should be between the upper level line(2) and lower level line(3) on side of battery. a. CORRECT FLUID LEVEL Charge the battery. b. BELOW LOWER LEVEL Replace battery.

The battery temperature must be estimated by feel and by the temperature the battery has been exposed to for the preceding few hours.
061RW001

4. Voltage Check
1. Put voltmeter test leads to battery terminals. a. VOLTAGE IS 12.4V OR ABOVE Go to Step 5. b. VOLTAGE IS UNDER 12.4V Go to procedure (2) below. 2. Determine fast charge amperage from specification. (See Main Data and Specifications in this section). Fast charge battery for 30 minutes at amperage rate no higher than specified value. Take voltage and amperage readings after charge. a. VOLTAGE IS ABOVE 16V AT BELOW 1/3 OF AMPERAGE RATE Replace battery. b. VOLTAGE IS ABOVE 16V AT ABOVE 1/3 OF AMPERAGE RATE Drop charging voltage to 15V and charge for 10 15 hours. Then go to Step 5. c. VOLTAGE IS BETWEEN 12V AND 16V Continue charging at the same rate for an additional 31/2 hours. Then go to Step 5. d. VOLTAGE BELOW 12V Replace Battery.

Battery Charging
Observe the following safety precautions when charging the battery: 1. Never attempt to charge the battery when the fluid level is below the lower level line on the side of the battery. In this case, the battery must be replaced. 2. Pay close attention to the battery during charging procedure. Battery charging should be discontinued or the rate of charge reduced if the battery feels hot to the touch. Battery charging should be discontinued or the rate of charge reduced if the battery begins to gas or spew electrolyte from the vent holes. 3. In order to more easily view the hydrometer blue dot or ring, it may be necessary to jiggle or tilt the battery. 4. Battery temperature can have a great effect on battery charging capacity. 5. The sealed battery used on this vehicle may be either quick charged or slow charged in the same manner as other batteries. Whichever method you decide to use, be sure that you completely charge the battery. Never partially charge the battery.

5. Load Test
1. Connect a voltmeter and a battery load tester across the battery terminals. 2. Apply 300 ampere load for 15 seconds to remove surface charge from the battery. Remove load. 3. Wait 15 seconds to let battery recover. Then apply specified load from specifications (See Main Data and Specifications in this section). Read voltage after 15 seconds, then remove load.

Jump Starting
Jump Starting with an Auxiliary (Booster) Battery
CAUTION: Never push or tow the vehicle in an attempt to start it. Serious damage to the emission system as well as other vehicle parts will result.

ENGINE ELECTRICAL
Treat both the discharged battery and the booster battery with great care when using jumper cables. Carefully follow the jump starting procedure, being careful at all times to avoid sparking. WARNING: FAILURE TO CAREFULLY FOLLOW THE JUMP STARTING PROCEDURE COULD RESULT IN THE FOLLOWING: 1. Serous personal injury, particularly to your eyes. 2. Property damage from a battery explosion, battery acid, or an electrical fire. 3. Damage to the electronic components of one or both vehicles particularly. Never expose the battery to an open flame or electrical spark. Gas generated by the battery may catch fire or explode. Remove any rings, watches, or other jewelry before working around the battery. Protect your eyes by wearing an approved set of goggles. Never allow battery fluid to come in contact with your eyes or skin. Never allow battery fluid to come in contact with fabrics or painted surfaces. Battery fluid is a highly corrosive acid. Should battery fluid come in contact with your eyes, skin, fabric, or a painted surface, immediately and thoroughly rinse the affected area with clean tap water. Never allow metal tools or jumper cables to come in contact with the positive battery terminal, or any other metal surface of the vehicle. This will protect against a short circuit. Always keep batteries out of reach of young children.

6D13

4. Attach one end of the remaining cable to the negative terminal of the booster battery. Attach the other end of the same cable to a solid engine ground (such as the air conditioning compressor bracket or the generator mounting bracket) of the vehicle with the discharged battery. The ground connection must be at least 450 mm (18 in.) from the battery of the vehicle whose battery is being charged. WARNING: NEVER ATTACH THE END OF THE JUMPER CABLE DIRECTLY TO THE NEGATIVE TERMINAL OF THE DEAD BATTERY. 5. Start the engine of the vehicle with the good battery. Make sure that all unnecessary electrical accessories have been turned OFF. 6. Start the engine of the vehicle with the dead battery. 7. To remove the jumper cables, follow the above directions in reverse order. Be sure to first disconnect the negative cable from the vehicle with the discharged battery.

Battery Removal

Jump Starting Procedure

1. Set the vehicle parking brake. If the vehicle is equipped with an automatic transmission, place the selector level in the PARK position. If the vehicle is equipped with a manual transmission, place the shift lever in the NEUTRAL position. Turn OFF the ignition. Turn OFF all lights and any other accessory requiring electrical power.
061RS002

2. Look at the builtin hydrometer. If the indication area of the builtin hydrometer is completely clear, do not try to jump start. 3. Attach the end of one jumper cable to the positive terminal of the booster battery. Attach the other end of the same cable to the positive terminal of the discharged battery. Do not allow the vehicles to touch each other. This will cause a ground connection, effectively neutralizing the charging procedure. Be sure that the booster battery has a 12 volt rating.

1. Remove negative cable (1). 2. Remove positive cable (2). 3. Remove retainer screw and rods (3). 4. Remove retainer (4). 5. Remove battery (5).

Battery Installation
1. Install battery (5). 2. Install retainer (4). 3. Instal retainer screw and rods (3). NOTE: Make sure that the rod is hooked on the body side. 4. Install positive cable (2). 5. Install negative cable (1).

6D14

ENGINE ELECTRICAL

Main Data and Specifications

General Specifications
Model (JIS) Voltage (V) Cold Cranking Performance (Amp) Reserve Capacity (Min) Load Test (Amp) Fast Charge Maximum Amperage (Amp) BCI Group No. 95D31RMF 12 622 159 310 20 27 80D26RMF 12 582 133 290 20 24 75D26RMF 12 490 123 245 20 24

SECTION
IGNITION SYSTEM
TROOPER

6D21

ENGINE
IGNITION SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D21 6D22 6D22 6D23 6D23 6D23 6D23 6D25 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Position Sensor . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . 6D25 6D25 6D25 6D26 6D26 6D26 6D27

Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.

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

6D22

IGNITION SYSTEM

General Description
Ignition is done by the electronic ignition (El) that directly fires the spark plugs from ignition coils through spark plug wires without using a distributor. A pair of ignition coils for the cylinders having different phases by 360 (No.1 and No.4,No.2 and No.5,No.3 and No.6) are fired simultaneously. Since the cylinder on exhaust stroke requires less energy to fire its ignition plug, energy from the ignition coils can be utilized to fire the mating cylinder on compression stroke. After additional 360 rotation, respective cylinder strokes are reversed. The EI consists of six ignition coils, ion sensing module, crankshaft position sensor, powertrain control module (PCM) and other components. The crankshaft position coils are connected with the PCM by means of a 80 pin connector. The PCM and ion sensing module turn on/off the primary circuit of ignition coils. A notch in the timing disc on the crankshaft activates the crank position sensor which then sends information such as firing order and starting timing of each ignition coil to the PCM. Further, the El employs ignition control (IC) to control similar to a distributor system. By receiving signals such as crank position,engine speed, water temperature and Manifold Absolute Pressure (MAP), combustion guality, the PCM controls the ignition timing.

D06RY00037

Diagnosis
Refer to Section Drivability and Emissions for the diagnosis to electronic ignition system (El system).

IGNITION SYSTEM

6D23

Ignition Coil
Removal
1. Disconnect battery ground cable. 2. Ignition coil connector and ignition coil. D Disconnect three connector from ignition coil. D Remove harness bracket bolt on cylinder head cover. D Remove fixing bolts on ignition coil. Measure resistance of ignition coil assembly, and replace the ignition coil assembly if its value exceeds the standard.

060RW006

Installation
1. Install the ignition coil assembly (3). Connect ignition coil connector (1) and ignition coil (3), then tighten bolt (2) to the specified torque. Torque: 4 Nm (35 lb in)

060RY023

Legend (1) Ignition Coil Connector (2) Bolt (3) Ignition Coil Assembly

Inspection and Repair

Check the ignition coil assembly for insulation. Check terminals for corrosion or damage, and replace as necessary. Measuring resistance of ignition coil assembly. Terminal No. 1 to 2 Limit Resistance cannot be 0 ohm (short) or infinity (open circuit). Same as above Same as above
060RY023

1 to 3 2 to 3

6D24

IGNITION SYSTEM

CAUTION: Ignition coil assembly # 6 is different from ignition coil assembly from # 1 to # 5. Ignition coil assembly # 6 is short type. So, note it when installing ignition coil assembly of # 6.

060RY00002

Legend (1) Long Type Ignition Coil Assemblies (# 1 # 5) (2) Short Type Ignition Coil Assembly (# 6) 2. Connect battery ground cable.

IGNITION SYSTEM

6D25

Spark Plug
Removal
1. Remove spark plugs.

Measuring Insulation Resistance

D Measure insulation resistance using a 500 volt megaohm meter. D Replace spark plugs if measured value is out of standard. Insulation resistance: 50 MW or more

Inspection and Repair

The spark plug affects entire engine performance and therefore its inspection is very important. D Check electrode and insulator for presence of cracks, and replace if any. D Check spark plug gap. Replace spark plugs if measured value is out of standard. Spark plug gap : 1.0 1.1 mm (0.4 0.043 in)

011RS010

Cleaning Spark Plugs

D Clean spark plugs with a spark plug cleaner. D After spark plug is thoroughly cleaned, check insulator for presence of cracks. D Clean threads and metal body with a wire brush.

011RS011

D Check gasket for damage, and replace if necessary. D Measure insulation resistance with an ohmmeter, and replace if faulty. D Check fuel and electrical systems if spark plug is extremely dirty. D Use spark plugs having low heat value (hot type plug) if fuel and electrical systems are normal. D Use spark plugs having high heat value (cold type plug) if insulator and electrode are extremely burned.

Installation
1. Spark plugs D Tighten spark plugs to the specified torque. Torque: 18 Nm (13 lb ft)

Sooty Spark Plugs

Much deposit of carbon or oil on the electrode and insulator of spark plug reduces the engine performance. Possible causes: D Too rich mixture D Presence of oil in combustion chamber D Incorrect spark plug gap

Burning Electrodes
This fault is characterized by scorched or heavily oxidized electrode or blistered insulator nose. Possible causes: D Too lean mixture D Improper heat value

6D26

IGNITION SYSTEM

Crankshaft Position Sensor

Removal
1. Disconnect battery ground cable 2. Wiring connector from crankshaft position sensor. 3. Remove crankshaft position sensor from cylinder block.

Installation
1. Install crankshaft position sensor into the cylinder block. Before installation,apply small amount of engine oil to the Oring. Torque: 10 Nm (87 lb in) 2. Reconnect wiring connector to crankshaft position sensor.

012RS008

IGNITION SYSTEM

6D27

Main Data and Specifications

General Specifications
Ignition System Ignition Form Spark Plug Type K16PRP11 (DENSO) RC10PYP4 (CHAMPION) PK16PR11 (DENSO) 1.0 mm (0.04 in) 1.1 mm (0.043 in) 18 Nm (13 lb ft) Electronic Ignition System (El system) with Crankshaft position Sensor

Plug gap Torque

Torque Specifications

E06R200001

SECTION
STARTING AND CHARGING SYSTEM
TROOPER

6D31

ENGINE
STARTING AND CHARGING SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . Starting System . . . . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . Charging System . . . . . . . . . . . . . . . . . . . . . . . . 6D31 6D32 6D32 6D34 6D35 6D35 6D35 6D36 6D37 6D39 6D313 6D315 6D318 General Description . . . . . . . . . . . . . . . . . . . . . General OnVehicle Inspection . . . . . . . . . . . Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Bench Test . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . 6D318 6D318 6D319 6D319 6D319 6D319 6D320 6D321 6D323 6D325 6D325 6D326

Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.

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

6D32

STARTING AND CHARGING SYSTEM

Starting System
General Description
Cranking Circuit
The cranking system consists of a battery, starter, starter switch, starter relay, etc. These main components are connected.

Starter
The cranking system employs a magnetic type reduction starter in which the motor shaft is also used as a pinion shaft. When the starter switch is turned on, the contacts of magnetic switch are closed, and the armature rotates. At the same time, the plunger is attracted, and the pinion is pushed forward by the shift lever to mesh with the ring gear. Then, the ring gear runs to start the engine. When the engine starts and the starter switch is turned off, the plunger returns, the pinion is disengaged from the ring gear, and the armature stops rotation. When the engine speed is higher than the pinion, the pinion idles, so that the armature is not driven.

STARTING AND CHARGING SYSTEM

6D33

C06RY00002

6D34

STARTING AND CHARGING SYSTEM

Diagnosis
Condition Starter does not run Possible cause Charging failure Battery Failure Terminal connection failure Starter switch failure Starter failure Correction Repair charging system Replace Battery Repair or replace terminal connector and/or wiring harness Repair or replace starter switch Repair or replace starter

STARTING AND CHARGING SYSTEM

6D35

Starter
Removal
1. Battery ground cable. 2. Disconnect Heated O2 Sensor connector (1). 3. Remove exhaust front left pipe(2). 3. Reconnect the connectors to terminals B and S and tighten Terminals B to specified torque. Torque: 9 Nm (78 lb in) 4. Install heat protector(3).

065RW027 035RW016

4. Remove heat protector(3). 5. Disconnect starter wiring connector from terminals B and S(4). 6. Remove starter assembly mounting bolts on inside and outside(5). 7. Remove starter assembly toward the bottom of engine(6).

5. Install exhaust front left pipe (2) and tighten bolts and nuts to specified torque. Stud Nuts Torque: 67 Nm (49 lb ft) Nuts (Exhaust front left pipeRight pipe) Torque: 57 Nm (42 lb ft) Nuts (Exhaust front left pipeSilencer) Torque: 43 Nm (32 lb ft) 6. Connect Heated O2 Sensor connector (1).

065RW027

Installation
1. Install starter assembly(6). 2. Install mounting bolts and tighten bolts to specified torque(5). Torque: 40 Nm (30 lb ft) 7. Reconnect the battery ground cable.

035RW016

6D36

STARTING AND CHARGING SYSTEM

Disassembled View

065RW002

Legend (1) Bolt (2 pcs) (2) Ball Bearing (3) Pinion (4) Shift Lever (5) Dust Cover (6) Torsion Spring (7) Dust Cover (8) Magnetic Switch (9) Nut (10) Gear Case (11) Bearing Cover (12) ERing (13) Thrust Washer (2)

(14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26)

Center Bracket Pinion Shaft Planet Gear (3) Internal Gear Center Bracket (A) Yoke Assembly Armature Brush Brush Holder Thrust Washer Rear Cover Screw (2 pcs) Through Bolt (2 pcs)

STARTING AND CHARGING SYSTEM

6D37

Disassembly
1. Loosen the nut(1) on terminal M of magnetic switch and disconnect the connector cable. 2. Remove bolt (2 pcs) (2).

7. Remove screw (2 pcs) (8). 8. Remove through bolt (2 pcs) (7). 9. Remove screws and through bolts, then the rear cover(9) then remove thrust washer(10). 10. Remove brush holder(6).

065RW003

3. Remove magnetic switch(5). 4. Remove dust cover(4). 5. Remove torsion spring bolts, then the magnetic switch assembly. 6. Remove torsion spring(3) from magnetic switch assembly(5).

065RW005

11. Raise a brush spring to detach brushes (4 pcs) from the commutator face and pull off the brush holder(12) and brush(11).

065RW006

065RW004

6D38

STARTING AND CHARGING SYSTEM

17. Remove ball bearing(19). 18. Remove bearing cover(20). 19. Remove a ball bearing and bearing cover from the gear case(18).

12. Remove yoke assembly(14). 13. Remove armature(15). 14. Pull off the yoke assembly, then remove armature, washer and center bracket.(A) (13). NOTE: In disassembling the yoke assembly, hold the armature and pull off slowly the yoke assembly. Because of strong magnetic force, avoid placing a metallic part near armature.

065RW021

20. Internal gear(21). 21. Remove internal gear and planet gear(3) (22).
065RW007

15. Remove dust cover(17). 16. Remove a dust cover and shift lever(16) from the gear case.

065RW009

065RW008

STARTING AND CHARGING SYSTEM

22. Remove an Ering(23) from the pinion shaft using a flat blade screwdriver.

6D39

Inspection and Repair

Repair or replace necessary parts if extreme wear or damage is found during inspection.

Armature
Measure the outer diameter of commutator, and replace with a new one if it is out of the limit. Standard: 33.0 mm (1.30 in) Limit: 32.0 mm (1.26 in)

065RW010

23. Holding the pinion shaft, push pinion toward the center bracket. and turn the pinion clockwise or counterclockwise by one tooth of spline, then pull off the pinion. 24. Remove thrust washer(24). 25. Remove center bracket 26. Remove pinion shaft.

065RS014

Check for continuity between commutator and segment. Replace commutator if there is no continuity (i.e., disconnected).

065RW011

065RS015

6D310 STARTING AND CHARGING SYSTEM

Check for continuity between commutator and shaft. Also, check for continuity between commutator and armature core,armature core and shaft. Replace commutator if there is continuity (i.e., internally grounded). Polish the commutator surface with sandpaper #500 to #600 if it is rough.

065RW012

065RS016

Measure runout of armature core and commutator with a dial gauge. Repair or replace, if it exceeds the limit. Armature Standard: 0.05 mm (0.002 in) Max. Limit: 0.10 mm (0.004 in) Commutator Standard: 0.05 mm (0.002 in) Max. Limit: 0.10 mm (0.004 in)

Measure the depth of insulator in commutator. Repair, if it is below the limit. Standard: 0.5 mm to 0.8 mm (0.02 in to 0.03 in) Limit: 0.2 mm (0.008 in)

065RW013

Legend (1) Steel Saw (2) Insulator (3) Commutator Segments

065RS017

STARTING AND CHARGING SYSTEM

6D311

Brush
Measure the length of brush. Replace with a new one, if it is below the limit. Standard: 16 mm (0.63 in) Limit: 11 mm (0.43 in)

Magnetic Switch
Check for continuity of shunt coil between terminals S and M. Replace, if there is no continuity (i.e., coil is disconnected).

065RW016 065RW014

Brush Holder
Check for continuity between brush holder (+) (4) and base (). Replace, if there is continuity (i.e., insulation is broken).

Continuity of Series Coil

Check for continuity between terminals S and M. Replace, if there is no continuity (i.e., coil is disconnected).

065RW017 065RW015

6D312 STARTING AND CHARGING SYSTEM

Continuity of Contacts
With the plunger faced downward, push down the magnetic switch. In this state, check for continuity between terminals B and M. Replace, if there is no continuity (i.e., contacts are faulty).

Yoke Assembly
Check a magnet inside the yoke. Replace the yoke assembly if it is broken.

065RS026

065RW018

Ball Bearing
Clamp the inner race of the ball bearing with your finger, and check for sticking or play when rotating the outer race. Replace, if abnormality is found.

Pinion
Check if the pinion rotates smoothly in drive direction by hand, or if it is locked when it is rotated in reverse. If not, replace the pinion.

065RS027 065RS025

STARTING AND CHARGING SYSTEM

Measure inner diameter of bushing in the rear cover, and replace if it exceeds the limit. Standard: 12.50 mm to 12.527 mm (0.492 in to 0.4932 in) Limit: 12.60 mm (0.4961 in)

6D313

Reassembly
To install, follow the removal steps in the reverse order, noting the following points: Grease application places D D D D D Bushing in rear cover and center bracket Gears in reduction gear Shift lever operating portion Sliding portion of pinion Plunger sliding portion of magnetic switch

Reassembling Yoke Assembly

Before reassembly, make sure that no metallic parts attach to the yoke assembly. Because of strong magnetic force, hold the yoke assembly and insert it slowly into the armature. Torque Torque for each part (See Torque Specifications in this section)

Pinion Jumpout Dimension

Connect the + cable of battery to terminal S and the cable to terminal M. Turn the switch on, and measure pinion travel dimension in thrust direction from the jumpout position. In measuring the dimension, pull the pinion out a little in the arrow direction. Dimension(L): 0.05 mm to 1.5 mm (0.002 in to 0.06 in)

065RS028

Measure inner diameter of bushing in the center bracket (P), and replace if it exceeds the limit. Standard: 18.01 mm to 18.127 mm (0.7091 in to 0.7137 in) Limit: 18.15 mm (0.7146 in)

065RS029

065RS030

6D314 STARTING AND CHARGING SYSTEM

If the measured value is out of standard, insert dust cover, or disassemble and adjust.

065RW019

Characteristic Test
For easily confirming the characteristics, conduct the no load test as follows: Rating as short as 30 seconds requires rapid testing. Fix the starter on the test bench, and wire as shown in illustration. When the switch is closed, the current flows and the starter runs under no load. At this time, measure current, voltage and speed to check if they satisfy the standard.

065RW020

Legend (1) Volt Meter (2) Tachometer (3) Battery (4) Ammeter (5) Switch

STARTING AND CHARGING SYSTEM

6D315

Main Data and Specifications

General Specifications
Model Rating Voltage Output Time Number of teeth of pinion Rotating direction(as viewed from pinion) Weight(approx.) No load characteristics Voltage /Current Speed Load characteristics Voltage/current Torque Speed Locking characteristics Voltage/current Torque 3V/750A or less 19Nm(14 lb ft) or more 8.4V/250A 7.3Nm(64lbin.) or more 1200rpm or more 11V/90A or less 2700rpm or more 12 V 1.4 Kw 30 sec 9 Clockwise 34 N (7.6 lb) HITACHI GD003138

6D316 STARTING AND CHARGING SYSTEM

Torque Specifications

E06RW023

STARTING AND CHARGING SYSTEM

6D317

060R200207

6D318 STARTING AND CHARGING SYSTEM

Charging System
General Description
The IC integral regulator charging system and its main components are connected as shown in the illustration. The regulator is a solid state type and it is mounted along with the brush holder assembly inside the generator installed on the rear end cover. The generator does not require particular maintenance such as voltage adjustment. The rectifier connected to the stator coil has eight diodes to transform AC voltage into DC voltage. This DC voltage is connected to the output terminal of generator.

General OnVehicle Inspection

The operating condition of charging system is indicated by the charge warning lamp. The warning lamp comes on when the starter switch is turned to ON position. The charging system operates normally if the lamp goes off when the engine starts. If the warning lamp shows abnormality or if undercharged or overcharged battery condition is suspected, perform diagnosis by checking the charging system as follows: 1. Check visually the belt and wiring connector. 2. With the engine stopped, turn the stator switch to ON position and observe the warning lamp. If lamp does not come on: Disconnect wiring connector from generator, and ground the terminal L on connector side. If lamp comes on: Repair or replace the generator.

F06RY00002

STARTING AND CHARGING SYSTEM

6D319

Generator
Removal
1. Disconnect battery ground cable. 2. Move drive belt tensioner to loose side using wrench then remove drive belt (1). 3. Disconnect the wire from terminal B and disconnect the connector (4). 4. Remove generator fixing bolt (3). 5. Remove generator assembly (2).

066RW001

If voltage is not present, the line between battery and connector is disconnected and so requires repair. 3. Reconnect the wiring connector to the generator, run the engine at middle speed, and turn off all electrical devices other than engine. 4. Measure battery voltage. If it exceeds 16V, repair or replace the generator. 5. Connect an ammeter to output terminal of generator, and measure output current under load by turning on the other electrical devices (eg., head lights). At this time, the voltage must not be less than 13V.

060RW002

Inspection
1. Disconnect the wiring connector from generator. 2. With the engine stopped, turn starter switch to ON and connect a voltmeter between connector terminal L (2) and ground or between terminal IG (1) and ground.

Installation
1. Install generator assembly to the position to be installed. 2. Install generator assembly and tighten the fixing bolts to the specified torque. Torque: M10 bolt: 41 Nm (30 lb ft) M8 bolt: 21 Nm (15 lb ft) 3. Connect wiring harness connector and direct terminal B. 4. Move drive belt tensioner to loose side using wrench, then install drive belt to normal position. 5. Reconnect battery ground cable.

6D320 STARTING AND CHARGING SYSTEM

Disassembled View

066RW007

Legend (1) Pulley Nut (2) Pulley (3) Front Cover Assembly (4) Rotor Assembly (5) Rear End Cover

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

Rectifier Terminal Insulator and Nut Regulator Assembly Brush Holder Assembly Rear Cover

STARTING AND CHARGING SYSTEM

6D321

Disassembly
1. Terminal insulator and nut(2). 2. Remove three nuts(1) on the rear cover and a nut on terminal B and insulator, then remove the rear cover(3).

4. Remove three screws on the IC regulator, then the IC regulator assembly(6).

060RW003

5. Remove four screws that fix rectifier(7) and stator lead wires.
060RW005

3. Remove two screws that fix the brush holder(5) and rectifier, then remove the brush holder assembly(4).

066RW004

060RW004

6D322 STARTING AND CHARGING SYSTEM

6. Secure the pulley directly in the vise between two copper plates, and remove the nut and pulley. 8. Use the puller to remove the rear end cover. 9. Rotor assembly

066RS010

066RS012

7. Remove four nuts(8) that secure the front cover assembly and rear end cover, and an insulator(9).

10. Pull the rotor assembly(10) off the front cover assembly(12) using a bench press(11).

066RW005

066RW006

STARTING AND CHARGING SYSTEM

6D323

Inspection and Repair

Repair or replace necessary parts if extreme wear or damage is found during inspection.

3. Check resistance between slip rings, and replace if there is no continuity.

Rotor Assembly
1. Check the rotor slip ring surfaces for contamination and roughness. If rough, polish with #500600 sandpaper.

066RS016

4. Check for continuity between slip ring and rotor core. In case of continuity, replace the rotor assembly.

066RS014

2. Measure the slip ring diameter, and replace if it exceeds the limit.

066RS017

066RS015

6D324 STARTING AND CHARGING SYSTEM

Stator Coil
1. Measure resistance between respective phases. 2. Measure insulation resistance between stator coil and core with a megaohmmeter. If less than standard, replace the coil.

Rectifier Assembly
Check for continuity across P and E in the 100W range of multimeter.

066RW002

066RS018

Brush
Measure the brush length. If more than limit, replace the brush. Standard: 10.mm (0.4134 in) Limit: 8.4.mm (0.3307 in)

Change polarity, and make sure that there is continuity in one direction, and not in the reverse direction. In case of continuity in both directions, replace the rectifier assembly.

IC Regulator Assembly
Check for continuity across B and F in the 100W range of multimeter.

066RS021

066RS019

STARTING AND CHARGING SYSTEM

Change polarity, and make sure that there is continuity in one direction, and not in the reverse direction. In case of continuity in both directions, replace the IC regulator assembly.

6D325

Bench Test
Conduct a bench test of the generator.

Reassembly
To reassemble, follow the disassembly steps in the reverse order, noting the following points: 1. Using a press with a socket wrench attached, reassemble rotor and rear end cover assembly in the front cover.

066RS023

Preparation
Remove generator from the vehicle (see Generator removal). 1. Secure generator to the bench test equipment and connect wires. Terminal IG for energization Terminal L for neutral (warning lamp) Terminal B for output 2. Conduct the generator characteristic test. Characteristics of generator are shown in illustration. Repair or replace the generator if its outputs are abnormal.

066RS022

2. Install pulley on the rotor. Secure the pulley directly in the vise between two copper plates, and tighten nut to the specified torque. Torque: 111 Nm (82 lb ft)

066RS010

B06RX001

6D326 STARTING AND CHARGING SYSTEM

Main Data and Specifications

General Specifications
Parts Number (Nippon denso) Model Rated voltage Rated output Rotating direction (As viewed from pulled) Pulley effective diameter Weight 1022111740 ACJV74 12 V 90 A Clockwise 57.5 mm (2.26 in) 49.7 N (11.2 lb)

SECTION
TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
TROOPER

6E1

ENGINE
TROOPER 3.5L ENGINE DRIVEABILITY AND EMISSIONS
CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . Tightening Specifications . . . . . . . . . . . . . . . Diagrams and Schematics . . . . . . . . . . . . . . . . PCM Wiring Diagram (1 of 8) . . . . . . . . . . . . PCM Wiring Diagram (2 of 8) . . . . . . . . . . . . PCM Wiring Diagram (3 of 8) . . . . . . . . . . . . PCM Wiring Diagram (4 of 8) . . . . . . . . . . . . PCM Wiring Diagram (5 of 8) . . . . . . . . . . . . PCM Wiring Diagram (6 of 8) . . . . . . . . . . . . PCM Wiring Diagram (7 of 8) . . . . . . . . . . . . PCM Wiring Diagram (8 of 8) . . . . . . . . . . . . PCM Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . PCM Pinout Table, 80-Way Blue Connector Row F1 20 . . . . . . . . . . . . . . . . . . . . . . PCM Pinout Table, 80-Way Blue Connector Row F20 40 . . . . . . . . . . . . . . . . . . . . . PCM Pinout Table, 80-Way Blue Connector Row F41 60 . . . . . . . . . . . . . . . . . . . . . PCM Pinout Table, 80-Way Blue Connector Row F61 80 . . . . . . . . . . . . . . . . . . . . . PCM Pinout Table, 80-Way Red Connector Row S1 20 . . . . . . . . . . . . . . . . . . . . . . PCM Pinout Table, 80-Way Red Connector Row S21 40 . . . . . . . . . . . . . . . . . . . . . PCM Pinout Table, 80-Way Red Connector Row S41 60 . . . . . . . . . . . . . . . . . . . . . PCM Pinout Table, 80-Way Red Connector Row S61 80 . . . . . . . . . . . . . . . . . . . . . Component Locators . . . . . . . . . . . . . . . . . . . Undercarriage Component Locator . . . . . . Fuse and Relay Panel (Underhood Electrical Center) . . . . . . . . . . . . . . . . . . . . . Sensors and Miscellaneous Component Locators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Strategy-Based Diagnostics . . . . . . . . . . . . . Strategy-Based Diagnostics . . . . . . . . . . . . . DTC Stored . . . . . . . . . . . . . . . . . . . . . . . . . . . No DTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No Matching Symptom . . . . . . . . . . . . . . . . . Intermittents . . . . . . . . . . . . . . . . . . . . . . . . . . No Trouble Found . . . . . . . . . . . . . . . . . . . . . Verifying Vehicle Repair . . . . . . . . . . . . . . . . General Service Information . . . . . . . . . . . . . . OBD II Serviceablity Issues . . . . . . . . . . . . . Visual / Physical Engine Compartment Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic Knowledge of Tools Required . . . . . . Serial Data Communications . . . . . . . . . . . . . . Class 2 Serial Data Communications . . . . . 6E6 6E6 6E7 6E7 6E8 6E9 6E10 6E11 6E12 6E13 6E14 6E15 6E15 6E16 6E18 6E20 6E22 6E24 6E26 6E28 6E30 6E32 6E33 6E34 6E36 6E36 6E36 6E36 6E36 6E36 6E36 6E36 6E36 6E36 6E36 6E37 6E37 6E38 6E38 On-Board Diagnostic (OBD II) . . . . . . . . . . . . . On-Board Diagnostic Tests . . . . . . . . . . . . . Comprehensive Component Monitor Diagnostic Operation . . . . . . . . . . . . . . . . . . System Status and Drive Cycle for Satisfying Federal Inspection/Maintenance (I/M 240) Regulations . . . . . . . . . . . . . . . . . . Common OBD II Terms . . . . . . . . . . . . . . . . . The Diagnostic Executive . . . . . . . . . . . . . . . DTC Types . . . . . . . . . . . . . . . . . . . . . . . . . . . Decimal/Binary/Hexadecimal Conversions Verifying Vehicle Repair . . . . . . . . . . . . . . . . Reading Diagnostic Trouble Codes Using The Tech 2 Scan Tool . . . . . . . . . . . . . . . . . Tech 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tech 2 Features . . . . . . . . . . . . . . . . . . . . . . . Getting Started . . . . . . . . . . . . . . . . . . . . . . . . Operating Procedure (For Example) . . . . . DTC Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC Information Mode . . . . . . . . . . . . . . . . . Miscellaneous Test . . . . . . . . . . . . . . . . . . . . Lamps Test . . . . . . . . . . . . . . . . . . . . . . . . . . . Relays Test . . . . . . . . . . . . . . . . . . . . . . . . . . . EVAP Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System Test . . . . . . . . . . . . . . . . . . . . . . Instruments Test . . . . . . . . . . . . . . . . . . . . . . . EGR Control Test . . . . . . . . . . . . . . . . . . . . . . Variable Intake Manifold Solenoid Test . . . Injector Balance Test . . . . . . . . . . . . . . . . . . . Plotting Snapshot Graph . . . . . . . . . . . . . . . . . Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information) . . . . . . Flow Chart for Snapshot Replay (Plotting Graph) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Primary System-Based Diagnostic . . . . . . . . . Primary System-Based Diagnostic . . . . . . . Fuel Control Heated Oxygen Sensor . . . . . HO2S Heater . . . . . . . . . . . . . . . . . . . . . . . . . Catalyst Monitor Heated Oxygen Sensors and Diagnostic Operation . . . . . . . . . . . . . . Misfire Monitor Diagnostic Operation . . . . . . . Misfire Monitor Diagnostic Operation . . . . . Misfire Counters . . . . . . . . . . . . . . . . . . . . . . . Fuel Trim System Monitor Diagnostic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Trim System Monitor Diagnostic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E38 6E38 6E38

6E39 6E39 6E39 6E40 6E41 6E42 6E42 6E43 6E44 6E44 6E45 6E46 6E46 6E47 6E47 6E49 6E50 6E51 6E53 6E55 6E55 6E57 6E57 6E58 6E59 6E60 6E60 6E60 6E60 6E60 6E61 6E61 6E61 6E62 6E62

6E2

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E62 6E63 6E63 6E63 6E63 6E66 6E66 6E66 6E67 6E71 6E71 6E71 6E71 6E71 6E71 6E71 6E72 6E76 6E76 6E76 6E76 6E79 6E79 6E81 6E81 6E87 6E87 6E87 6E90 6E90 6E90 6E92 6E92 6E92 6E95 6E95 6E95 6E97 6E99 6E99 6E99 6E104 6E105 6E105 6E105 6E105 6E108 6E109 Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . Test Description . . . . . . . . . . . . . . . . . . . . . . . Fuel System Diagnosis . . . . . . . . . . . . . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Test Description . . . . . . . . . . . . . . . . . . . . . . . Fuel Pressure Relief Procedure . . . . . . . . . Exhaust Gas Recirculation (EGR) System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Manifold Absolute Pressure (MAP) Output Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Evaporative (EVAP) Emissions Canister Purge Valve Check . . . . . . . . . . . . . . . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . PCM Diagnostic Trouble Codes . . . . . . . . . . . DTC P0101 MAF System Performance . . . . DTC P0102 MAF Sensor Circuit Low Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0103 MAF Sensor Circuit High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0106 MAP System Performance . . . . DTC P0107 MAP Sensor Circuit Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0108 MAP Sensor Circuit High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0112 IAT Sensor Circuit Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0113 IAT Sensor Circuit High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0117 ECT Sensor Circuit Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0118 ECT Sensor Circuit High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0125 ECT Excessive Time to Closed Loop Fuel Control . . . . . . . . . . . . . . . . . . . . . . . DTC P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0132 HO2S Circuit High Voltage Bank 1 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0133 HO2S Slow Response Bank 1 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0135 HO2S Heater Circuit Bank 1 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0137 HO2S Circuit Low Voltage Bank 1 Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0138 HO2S Circuit High Voltage Bank 1 Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0140 HO2S Circuit Insufficient Activity Bank 1 Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0141 HO2S Heater Circuit Bank 1 Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . 6E109 6E109 6E112 6E113 6E113 6E114 6E117 6E117 6E119 6E119 6E121 6E121 6E121 6E124 6E128 6E131 6E134 6E136 6E139 6E142 6E145 6E148 6E151 6E154 6E157 6E160 6E163 6E166 6E170 6E173 6E176 6E179 6E182 6E185

Fuel Trim Cell Diagnostic Weights . . . . . . . On-Board Diagnostic (OBD II) System Check Circuit Description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . Test Description . . . . . . . . . . . . . . . . . . . . . . . A/C Clutch Control Circuit Diagnosis . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . A/C Clutch Diagnosis . . . . . . . . . . . . . . . . . . Electronic Ignition System Diagnosis . . . . . . . EVAP Canister Purge Solenoid and EVAP Vent Solenoid Valve . . . . . . . . . . . . . . . . . . . . . Visual Check of The Evaporative Emission Canister . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Metering System Check . . . . . . . . . . . . . Fuel System Pressure Test . . . . . . . . . . . . . . . Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure . . . . . . . . . . Test Description . . . . . . . . . . . . . . . . . . . . . . . Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11) . . . . . . . . . . . . . . . . . . . . . . . . . . Powertrain Control Module (PCM) Diagnosis Multiple PCM Information Sensor DTCs Set Circuit Description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Gas Recirculation (EGR) Diagnosis Engine Tech 2 Data Definitions and Ranges Typical Scan Data Values . . . . . . . . . . . . . . . . Test Conditions . . . . . . . . . . . . . . . . . . . . . . . . No Malfunction Indicator Lamp (MIL) . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . Malfunction Indicator Lamp (MIL) ON Steady . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . No Reduced Power Lamp (RPL) . . . . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . Reduced Power Lamp (RPL) ON Steady . . Circuit description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . Engine Cranks But Will Not Run . . . . . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . Test Description . . . . . . . . . . . . . . . . . . . . . . . Fuel System Electrical Test . . . . . . . . . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . Test Description . . . . . . . . . . . . . . . . . . . . . . . Fuel Pressure Relief Procedure . . . . . . . . . Electric Throttle Control (ETC) System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . .

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0152 HO2S Circuit High Voltage Bank 2 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0153 HO2S Slow Response Bank 2 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0155 HO2S Heater Circuit Open Bank 2 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0157 HO2S Circuit Low Voltage Bank 2 Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0158 HO2S Circuit High Voltage Bank 2 Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0160 HO2S Circuit Insufficient Activity Bank 2 Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0161 HO2S Heater Circuit Bank 2 Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0171 Fuel Trim System Lean Bank 1 . DTC P0172 Fuel Trim System Rich Bank 1 . DTC P0174 Fuel Trim System Lean Bank 2 . DTC P0175 Fuel Trim System Rich Bank 2 . DTC P0201 Injector 1 Control Circuit . . . . . . DTC P0202 Injector 2 Control Circuit . . . . . . DTC P0203 Injector 3 Control Circuit . . . . . . DTC P0204 Injector 4 Control Circuit . . . . . . DTC P0205 Injector 5 Control Circuit . . . . . . DTC P0206 Injector 6 Control Circuit . . . . . . DTC P0300 Engine Misfire Detected . . . . . . . DTC P0325 ION Sensing Module/ION Sensing Knock Intensity Circuit Fault . . . . . . . . . . . . . . DTC P0336 58X Reference Signal Circuit . . DTC P0337 CKP Sensor Circuit Low Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0351 Ignition 1 Control Circuit . . . . . . . DTC P0352 Ignition 2 Control Circuit . . . . . . . DTC P0353 Ignition 3 Control Circuit . . . . . . . DTC P0354 Ignition 4 Control Circuit . . . . . . . DTC P0355 Ignition 5 Control Circuit . . . . . . . DTC P0356 Ignition 6 Control Circuit . . . . . . . DTC P0401 EGR Flow Insufficient . . . . . . . . . DTC P0402 EGR Pintle Crank Error . . . . . . . DTC P0404 EGR Open Stuck . . . . . . . . . . . . . DTC P0405 EGR Low Voltage . . . . . . . . . . . . DTC P0406 EGR High Voltage . . . . . . . . . . . DTC P0420 TWC System Low Efficiency Bank 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0430 TWC System Low Efficiency Bank 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0440 EVAP System . . . . . . . . . . . . . . . . DTC P0442 EVAP System Small Leak Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0444 EVAP Purge Control Circuit Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E188 6E191 6E194 6E198 6E201 6E204 6E207 6E210 6E213 6E216 6E220 6E224 6E228 6E232 6E235 6E238 6E241 6E244 6E247 6E250 6E254 6E257 6E260 6E263 6E266 6E269 6E272 6E275 6E278 6E281 6E284 6E286 6E288 6E291 6E294 6E297 6E300 6E303 6E306 DTC P0445 EVAP Purge Control Circuit Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0446 EVAP Canister Vent Control Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0447 EVAP Vent Solenoid Circuit Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0448 EVAP Vent solenoid Circuit Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0452 Fuel Tank Pressure Sensor (Vapor Pressure Sensor) Low Voltage . . . . . DTC P0453 Fuel Tank Pressure Sensor (Vapor Pressure Sensor) High Voltage . . . . . DTC P0456 EVAP Very Small Leak . . . . . . . DTC P0461 Fuel Level Sensor Performance DTC P0462 Fuel Level Sensor CircuitLow Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0463 Fuel Level Sensor CircuitHigh Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0464 Fuel Level Sensor Noisy Signal DTC P0502 VSS Circuit Low Input . . . . . . . . . DTC P0506 Idle Air Control System Low RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0507 Idle Air Control System High RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0562 System Voltage Low . . . . . . . . . . DTC P0563 System Voltage High . . . . . . . . . DTC P0565 Cruise Main Switch Circuit Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0566 Cruise Cancel Switch Circuit Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0567 Cruise Resume Switch Circuit Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0568 Cruise Set Switch Circuit Error . DTC P0571 No Brake Switch Signal . . . . . . . DTC P0601 PCM Memory . . . . . . . . . . . . . . . . DTC P0602 PCM Programming Error . . . . . . DTC P0604 PCM RAM Error . . . . . . . . . . . . . . DTC P0606 PCM Internal Performance . . . . DTC P0660 VIM Solenoid Circuit Open . . . . DTC P0662 VIM Solenoid Circuit Short . . . . . DTC P1106 MAP Sensor Circuit Intermittent High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1107 MAP Circuit Intermittent Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1111 IAT Sensor Circuit Intermittent High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1112 IAT Sensor Circuit Intermittent Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1114 ECT Sensor Circuit Intermittent Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1115 ECT Sensor Circuit Intermittent High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1120-TPS 1 Throttle Position Sensor (TPS1) Circuit Fault . . . . . . . . . . . . . . . . . . . . . DTC P1125 ETC (Electric throttle control) Limit Performance Mode . . . . . . . . . . . . . . . . .

6E3
6E308 6E310 6E313 6E315 6E317 6E320 6E323 6E326 6E328 6E331 6E333 6E335 6E338 6E341 6E344 6E346 6E348 6E350 6E352 6E354 6E356 6E358 6E360 6E362 6E364 6E366 6E368 6E370 6E372 6E374 6E377 6E379 6E381 6E384 6E387

6E4

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E390 6E394 6E398 6E402 6E406 6E408 6E410 6E413 6E416 6E419 6E422 6E425 6E428 6E430 6E432 6E434 6E436 6E438 6E440 6E443 6E446 6E449 6E452 6E455 6E458 6E461 6E465 6E468 6E471 6E474 6E476 6E478 6E479 6E481 6E483 Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . Default Matrix Table . . . . . . . . . . . . . . . . . . . . . On Vehicle Service Crankshaft Position (CKP) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Coolant Temperature (ECT) Sensor . Heated Oxygen Sensor (HO2S) . . . . . . . . . . . Intake Air Temperature (IAT) Sensor . . . . . . . ION Sensing Module . . . . . . . . . . . . . . . . . . . . . Mass Air Flow (MAF) Sensor . . . . . . . . . . . . . Manifold Absolute Pressure (MAP) Sensor . Malfunction Indicator Lamp (MIL) . . . . . . . . . . Reduced Power Lamp . . . . . . . . . . . . . . . . . . . Powertrain Control Module (PCM) . . . . . . . . . Service Precaution . . . . . . . . . . . . . . . . . . . . Removal Procedure . . . . . . . . . . . . . . . . . . . . Installation Procedure . . . . . . . . . . . . . . . . . . EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Throttle Position (TP) Sensor . . . . . . . . . . . . . Vehicle Speed Sensor (VSS) . . . . . . . . . . . . . Air Cleaner/Air Filter . . . . . . . . . . . . . . . . . . . . . Common Chamber . . . . . . . . . . . . . . . . . . . . . . Accelerator Pedal Replacement . . . . . . . . . . . Accelerator Position Sensor Replacement . . Accelerator Position Sensor Adjustment . . . . Fuel Filler Cap . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Gauge Unit . . . . . . . . . . . . . . . . . . . . . . . . Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Metering System . . . . . . . . . . . . . . . . . . . . Fuel Pump Assembly . . . . . . . . . . . . . . . . . . . . Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . . . Fuel Rail Assembly . . . . . . . . . . . . . . . . . . . . . . Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Throttle Body (TB) . . . . . . . . . . . . . . . . . . . . . . . Electronic Ignition System . . . . . . . . . . . . . . . . Catalytic Converter . . . . . . . . . . . . . . . . . . . . . . Air Conditioning Thermo Relay . . . . . . . . . . . EVAP Canister Hoses . . . . . . . . . . . . . . . . . . . . EVAP Canister . . . . . . . . . . . . . . . . . . . . . . . . . . EVAP Canister Vent Solenoid . . . . . . . . . . . . . Fuel Tank Pressure (Vapor Pressure) Sensor EVAP Canister Purge Solenoid (Purge Duty Solenoid Valve) . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Tank Vent Valve (Vent Solenoid Valve) . Linear Exhaust Gas Recirculation (EGR) Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Positive Crankcase Ventilation (PCV) Valve . PCV Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring and Connectors . . . . . . . . . . . . . . . . . . . PCM Connectors and Terminals . . . . . . . . . . . Wire Harness Repair: Twisted Shielded Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Twisted Leads . . . . . . . . . . . . . . . . . . . . . . . . . . Weather-Pack Connector . . . . . . . . . . . . . . . . . 6E486 6E515 6E518 6E518 6E519 6E522 6E522 6E523 6E524 6E525 6E525 6E525 6E525 6E525 6E526 6E527 6E527 6E528 6E529 6E529 6E530 6E531 6E531 6E532 6E532 6E534 6E534 6E535 6E536 6E536 6E537 6E538 6E538 6E540 6E541 6E541 6E541 6E542 6E543 6E544 6E545 6E545 6E545 6E546 6E547 6E547 6E548 6E548 6E549 6E550

DTC P1133 HO2S Insufficient Switching Bank 1 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P1134 HO2S Transition Time Ratio Bank 1 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P1153 HO2S Insufficient Switching Bank 2 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P1154 HO2S Circuit Transition Time Ratio Bank 2 Sensor 1 . . . . . . . . . . . . . . . . . . DTC P1167 Fuel System Rich During Decel Fuel Cut Off (Bank 1) . . . . . . . . . . . . . . . . . . . . DTC P1169 Fuel System Rich During Decel Fuel Cut Off (Bank 2) . . . . . . . . . . . . . . . . . . . . DTC P1171 Fuel System Lean During Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1220 Throttle Position Senser2 (TPS2) Circuit Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1221 TPS1 TPS2 correlation (Circuit Performance) . . . . . . . . . . . . . . . . . . . DTC P1271 APS 1 2 Correlation Error . . . . DTC P1272 APS 2 3 Correlation Error . . . . DTC P1273 APS 1 3 Correlation Error . . . . DTC P1275 APS 1 Circuit Fault . . . . . . . . . . . DTC P1280 APS 2 Circuit Fault . . . . . . . . . . . DTC P1285 APS 3 Circuit Fault . . . . . . . . . . . DTC P1290 ETC Forced Idle Mode . . . . . . . . DTC P1295 Power Management Mode . . . . DTC P1299 ETC Forced Engine Shutdown Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1310 ION Sensing Module Diagnosis DTC P1311 ION Sensing Module SEC Line 1 Circuit Fault . . . . . . . . . . . . . . . . . . . . . . DTC P1312 ION Sensing Module SEC Line 2 Circuit Fault . . . . . . . . . . . . . . . . . . . . . . DTC P1326 ION Sensing Module Combustion Quality Input Circuit Fault . . . . . . . . . . . . . . . . DTC P1340 ION Sensing Module Cylinder ID Fault (Cylinder Synchronization Fail) . . . . . . DTC P1404 EGR Stuck Closed . . . . . . . . . . . DTC P1441 EVAP System Flow During Non-Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1514 TPS - MAF Correlation Error . . . DTC P1515 Command - Actual TPS Correlation Error . . . . . . . . . . . . . . . . . . . . . . . . DTC P1516 Command - Actual TPS Correlation Error . . . . . . . . . . . . . . . . . . . . . . . . DTC P1523 Actuator Control Return Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1574 Brake Switch No Operation . . . . DTC P1635 Reference Voltage # 1 Circuit Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1636 PCM RAM Stack . . . . . . . . . . . . . DTC P1639 Reference Voltage # 2 Circuit Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1640 Driver-1-Output Circuit Fault (ODM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1650 Quad Driver Module A Fault . .

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Com-Pack III . . . . . . . . . . . . . . . . . . . . . . . . . . . Metri-Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Description (PCM and Sensors) . . . 58X Reference PCM Input . . . . . . . . . . . . . . A/C Request Signal . . . . . . . . . . . . . . . . . . . . Crankshaft Position (CKP) Sensor . . . . . . . Engine Coolant Temperature (ECT) Sensor Electrically Erasable Programmable Read Only Memory (EEPROM) . . . . . . . . . . . . . . Fuel Control Heated Oxygen Sensors . . . . Catalyst Monitor Heated Oxygen Sensors Intake Air Temperature (IAT) Sensor . . . . . Linear Exhaust Gas Recirculation (EGR) Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mass Air Flow (MAF) Sensor . . . . . . . . . . . . Manifold Absolute Pressure (MAP) Sensor Powertrain Control Module (PCM) . . . . . . . PCM Function . . . . . . . . . . . . . . . . . . . . . . . . . PCM Components . . . . . . . . . . . . . . . . . . . . . PCM Voltage Description . . . . . . . . . . . . . . . PCM Input/Outputs . . . . . . . . . . . . . . . . . . . . PCM Service Precautions . . . . . . . . . . . . . . Reprogramming The PCM . . . . . . . . . . . . . . Throttle Position (TP) Sensor . . . . . . . . . . . Transmission Fluid Temperature (TFT) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Range Switch (Mode Switch) Vehicle Speed Sensor (VSS) . . . . . . . . . . . . Use of Circuit Testing Tools . . . . . . . . . . . . . Aftermarket Electrical and Vacuum Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrostatic Discharge Damage . . . . . . . . . General Description (Air Induction) . . . . . . . . Air Induction System . . . . . . . . . . . . . . . . . . . General Description (Fuel Metering) . . . . . . . Acceleration Mode . . . . . . . . . . . . . . . . . . . . . Battery Voltage Correction Mode . . . . . . . . Clear Flood Mode . . . . . . . . . . . . . . . . . . . . . Deceleration Mode . . . . . . . . . . . . . . . . . . . . Engine Speed/Vehicle Speed/Fuel Disable Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Cutoff Mode . . . . . . . . . . . . . . . . . . . . . . 6E551 6E552 6E553 6E553 6E553 6E553 6E553 6E553 6E553 6E554 6E554 6E555 6E555 6E555 6E556 6E556 6E556 6E556 6E556 6E557 6E557 6E557 6E557 6E557 6E557 6E557 6E558 6E558 6E558 6E558 6E559 6E559 6E559 6E559 6E559 6E559 6E559 Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Metering System Components . . . . . . Fuel Metering System Purpose . . . . . . . . . . Fuel Pressure Regulator . . . . . . . . . . . . . . . . Fuel Pump Electrical Circuit . . . . . . . . . . . . . Fuel Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting Mode . . . . . . . . . . . . . . . . . . . . . . . . . Throttle Body Unit . . . . . . . . . . . . . . . . . . . . . General Description (Electronic Ignition System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Position (CKP) Sensor . . . . . . . Electronic Ignition . . . . . . . . . . . . . . . . . . . . . Ignition Coils . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition Control . . . . . . . . . . . . . . . . . . . . . . . . Ignition Control PCM Output . . . . . . . . . . . . Powertrain Control Module (PCM) . . . . . . . Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . A/C Clutch Diagnosis . . . . . . . . . . . . . . . . . . . . A/C Clutch Circuit Operation . . . . . . . . . . . . A/C Clutch Circuit Purpose . . . . . . . . . . . . . A/C Request Signal . . . . . . . . . . . . . . . . . . . . General Description (Evaporative (EVAP) Emission System) . . . . . . . . . . . . . . . . . . . . . . EVAP Emission Control System Purpose . EVAP Emission Control System Operation Enhanced Evaporative Emission Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Description (Exhaust Gas Recirculation (EGR) System) . . . . . . . . . . . . . EGR Purpose . . . . . . . . . . . . . . . . . . . . . . . . . Linear EGR Valve . . . . . . . . . . . . . . . . . . . . . Linear EGR Control . . . . . . . . . . . . . . . . . . . . Linear EGR Valve Operation and Results of Incorrect Operation . . . . . . . . . . . . . . . . . . . . EGR Pintle Position Sensor . . . . . . . . . . . . . General Description (Positive Crankcase Ventilation (PCV) System) . . . . . . . . . . . . . . . Crankcase Ventilation System Purpose . . . Crankcase Ventilation System Operation . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . .

6E5
6E559 6E559 6E559 6E560 6E560 6E560 6E560 6E560 6E561 6E561 6E561 6E561 6E561 6E561 6E562 6E562 6E563 6E564 6E564 6E564 6E564 6E565 6E565 6E565 6E565 6E568 6E568 6E569 6E569 6E569 6E569 6E569 6E569 6E569 6E571

6E6

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Specifications
Tightening Specifications
Application EGR Bolt Engine Coolant Temperature Sensor Fuel Drain Plug Fuel Pressure Regulator Attaching Screw Fuel Rail Bolts Fuel Tank Undercover Retaining Bolts Heated Oxygen Sensor Lower Intake Manifold to Engine Block Bolts Lower Intake Manifold to Engine Block Nuts Spark Plugs Throttle Body Mounting Bolts Common Chamber to Lower Intake Manifold Bolts VSS Retaining Bolt Nm 25 30 20 3 25 36 55 25 25 18 10 25 16 Lb Ft. 18 22 14 18 27 40 18 18 13 18 12 Lb In. 26 87

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E7

Diagrams and Schematics

PCM Wiring Diagram (1 of 8)

D06R200030

6E8

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

PCM Wiring Diagram (2 of 8)

D06R200031

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E9

PCM Wiring Diagram (3 of 8)

D06R200032

6E10

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

PCM Wiring Diagram (4 of 8)

D06R200033

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E11

PCM Wiring Diagram (5 of 8)

D06R200086

6E12

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

PCM Wiring Diagram (6 of 8)

D06R200035

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E13

PCM Wiring Diagram (7 of 8)

D06R200036

6E14

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

PCM Wiring Diagram (8 of 8)

D06R200037

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E15

PCM Pinouts
PCM Pinout Table, 80-Way Blue Connector Row F1 20

060RY00045

PIN F1 F2 F3 F4

PIN Function PCM Ground 5Volt Referrence2 (AP Sensor 2) 5Volt Referrence2 (TP Sensor 2) A/C Clutch

Wire Color BLK/BLU GRN RED/WHT GRN/BLK

IGN ON 0.0V 5.0V 5.0V B+(A/C off)

ENG RUN 0.0V 5.0V 5.0V B+(A/C off)

Refer To Chassis Electrical AP Sensor AP Sensor General Description and Operation,A/C Cluch Circuit Opreation 4L30E T/Mission Chassis Electrical General Description, Mass Air Flow Sensor General Description and Operation, Catalyst Monitor HO2S 2 6D Section 6D Section

F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 F17

Mission Main Case Not Used Tachometer Not Used Not Used Not Used T.O.D Not Used Not Used Mass Air Flow(MAF) Not Used Not Used Bank 1 HO2S Low

GRN/RED BLK/RED RED/WHT YEL RED

0.0V 8.8V 4.9V 0.0V

0.0V 10.0V(at idle) 4.2V 0.1V

F18 F19 F20

Not Used Ignition Feed Ignition Feed

RED/BLU WHT

B+ B+

B+ B+

6E16

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

PCM Pinout Table, 80-Way Blue Connector Row F20 40

060RY00156

PIN F21

PIN Function Bank 1 HO2S 1 Ground

Wire Color WHT

IGN ON 0.0V

ENG RUN 0.0V

Refer To General Description and Operation, Catalyst Monitor HO2S 1 General Description and Operation, Catalyst Monitor HO2S 1 General Description and Operation,ION Sensing Module General Description and Operation,ION Sensing Module General Description and Operation, IAT General Description and Operation, Manifold Absolute Pressure

F22 F23

Not Used Bank 2 HO2S 1 Ground BLU

0.0V

0.0V

F24 F25

Not Used ION Sensing Module

RED/BLU

1.555V

1.555V

F26

ION Sensing Module

RED/BLK

1.555V

1.555V

F27 F28 F29

Intake Air Temperature (IAT)Sensor Not Used Manifold Absolute Pressure(MAP)

YEL/GRN RED

0.54.9V 3.5V4.9V (depends on altitude and barometric pressure)

0.54.9V 0.6-1.3V

F30 F31 F32 F33 F34 F35 F36 F37 F38

Not Used Not Used Power Lamp Reduse Power Lamp Winter Lamp Not Used Not Used Power Steering Pressure (PSP) Illuminated Switch

GRN/WHT RED/WHT PNK/GRN GRN/YEL GRN/YEL

B+ B+ B+ B+ B+

B+ B+ B+ B+ B+

4L30E T/Mission Chassis Electrical 4L30E T/Mission Power Steering Chassis Electrical

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

PIN F39 F40 PIN Function Brake Swich PCM Ground Wire Color GRN/YEL BLK/RED IGN ON 0.0V 0.0V ENG RUN 0.0V 0.0V Refer To 4L30E T/Mission Chassis Electrical

6E17

6E18

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

PCM Pinout Table, 80-Way Blue Connector Row F41 60

060RY00046

PIN F41 F42 F43 F44

PIN Function Throttle Position(TP) 1 Sensor Ground Fuel Pump Relay Adaptor Case Bank 1 HO2S 2 Heater Ground A/C Request Auto Cruise Brake Switch Adaptor Case Throttle Valve DC Motor() Not Used Bank 2 HO2S 2 Ground

Wire Color GRN SIL/BLK VIO/RED BLK/PNK

IGN ON 0.0V 0.0V 0.0V 0.0V

ENG RUN 0.0V B+ 0.0V 0.0V

Refer To General Description and Operation,TPS On Vehicle Service, Fuel Pump Relay 4L30E T/Mission General Description and Operation, Catalyst Monitor HO2S 2 Chassis Electrical Chassis Electrical 4L30E T/Mission General Description and Operation, ETC General Description and Operation, Catalyst Monitor HO2S 2 Chassis Electrical General Description and Operation, Catalyst Monitor HO2S 2 General Description and Operation,ECT Sensor General Description and Operation,VP Sensor General Description and Operation,Fuel Injector Chassis Electrical General Description

F45 F46 F47 F48 F49 F50

GRN/ORN ORN VIO/RED BLK ORN

0.0V 0.0V B+ Duty Cycle 0.0V

0.0V 0.0V B+ Duty Cycle 0.0V

F51 F52

DLC Serial Data Bank 1 HO2S 2 Ground

ORN RED

5.0V 0.0V

5.0V 0.0V

F53 F54 F55 F56 F57 F58

ECT Ground Vapor Pressure Sensor Ground Not Used Injector Cylinder #5 Ignition Feed Class 2 Data

GRN GRY/RED GRN/BLK WHT ORN/GRN

0.0V 0.0V B+ B+ 0.0V

0.0V 0.0V B+ B+ 0.0V

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

PIN F59 F60 PIN Function Not Used Not Used Wire Color IGN ON ENG RUN Refer To

6E19

6E20

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

PCM Pinout Table, 80-Way Blue Connector Row F61 80

060RY00047

PIN F61 F62 F63 F64 F65 F66 F67

PIN Function Throttle Position(TP) 2 Sensor Ground Injector Cylinder #2 AP Sensor 1 Sensor Ground Injector Cylinder #4 Throttle Psition(TP) 2 Sensor Signal Injector Cylinder #3 ION Sensing Module

Wire Color GRN/WHT GRN/ORN RED GRN/RED BLU/WHT GRN YEL

IGN ON 0.0V B+ 0.0V B+ 0.50.8V B+ 1.555V

ENG RUN 0.0V B+ 0.0V B+ 0.80.8V (at idle) B+ 1.555V

Refer To General Description and Operation,TPS General Description and Operation,Fuel Injector General Description and Operation,APS General Description and Operation,Fuel Injector General Description and Operation,TPS General Description and Operation,Fuel Injector General Description and Operation, ION Sensing Module General Description and Operation, ION Sensing Module General Description and Operation,Fuel Injector General Description and Operation, Catalyst Monitor HO2S 2 Chassis Electrical General Description and Operation, CKP sensor General Description and Operation, ECT Sensor Chassis Electrical Manual T/Mission 4L30E T/Mission

F68

ION Sensing Module

RED

1.555V

1.555V

F69 F70 F71

Injector Cylinder #1 Not Used Bank 2 HO2S 2 Heater Ground Auto Cruise Switch Resume Cranshaft Position Sensor ECT Sensor Ignition Feed Clutch Switch(M/T only) Mode Switch(A/T only)

GRN/WHT BLK

B+ 0.0V

B+ 0.0V

F72 F73 F74 F75 F76

BRN/YEL YEL BLU/RED RED/BLU YEL/GRN YEL/GRN

0.0V 0.3V 0.54.9V B+ B+ B+

0.0V 2.2V 0.54.9V B+ B+ B+

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

PIN F77 F78 F79 F80 PIN Function Mode Switch Mode Switch Mode Switch AP Sensor 2 Sensor Ground Wire Color BLU/WHT BLU/BLK BLU/YEL BLU IGN ON B+ B+ B+ 0.0V ENG RUN B+ B+ B+ 0.0V Refer To 4L30E T/Mission 4L30E T/Mission 4L30E T/Mission

6E21

General Description and Operation, APS

6E22

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

PCM Pinout Table, 80-Way Red Connector Row S1 20

060RY00069

PIN S1 S2

PIN Function PCM Ground Bank 1 HO2S 1 Heater Ground Not Used ATF Warning Lamp 5Volt Referrence2 (CKP Sensor/CMP Sensor) Auto Cruise Switch Cancel EVAP Parge Solenoid Valve Not Used Not Used Shift High(Band Apply) Malfunction Indicator (Check Engine) Lamp Not Used ION Sensing Module

Wire Color BLK/WHT BLK

IGN ON 0.0V 0.0V

ENG RUN 0.0V 0.0V

Refer To Chassis Electrical General Description and Operation, Catalyst Monitor HO2S 4L30E T/Mission Appropriate Sensor (CKP Sensor, CMP Sensor ,AP2 Sensor) Chassis Electrical General Description and Operation, EVAP Emission Control System 4L30E T/Mission Chassis Electrical General Description and Operation, ION Sensing Module General Description and Operation, Catalyst Monitor HO2S 1 General Description and Operation, Catalyst Monitor HO2S 2 General Description and Operation, Catalyst Monitor HO2S

S3 S4 S5

ORN/BLU YEL/RED

B+ 5.0V

B+ 5.0V

S6 S7

GRY/GRN RED/BLU

0.0V B+

0.0V 5.7V

S8 S9 S10 S11 S12 S13

BRN/YEL VIO RED/WHT

B+ 0.0V 1.555V

B+ B+ 1.555V

S14

Bank 2 HO2S 1 Ground Jump Bank 2 HO2S 2 Ground Jump Bank 2 HO2S 2 Low

BLU

0.0V

0.0V

S15

ORN

0.0V

0.0V

S16

BLU

0.0V

0.1V

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

PIN S17 PIN Function Bank 1 HO2S 1 Ground Jump Bank 1 HO2S 1 Low Wire Color WHT IGN ON 0.0V ENG RUN 0.0V Refer To

6E23

General Description and Operation, Catalyst Monitor HO2S 1 General Description and Operation, Catalyst Monitor HO2S General Description and Operation, ION Sensing Module 4L30E T/Mission

S18

GRN

0.0V

0.1V

S19

ION Sensing Module

RED/YEL

1.555V

1.555V

S20

Transmission Fluid Temperature Sensor Ground

RED/WHT

0.0V

0.0V

6E24

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

PCM Pinout Table, 80-Way Red Connector Row S21 40

060RY00049

PIN S21 S22 S23 S24

PIN Function Not Used Transmissin Output Speed Sensor PCM Ground Bank 1 HO2S 2 Ground Jump Not Used EGR Control Low VSS Input Injector Cylinder #6 Winter Switch Auto Cruise Main Switch Transmissin Range Signal23 Ignition Feed TCC Solenoid Not Used ION Sensing Module

Wire Color RED BLK/RED RED

IGN ON 0.0V 0.0V 0.0V

ENG RUN 0.0V 0.0V 0.0V

Refer To 4L30E T/Mission Chassis Electrical General Description and Operation, Catalyst Monitor HO2S 2 General Description and Operation, EGR Control Chassis Electrical General Description and Operation, Fuel Injector 4L30E T/Mission Chassis Electrical 4L30E T/Mission Chassis Electrical T/Mission General Description and Operation, ION Sensing Module AP Sensor (Fuel Tank Pressure Sensor/MAP Sensor/EGR Posistion Sensor) Sensor TP Sensor

S25 S26 S27 S28 S29 S30 S31 S32 S33 S34 S35

BLK/YEL Light GRN/WHT GRN/YEL VIO/GRN PNK/BLK GRN RED/BLU RED/BRN RED/GRN

B+ 0.0V B+ B+ 0.0V 0.0V B+ 0.0V 1.555V

B+ 0.1V (at rest) B+ B+ 0.0V 0.0V B+ 0.0V 1.555V

S36 S37

5Volt Referrence (AP Sensor 1) 5Volt Referrence (Fuel Tank Pressure Sensor/MAP Sensor/EGR Posistion Sensor) 5Volt Referrence (TP Sensor 1)

BLK RED/BLU

5.0V 5.0V

5.0V 5.0V

S38

RED/BLU

5.0V

5.0V

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

PIN S39 S40 PIN Function Auto Cruise Lamp PCM Ground Wire Color BLK/ORN BLK IGN ON 0.0V 0.0V ENG RUN 0.0V 0.0V Refer To Chassis Electrical Chassis Electrical

6E25

6E26

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

PCM Pinout Table, 80-Way Red Connector Row S41 60

060RY00050

PIN S41 S42

PIN Function AP Sensor 3 Sensor Ground Bank 2 HO2S 1 Heater Ground Transmissin Range Signal12 34 Not Used Antilock Brake System (ABS) Off Switch A/T Check Transmission Lamp M/T Up Shift Lamp Water Temp Gauge Fuel Gauge DLC Fuel Sender Unit TCC Solenoid Vapor Pressure Sensor Signal Power Switch Bank 2 HO2S 1 Low

Wire Color BLU/ORN BLK

IGN ON 0.0V 0.0V

ENG RUN 0.0V 0.0V

Refer To General Description and Operation, APS General Description and Operation, Catalyst Monitor HO2S 4L30E T/Mission Antilock Brake System Chassis Electrical Chassis Electrical Chassis Electrical Chassis Electrical General Description T/Mission General Description and Operation,VP Sensor 4L30E T/Mission General Description and Operation, Catalyst Monitor HO2S 4L30E T/Mission General Description and Operation, Catalyst Monitor HO2S

S43 S44 S45 S46

GRY/WHT VIO/WHT ORN/BLK ORN/BLK WHT/BLK YEL/RED ORN/BLU YEL/VIO BRN/BLU GRY VIO/RED BLU

0.0V B+ B+ B+ B+ B+ B+ 0.0V B+ 0.24.8V B+ 0.0V

0.0V B+ B+ B+ B+ B+ B+ 0.0V B+ 0.24.8V B+ 0.1V

S47 S48 S49 S50 S51 S52 S53 S54

S55 S56 S57 S58

Transmissin Output Speed Sensor Not Used Not Used Bank 2 HO2S 1 High

WHT RED

0.0V 0.3V

0.0V 0.10.9V

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

PIN S59 S60 PIN Function Auto Cruise Steering Set Switch Fuel Sender Unit Wire Color Light GRN GRY IGN ON 0.0V 0.54.9V ENG RUN 0.0V 0.54.9V Refer To Chassis Electrical

6E27

ON-Vehicle Service PCM and Sensors

6E28

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

PCM Pinout Table, 80-Way Red Connector Row S61 80

060RY00051

PIN S61 S62

PIN Function Intake Air Temperature (IAT)Sensor Ground ION Sensing Module

Wire Color GRN RED

IGN ON 0.0V 1.555V

ENG RUN 0.0V 1.555V

Refer To General Description and Operation, IAT General Description and Operation, ION Sensing Module General Description and Operation, Catalyst Monitor HO2S General Description and Operation, Catalyst Monitor HO2S General Description and Operation, Catalyst Monitor HO2S 4L30E T/Mission

S63

Bank 1 HO2S 2 High

WHT

0.3V

0.10.9V

S64

Bank 2 HO2S 1 High

PNK

0.3V

0.10.9V

S65

Bank 2 HO2S 2 High

GRN

0.3V

0.10.9V

S66

Transmission Fluid Temperature Sensor Exhaust Gas Recirculation (EGR) Accelerator Position(AP) Sensor 1 Throttle Valve DC Motor(+) Not Used Not Used Ignition Feed for ETC Auto Cruise Main Lamp Variable Intake Manifold Canister Vent Valve Throttle Position(TP) 1 Sensor Signal

RED/BLK

0.54.9V (depends on temperature) 0.6V 0.410.45V Duty Cycle

0.54.9V (depends on temperature) 0.6V 0.410.45V Duty Cycle B+ B+ B+(rpm 3600 over) 5.7V Tank empty 0.50.8V (at idle)

S67 S68 S69 S70 S71 S72 S73 S74 S75 S76

YEL/RED WHT RED RED/BLU GRY/BLU WHT/BLU BLU/PNK BLU/PNK

General Description and Operation,EGR Control General Description and Operation,AP Sensor General Description and Operation,ETC Chassis Electrical Chassis Electrical General Description General Description and Operation, EVAP General Description and Operation,TPS

B+ B+ 0.0V 6.0V Tank empty 0.50.8V

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

PIN S77 S78 S79 S80 PIN Function 5Volt Referrence (AP Sensor 3) Accelerate Position(AP) Sensor 2 Accelerate Position(AP) Sensor 3 Manifold Absolute Pressure(MAP) Wire Color ORN YEL BLU/GRN GRN IGN ON 5.0V 0.410.45V 4.554.99V 0V ENG RUN 5.0V 0.410.45V 0.410.45V 0V Refer To Appropriate Sensor

6E29

General Description and Operation,AP Sensor General Description and Operation,AP Sensor General Description and Operation, Manifold Absolute Pressure

6E30

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Component Locators
Engine Component Locator

060R200243

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Engine Component Locator Table Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Name Linear Exhaust Gas Recirculation (EGR) Valve Throttle Position (TP) Sensor Intake Air Temperature (IAT) Sensor Check Engine (MIL) Light Positive Crankcase Ventilation (PCV) Valve Air Cleaner Mass Air Flow (MAF) Sensor Fuel Rail Fuel Pressure Regulator ION Sensing module Common Chamber EVAP Duty Solenoid Valve Fuse/Relay Box Manifold Absolute Pressure (MAP) Sensor Throttle Body Engine Coolant Temperature Sensor Power Train Control Module (PCM) Location Rear right side of the engine On the throttle body

6E31

On the intake air duct near the throttle body On the instrument panel beneath the tachometer On the left of the cylinder head cover Left front of the engine bay Attached to the air filter box On the Common Chamber Rear side of the engine Bolted to the top of the Common Chamber Top of the engine Bolted to the front of the coolant pipe Along the inside of the right fender Bolted to the top of the Common Chamber Between the intake air duct and the Common Chamber On the coolant crossover pipe at the front of the engine, near the throttle body Along the inside of the left fender

6E32

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Undercarriage Component Locator

F00RW032

Undercarriage Component Locator Table Number 1 2 3 4 5 6 Name Fuel Pump Assembly EVAP Canister Vent Solenoid (EVAP Canister) Fuel Gauge Unit Fuel Filter Vehicle Speed Sensor (VSS) Location Installed in the top of the fuel tank On the top of the bracket that is located behind of the cross member On the top of the bracket that is located behind of the cross member Installed in the front edge of the fuel tank, on the right side Located along the inside of the right frame rail, ahead of the rear axle 2WD: Protrudes from the transmission housing, just ahead of the propeller shaft. 4WD: Protrudes from the rear output shaft housing of the transfer case. Threaded into the exhaust pipe behind the right-hand catalytic converter Threaded into the exhaust pipe ahead of the right-hand catalytic converter Threaded into the exhaust pipe ahead the left-hand catalytic converter Threaded into the exhaust pipe behind the left-hand catalytic converter

7 8 9 10

Heated Oxygen Sensor (Bank 1, HO2S 1) Heated Oxygen Sensor (Bank 1, HO2S 2) Heated Oxygen Sensor (Bank 2, HO2S 1) Heated Oxygen Sensor (Bank 2, HO2S 2)

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E33

Fuse and Relay Panel (Underhood Electrical Center)

060R200212

6E34

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Sensors and Miscellaneous Component Locators

060RY00013

060RW111

T321067

060R200201

060R200224

055RY00002

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E35

041RW004

060R200208

025RW005

060R200209

060RY00014

6E36

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

3. Use a check sheet or other method to identify the circuit or electrical system component. 4. Follow the suggestions for intermittent diagnosis found in the service documentation. Most Scan Tools, such as the Tech 2, have data-capturing capabilities that can assist in detecting intermittents.

Diagnosis Strategy-Based Diagnostics

Strategy-Based Diagnostics
The strategy-based diagnostic is a uniform approach to repair all Electrical/Electronic (E/E) systems. The diagnostic flow can always be used to resolve an E/E system problem and is a starting point when repairs are necessary. The following steps will instruct the technician how to proceed with a diagnosis: 1. Verify the customer complaint. D To verify the customer complaint, the technician should know the normal operation of the system. 2. Perform preliminary checks. D Conduct a thorough visual inspection. D Review the service history. D Detect unusual sounds or odors. D Gather diagnostic trouble code information to achieve an effective repair. 3. Check bulletins and other service information. D This includes videos, newsletters, etc. 4. Refer to service information (manual) system check(s). D System checks contain information on a system that may not be supported by one or more DTCs. System checks verify proper operation of the system. This will lead the technician in an organized approach to diagnostics. 5. Refer to service diagnostics.

No Trouble Found
This condition exists when the vehicle is found to operate normally. The condition described by the customer may be normal. Verify the customer complaint against another vehicle that is operating normally. The condition may be intermittent. Verify the complaint under the conditions described by the customer before releasing the vehicle. 1. Re-examine the complaint. When the complaint cannot be successfully found or isolated, a re-evaluation is necessary. The complaint should be re-verified and could be intermittent as defined in Intermittents section, or could be normal. 2. Repair and verify. After isolating the cause, the repairs should be made. Validate for proper operation and verify that the symptom has been corrected. This may involve road testing or other methods to verify that the complaint has been resolved under the following conditions: D Conditions noted by the customer. D If a DTC was diagnosed, verify a repair by duplicating conditions present when the DTC was set as noted in the Failure Records or Freeze Frame data.

Verifying Vehicle Repair

Verification of the vehicle repair will be more comprehensive for vehicles with OBD II system diagnostics. Following a repair, the technician should perform the following steps: IMPORTANT: Follow the steps below when you verify repairs on OBD II systems. Failure to follow these steps could result in unnecessary repairs. 1. Review and record the Failure Records and the Freeze Frame data for the DTC which has been diagnosed (Freeze Frame data will only be stored for an A or B type diagnostic and only if the MIL(Check Engine lamp) has been requested). 2. Clear the DTC(S). 3. Operate the vehicle within conditions noted in the Failure Records and Freeze Frame data. 4. Monitor the DTC status information for the DTC which has been diagnosed until the diagnostic test associated with that DTC runs.

DTC Stored
Follow the designated DTC chart exactly to make an effective repair.

No DTC
Select the symptom from the symptom tables. Follow the diagnostic paths or suggestions to complete the repair. You may refer to the applicable component/system check in the system checks.

No Matching Symptom
1. Analyze the complaint. 2. Develop a plan for diagnostics. 3. Utilize the wiring diagrams and the theory of operation. Combine technician knowledge with efficient use of the available service information.

Intermittents
Conditions that are not always present are called intermittents. To resolve intermittents, perform the following steps: 1. Observe history DTCs, DTC modes, and freeze frame data. 2. Evaluate the symptoms and the conditions described by the customer.

General Service Information

OBD II Serviceablity Issues
With the introduction of OBD II diagnostics across the entire passenger car and light-duty truck market in 1996, illumination of the MIL (Check Engine lamp) due to a non-vehicle fault could lead to misdiagnosis of the vehicle, increased warranty expense and customer

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

dissatisfaction. The following list of non-vehicle faults does not include every possible fault and may not apply equally to all product lines. Fuel Quality Fuel quality is not a new issue for the automotive industry, but its potential for turning on the MIL (Check Engine lamp) with OBD II systems is new. Fuel additives such as dry gas and octane enhancers may affect the performance of the fuel. If this results in an incomplete combustion or a partial burn, it will show up as a Misfire DTC P0300. The Reed Vapor Pressure of the fuel can also create problems in the fuel system, especially during the spring and fall months when severe ambient temperature swings occur. A high Reed Vapor Pressure could show up as a Fuel Trim DTC due to excessive canister loading. High vapor pressures generated in the fuel tank can also affect the Evaporative Emission diagnostic as well. Using fuel with the wrong octane rating for the vehicle may cause driveability problems. Many of the major fuel companies advertise that using premium gasoline will improve the performance of the vehicle. Most premium fuels use alcohol to increase the octane rating of the fuel. Although alcohol-enhanced fuels may raise the octane rating, the fuels ability to turn into vapor in cold temperatures deteriorates. This may affect the starting ability and cold driveability of the engine. Low fuel levels can lead to fuel starvation, lean engine operation, and eventually engine misfire. Non-OEM Parts All of the OBD II diagnostics have been calibrated to run with OEM parts. Something as simple as a high-performance exhaust system that affects exhaust system back pressure could potentially interfere with the operation of the EGR valve and thereby turn on the MIL (Check Engine lamp). Small leaks in the exhaust system near the post catalyst oxygen sensor can also cause the MIL (Check Engine lamp) to turn on. Aftermarket electronics, such as transceivers, stereos, and anti-theft devices, may radiate EMI into the control system if they are improperly installed. This may cause a false sensor reading and turn on the MIL (Check Engine lamp). Environment Temporary environmental conditions, such as localized flooding, will have an effect on the vehicle ignition system. If the ignition system is rain-soaked, it can temporarily cause engine misfire and turn on the MIL (Check Engine lamp). Refueling A new OBD II diagnostic was introduced in 1996 on some vehicles. This diagnostic checks the integrity of the entire evaporative emission system. If the vehicle is restarted after refueling and the fuel cap is not secured correctly, the on-board diagnostic system will sense this as a system fault and turn on the MIL (Check Engine lamp) with a DTC P0440.

6E37

Vehicle Marshaling The transportation of new vehicles from the assembly plant to the dealership can involve as many as 60 key cycles within 2 to 3 miles of driving. This type of operation contributes to the fuel fouling of the spark plugs and will turn on the MIL (Check Engine lamp) with a P0300 Misfire DTC. Poor Vehicle Maintenance The sensitivity of OBD II diagnostics will cause the MIL (Check Engine lamp) to turn on if the vehicle is not maintained properly. Restricted air filters, fuel filters, and crankcase deposits due to lack of oil changes or improper oil viscosity can trigger actual vehicle faults that were not previously monitored prior to OBD II. Poor vehicle maintenance cant be classified as a non-vehicle fault, but with the sensitivity of OBD II diagnostics, vehicle maintenance schedules must be more closely followed. Related System Faults Many of the OBD II system diagnostics will not run if the PCM detects a fault on a related system or component. One example would be that if the PCM detected a Misfire fault, the diagnostics on the catalytic converter would be suspended until Misfire fault was repaired. If the Misfire fault was severe enough, the catalytic converter could be damaged due to overheating and would never set a Catalyst DTC until the Misfire fault was repaired and the Catalyst diagnostic was allowed to run to completion. If this happens, the customer may have to make two trips to the dealership in order to repair the vehicle.

Visual / Physical Engine Compartment Inspection

Perform a careful visual and physical engine compartment inspection when performing any diagnostic procedure or diagnosing the cause of an emission test failure. This can often lead to repairing a problem without further steps. Use the following guidelines when performing a visual/physical inspection: D Inspect all vacuum hoses for pinches, cuts, disconnections, and proper routing. D Inspect hoses that are difficult to see behind other components. D Inspect all wires in the engine compartment for proper connections, burned or chafed spots, pinched wires, contact with sharp edges or contact with hot exhaust manifolds or pipes.

Basic Knowledge of Tools Required

NOTE: Lack of basic knowledge of this powertrain when performing diagnostic procedures could result in an incorrect diagnosis or damage to powertrain components. Do not attempt to diagnose a powertrain problem without this basic knowledge. A basic understanding of hand tools is necessary to effectively use this section of the Service Manual.

6E38

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

powertrain components. The CARB OBD II Comprehensive Component Monitoring List Of Components Intended To illuminate MIL is a list of components, features or functions that could fall under this requirement. Input Components: Input components are monitored for circuit continuity and out-of-range values. This includes rationality checking. Rationality checking refers to indicating a fault when the signal from a sensor does not seem reasonable, i.e. Throttle Position (TP) sensor that indicates high throttle position at low engine loads or MAP voltage. Input components may include, but are not limited to the following sensors: D Vehicle Speed Sensor (VSS) D Crankshaft Position (CKP) sensor D Throttle Position (TP) sensor D Engine Coolant Temperature (ECT) sensor D Manifold Absolute Pressure (MAP) sensor D Mass Air Flow (MAF) sensor In addition to the circuit continuity and rationality check, the ECT sensor is monitored for its ability to achieve a steady state temperature to enable closed loop fuel control. Output Components: Output components are diagnosed for proper response to control module commands. Components where functional monitoring is not feasible will be monitored for circuit continuity and out-of-range values if applicable. Output components to be monitored include, but are not limited to, the following circuits: D Control module controlled EVAP Canister Purge Valve D Electronic Transmission controls D A/C relays D VSS output D MIL control D Cruise control inhibit Refer to PCM and Sensors in General Descriptions. Passive and Active Diagnostic Tests A passive test is a diagnostic test which simply monitors a vehicle system or component. Conversely, an active test, actually takes some sort of action when performing diagnostic functions, often in response to a failed passive test. For example, the EGR diagnostic active test will force the EGR valve open during closed throttle decel and/or force the EGR valve closed during a steady state. Either action should result in a change in manifold pressure. Intrusive Diagnostic Tests This is any on-board test run by the Diagnostic Management System which may have an effect on vehicle performance or emission levels.

Serial Data Communications

Class 2 Serial Data Communications
Government regulations require that all vehicle manufacturers establish a common communication system. This vehicle utilizes the Class 2 communication system. Each bit of information can have one of two lengths: long or short. This allows vehicle wiring to be reduced by transmitting and receiving multiple signals over a single wire. The messages carried on Class 2 data streams are also prioritized. If two messages attempt to establish communications on the data line at the same time, only the message with higher priority will continue. The device with the lower priority message must wait. The most significant result of this regulation is that it provides Scan tool manufacturers with the capability to access data from any make or model vehicle that is sold. The data displayed on other Scan tools will appear the same, with some exceptions. Some Scan tools will only be able to display certain vehicle parameters as values that are a coded representation of the true or actual value. On this vehicle the Scan tool displays the actual values for vehicle parameters. It will not be necessary to perform any conversions from coded values to actual values.

On-Board Diagnostic (OBD II)

On-Board Diagnostic Tests
A diagnostic test is a series of steps, the result of which is a pass or fail reported to the diagnostic executive. When a diagnostic test reports a pass result, the diagnostic executive records the following data: D The diagnostic test has been completed since the last ignition cycle. D The diagnostic test has passed during the current ignition cycle. D The fault identified by the diagnostic test is not currently active. When a diagnostic test reports a fail result, the diagnostic executive records the following data: D The diagnostic test has been completed since the last ignition cycle. D The fault identified by the diagnostic test is currently active. D The fault has been active during this ignition cycle. D The operating conditions at the time of the failure. Remember, a fuel trim DTC may be triggered by a list of vehicle faults. Make use of all information available (other DTCs stored, rich or lean condition, etc.) when diagnosing a fuel trim fault.

Comprehensive Component Monitor Diagnostic Operation

Comprehensive component monitoring diagnostics are required to monitor emissions-related input and output

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Warm-Up Cycle A warm-up cycle means that engine at temperature must reach a minimum of 70C (160F) and rise at least 22C (40F) over the course of a trip. Freeze Frame Freeze Frame is an element of the Diagnostic Management System which stores various vehicle information at the moment an emissions-related fault is stored in memory and when the MIL is commanded on. These data can help to identify the cause of a fault. Refer to Storing And Erasing Freeze Frame Data in this section for more detailed information. Failure Records Failure Records data is an enhancement of the OBD II Freeze Frame feature. Failure Records store the same vehicle information as does Freeze Frame, but it will store that information for any fault which is stored in on-board memory, while Freeze Frame stores information only for emission-related faults that command the MIL on. D D D D D D D D D D vehicle speed ECT MAF/MAP barometric pressure IAT TP high canister purge fuel trim TCC enabled A/C on

6E39

System Status and Drive Cycle for Satisfying Federal Inspection/Maintenance (I/M 240) Regulations
I/M Ready Status means a signal or flag for each emission system test that had been set in the PCM. I/M Ready Status indicates that the vehicle on-board emissions diagnostics have been run. I/M Ready Status is not concerned whether the emission system passed or failed the test, only that on-board diagnosis is complete. Not all vehicles use all possible I/M flags.

Common OBD II Terms

Diagnostic When used as a noun, the word diagnostic refers to any on-board test run by the vehicles Diagnostic Management System. A diagnostic is simply a test run on a system or component to determine if the system or component is operating according to specification. There are many diagnostics, shown in the following list: D Misfire D Oxygen sensors D Oxygen sensor heaters D EGR D Catalyst monitoring Enable Criteria The term enable criteria is engineering language for the conditions necessary for a given diagnostic test to run. Each diagnostic has a specific list of conditions which must be met before the diagnostic will run. Enable criteria is another way of saying conditions required. The enable criteria for each diagnostic is listed on the first page of the DTC description in Section 6E under the heading Conditions for Setting the DTC. Enable criteria varies with each diagnostic, and typically includes, but is not limited to the following items: D engine speed

Trip Technically, a trip is a key on-run-key off cycle in which all the enable criteria for a given diagnostic are met, allowing the diagnostic to run. Unfortunately, this concept is not quite that simple. A trip is official when all the enable criteria for a given diagnostic are met. But because the enable criteria vary from one diagnostic to another, the definition of trip varies as well. Some diagnostics are run when the vehicle is at operating temperature, some when the vehicle first starts up; some require that the vehicle be cruising at a steady highway speed, some run only when the vehicle is idle; some diagnostics function with the TCC disabled. Some run only immediately following a cold engine start-up. A trip then, is defined as a key on-run-key off cycle in which the vehicle was operated in such a way as to satisfy the enabling criteria for a given diagnostic, and this diagnostic will consider this cycle to be one trip. However, another diagnostic with a different set of enable criteria (which were not met) during this driving event, would not consider it a trip. No trip will occur for that particular diagnostic until the vehicle is driven in such a way as to meet all the enable criteria.

The Diagnostic Executive

The Diagnostic Executive is a unique segment of software which is designed to coordinate and prioritize the diagnostic procedures as well as define the protocol for recording and displaying their results. The main responsibilities of the Diagnostic Executive are listed as the following: D Commanding the MIL (Check Engine lamp) on and off D DTC logging and clearing D Freeze Frame data for the first emission related DTC recorded D Non-emission related Service Lamp D Operating conditions Failure Records buffer, (the number of records will vary) D Current status information on each diagnostic D System Status (I/M ready) The Diagnostic Executive records DTCs and turns on the MIL when emission-related faults occur. It can also turn off the MIL if the conditions cease which caused the DTC to set.

6E40

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

D It informs the driver that a fault affects vehicle emission levels has occurred and that the vehicle should be taken for service as soon as possible. D As a bulb and system check, the MIL will come ON with the key ON and the engine not running. When the engine is started, the MIL will turn OFF. D When the MIL remains ON while the engine is running, or when a malfunction is suspected due to a driveability or emissions problem, a Powertrain On-Board Diagnostic (OBD ll) System Check must be performed. The procedures for these checks are given in On-Board Diagnostic (OBD) System Check. These checks will expose faults which may not be detected if other diagnostics are performed first.

Diagnostic Information The diagnostic charts and functional checks are designed to locate a faulty circuit or component through a process of logical decisions. The charts are prepared with the requirement that the vehicle functioned correctly at the time of assembly and that there are no multiple faults present. There is a continuous self-diagnosis on certain control functions. This diagnostic capability is complemented by the diagnostic procedures contained in this manual. The language of communicating the source of the malfunction is a system of diagnostic trouble codes. When a malfunction is detected by the control module, a diagnostic trouble code is set and the Malfunction Indicator Lamp (MIL) (Check Engine lamp) is illuminated. Malfunction Indicator Lamp (MIL) The Malfunction Indicator Lamp (MIL) looks the same as the MIL you are already familiar with (Check Engine lamp). However, OBD II requires that it illuminate under a strict set of guide lines. Basically, the MIL is turned on when the PCM detects a DTC that will impact vehicle emissions. The MIL is under the control of the Diagnostic Executive. The MIL will be turned on if an emissions-related diagnostic test indicates a malfunction has occurred. It will stay on until the system or component passes the same test, for three consecutive trips, with no emissions related faults. If the vehicle is experiencing a misfire malfunction which may cause damage to the Three-Way Catalytic Converter (TWC), the MIL will flash once per second. This will continue until the vehicle is outside of speed and load conditions which could cause possible catalyst damage, and the MIL will stop flashing and remain on steady. Extinguishing the MIL When the MIL is on, the Diagnostic Executive will turn off the MIL after three(3) consecutive trips that a test passed has been reported for the diagnostic test that originally caused the MIL to illuminate. Although the MIL has been turned off, the DTC will remain in the PCM memory (both Freeze Frame and Failure Records) until forty(40) warm-up cycles after no faults have been completed. If the MIL was set by either a fuel trim or misfire-related DTC, additional requirements must be met. In addition to the requirements stated in the previous paragraph, these requirements are as follows: D The diagnostic tests that are passed must occur within 375 RPM of the RPM data stored at the time the last test failed. D Plus or minus ten (10) percent of the engine load that was stored at the time the last failed. D Similar engine temperature conditions (warmed up or warming up ) as those stored at the time the last test failed. Meeting these requirements ensures that the fault which turned on the MIL has been corrected. The MIL (Check Engine lamp) is on the instrument panel and has the following function:

DTC Types
Each DTC is directly related to a diagnostic test. The Diagnostic Management System sets DTC based on the failure of the tests during a trip or trips. Certain tests must fail two (2) consecutive trips before the DTC is set. The following are the four (4) types of DTCs and the characteristics of those codes: D Type A D Emissions related D Requests illumination of the MIL of the first trip with a fail D Stores a History DTC on the first trip with a fail D Stores a Freeze Frame (if empty) D Stores a Fail Record D Updates the Fail Record each time the diagnostic test fails D Type B D Emissions related D Armed after one (1) trip with a fail D Disarmed after one (1) trip with a pass D Requests illumination of the MIL on the second consecutive trip with a fail D Stores a History DTC on the second consecutive trip with a fail (The DTC will be armed after the first fail) D Stores a Freeze Frame on the second consecutive trip with a fail (if empty) D Stores a Fail Record when the first test fails (not dependent on consecutive trip fails) D Updates the Fail Record each time the diagnostic test fails (Some special conditions apply to misfire and fuel trim DTCs) D Type C (if the vehicle is so equipped) D Non-Emissions related D Requests illumination of the Service D Stores a History DTC on the first trip with a fail D Does not store a Freeze Frame D Stores Fail Record when test fails D Updates the Fail Record each time the diagnostic test fails D Type D D Non-Emissions related

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

D D D D D Not request illumination of any lamp Stores a History DTC on the first trip with a fail Does not store a Freeze Frame Stores Fail Record when test fails Updates the Fail Record each time the diagnostic test fails D D D D D D D D D D D Air Flow Rate Fuel Trim Engine Speed Engine Load Engine Coolant Temperature Vehicle Speed TP Angle AP Angle MAP/BARO Injector Base Pulse Width Loop Status

6E41

IMPORTANT: Only four Fail Records can be stored. Each Fail Record is for a different DTC. It is possible that there will not be Fail Records for every DTC if multiple DTCs are set. Special Cases of Type B Diagnostic Tests Unique to the misfire diagnostic, the Diagnostic Executive has the capability of alerting the vehicle operator to potentially damaging levels of misfire. If a misfire condition exists that could potentially damage the catalytic converter as a result of high misfire levels, the Diagnostic Executive will command the MIL to flash at a rate of once per second during those the time that the catalyst damaging misfire condition is present. Fuel trim and misfire are special cases of Type B diagnostics. Each time a fuel trim or misfire malfunction is detected, engine load, engine speed, and engine coolant temperature are recorded. When the ignition is turned off, the last reported set of conditions remain stored. During subsequent ignition cycles, the stored conditions are used as reference for similar conditions. If a malfunction occurs during two consecutive trips, the Diagnostic Executive treats the failure as a normal Type B diagnostic, and does not use the stored conditions. However, if a malfunction occurs on two non-consecutive trips, the stored conditions are compared with the current conditions. The MIL will then illuminate under the following conditions: D When the engine load conditions are within 10% of the previous test that failed. D Engine speed is within 375 rpm, of the previous test that failed. D Engine coolant temperature is in the same range as the previous test that failed. Storing and Erasing Freeze Frame Data and Failure Records Government regulations require that engine operating conditions be captured whenever the MIL is illuminated. The data captured is called Freeze Frame data. The Freeze Frame data is very similar to a single record of operating conditions. Whenever the MIL is illuminated, the corresponding record of operating conditions is recorded to the Freeze Frame buffer. Freeze Frame data can only be overwritten with data associated with a misfire or fuel trim malfunction. Data from these faults take precedence over data associated with any other fault. The Freeze Frame data will not be erased unless the associated history DTC is cleared. Each time a diagnostic test reports a failure, the current engine operating conditions are recorded in the Failure Records buffer. A subsequent failure will update the recorded operating conditions. The following operating conditions for the diagnostic test which failed typically include the following parameters: D Air Fuel Ratio

Intermittent Malfunction Indicator Lamp In the case of an intermittent fault, the MIL (Check Engine lamp) may illuminate and then (after three trips) go OFF. However, the corresponding diagnostic trouble code will be stored in memory. When unexpected diagnostic trouble codes appear, check for an intermittent malfunction. A diagnostic trouble code may reset. Consult the Diagnostic Aids associated with the diagnostic trouble code. A physical inspection of the applicable sub-system most often will resolve the problem. Data Link Connector (DLC) The provision for communication with the control module is the Data Link Connector (DLC). It is located at the lower left of the instrument panel behind a small square cover. The DLC is used to connect to the Tech 2 Scan Tool. Some common uses of the Tech 2 are listed below: D Identifying stored Diagnostic Trouble Codes (DTCs). D Clearing DTCs. D Performing output control tests. D Reading serial data.

TS24064

Decimal/Binary/Hexadecimal Conversions
Beginning in 1996, Federal Regulations require that all auto manufacturers selling vehicles in the United States provide Scan Tool manufacturers with software information to display vehicle operating parameters. All

6E42

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

When a Scan Tool is not available, DTCs can also be cleared by disconnecting one of the following sources for at least thirty (30) seconds. NOTE: To prevent system damage, the ignition key must be OFF when disconnecting or reconnecting battery power. D The power source to the control module. Examples: fuse, pigtail at battery PCM connectors, etc. D The negative battery cable. (Disconnecting the negative battery cable will result in the loss of other on-board memory data, such as preset radio tuning).

Scan Tool manufacturers will display a variety of vehicle information which will aid in repairing the vehicle. Some Scan Tools will display encoded messages which will aid in determining the nature of the concern. The method of encoding involves the use of a two additional numbering systems: Binary and Hexadecimal. The binary number system has a base of two numbers. Each digit is either a 0 or a 1. A binary number is an eight digit number and is read from right to left. Each digit has a position number with the farthest right being the 0 position and the farthest left being the 7 position. The 0 position, when displayed by a 1, indicates 1 in decimal. Each position to the left is double the previous position and added to any other position values marked as a 1. A hexadecimal system is composed of 16 different alpha numeric characters. The alpha numeric characters used are numbers 0 through 9 and letters A through F. The hexadecimal system is the most natural and common approach for Scan Tool manufacturers to display data represented by binary numbers and digital code.

Verifying Vehicle Repair

Verification of vehicle repair will be more comprehensive for vehicles with OBD II system diagnostic. Following a repair, the technician should perform the following steps: 1. Review and record the Fail Records and/or Freeze Frame data for the DTC which has been diagnosed (Freeze Frame data will only be stored for an A or B type diagnostic and only if the MIL has been requested). 2. Clear DTC(s). 3. Operate the vehicle within conditions noted in the Fail Records and/or Freeze Frame data. 4. Monitor the DTC status information for the DTC which has been diagnosed until the diagnostic test associated with that DTC runs. Following these steps are very important in verifying repairs on OBD ll systems. Failure to follow these steps could result in unnecessary repairs.

Reading Diagnostic Trouble Codes Using The Tech 2 Scan Tool

The procedure for reading diagnostic trouble code(s) is to use a diagnostic Scan Tool. When reading DTC(s), follow instructions supplied by tool manufacturer. Clearing Diagnostic Trouble Codes IMPORTANT: Do not clear DTCs unless directed to do so by the service information provided for each diagnostic procedure. When DTCs are cleared, the Freeze Frame and Failure Record data which may help diagnose an intermittent fault will also be erased from memory. If the fault that caused the DTC to be stored into memory has been corrected, the Diagnostic Executive will begin to count the warm-up cycles with no further faults detected, the DTC will automatically be cleared from the PCM memory. To clear Diagnostic Trouble Codes (DTCs), use the diagnostic Scan Tool clear DTCs or clear information function. When clearing DTCs follow instructions supplied by the tool manufacturer.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E43

Tech 2
From 98 MY, Isuzu dealer service departments are recommended to use the Tech 2 Scan Tool. Please refer to the Tech 2 user guide.

060M200031

Legend (1) PCMCIA Card (2) SAE 16/19 Adaptor

(3) DLC Cable (4) Tech2

6E44

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

7. Power the Tech 2 ON and verify the Tech 2 power up display.

Tech 2 Features
1. Tech 2 is a 12 volt system. Do not apply 24 volts. 2. After connecting and/or installing the Vehicle Communications Interface (VCI) module, PCMCIA card and DLC connector to the Tech 2, connect the tool to the vehicle DLC. 3. Make sure the Tech 2 is OFF when removing or installing the PCMCIA card. 4. The PCMCIA card has a capacity of 10 Megabytes which is 10 times greater than the memory of the Tech 1 Mass Storage Cartridge. 5. The Tech 2 has the capability of two snapshots. 6. The PCMCIA card is sensitive to magnetism and static electricity, so care should be taken in the handling of the card. 7. The Tech 2 can plot a graph when replaying a snapshot. 8. Always return to the Main Menu by pressing the EXIT key several times before shutting down. 9. To clear Diagnostic Trouble Codes (DTCs), open Application Menu and press F1: Clear DTC Info.

060RW009

Getting Started
D Before operating the Isuzu PCMCIA card with the Tech 2, the following steps must be performed: 1. Insert the Isuzu system PCMCIA card (1) into the Tech 2 (5). 2. Connect the SAE 16/19 adapter (3) to the DLC cable (4). 3. Connect the DLC cable to the Tech 2 (5) 4. Make sure the vehicle ignition is off. 5. Connect the Tech 2 SAE 16/19 adapter to the vehicle DLC.

NOTE: The RS232 Loop back connector is only to use for diagnosis of Tech 2. Refer to user guide of the Tech 2.

821RW021

6. Turn on the vehicle ignition.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E45

Operating Procedure (For Example)

The power up screen is displayed when you power up the tester with the Isuzu systems PCMCIA card. Follow the operating procedure below.

060R200202

060R100102

6E46
Menu

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

D The following table shows which functions are used for the available equipment versions.

060RW223

060R100018

The following is a brief description of each of the sub menus in DTC Info and DTC. The order in which they appear here is alphabetical and not necessarily the way they will appear on the Tech 2.

DTC Modes

DTC Information Mode

Use the DTC info mode to search for a specific type of stored DTC information. DTC Status This selection will display any DTCs that have not run during the current ignition cycle or have reported a test failure during this ignition up to DTCs. DTC tests which run and pass will cause that DTC number to be removed from Tech 2 screen. Fail This Ignition This selection will display all DTCs that have failed during the present ignition cycle. History This selection will display only DTCs that are stored in the PCMs history memory. It will display all type A and B DTCs that have requested the MIL and have failed within the last 40 warm-up cycles. In addition, it will display all type C and type D DTCs that have failed within the last 40 warm-up cycles. Last Test Failed This selection will display only DTCs that have failed the last time the test run. The last test may have run during a previous ignition cycle if a type A or type B DTC is displayed. For type C and type D DTCs, the last failure must have occurred during the current ignition cycle to appear as Last Test Fail. MILSVC or Message Request This selection will display only DTCs that are requesting the MIL. Type C and type D DTCs cannot be displayed using this option. This selection will report type B DTCs only after the MIL has been requested.

060R100077

On OBD II vehicles there are options available in Tech 2 DTC mode to display the enhanced information available. After selecting DTC, the following menu appears: 1. Read DTC Info by Priority 2. Freeze Frame 3. Fail Records (not all applications) 4. DTC Info 5. Clear Info

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Not Run Since Code Cleared This option will display up to DTCs that have not run since the DTCs were last cleared. Since any displayed DTCs have not run, their condition (passing or failing) is unknown. Test Failed Since Code Cleared This selection will display all active and history DTCs that have reported a test failure since the last time DTCs were cleared. DTCs that last failed more than 40 warm-up cycles before this option is selected will not be displayed.

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4. Select F0:Lamps Test in the Miscellaneous Test.

Miscellaneous Test
This test consists of eight menus-Lights, Relays, EVAP, Fuel System, Instruments, EGR Control, Variable Intake Manifold Solenoid, and Injector Balance Tests. In these tests, Tech 2 sends operating signals to the systems to confirm their operations thereby to judge the normality of electric circuits. To judge intermittent trouble, 1. Confirm DTC freeze frame data, and match the freeze frame data as test conditions with the data list displayed by Miscellaneous Test. 2. Confirm DTC setting conditions, and match the setting conditions as test conditions with the data list displayed by Miscellaneous Test. 3. Refer to the latest Service Bulletin. Check to see if the Latest software is released or not. Down load the LATEST PROGRAMMED SOFTWARE to the replacement PCM.

060RY00080

5. Select F0:Malfunction Indicator Lamp.

Lamps Test
This test is conducted check MIL, Up Shift Lamp, Low Fuel Lamp, Reduced Power Lamp and Cruise Control Lamp for its working. Tech2 must be used for this test. Test Procedure: 1. Connect Tech 2 to the vehicle DLC. 2. Run the Engine at idle. 3. Select F3: Miscellaneous Test in the Application Menu.
060RY00091

6. PushOn soft key. 7. Make sure Lamp illuminates. 8. If lamp illuminates, the Lamp is operating correctly.

060R100078

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TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

17. Select F3:Reduced Power Lamp

9. Select F2: Up Shift Lamp

060RY00076

060RY00077

10. Push On soft key. 11. Make sure Lamp illuminates. 12. If Lamp illuminates, the Lamp is operating correctly. 13. Select F2:Low Fuel Lamp

18. Push On soft key. 19. Make sure Lamp illuminates. 20. If Lamp illuminates, the Lamp is operating correctly. 21. Select F5:Cruise Control Lamp

060RY00092

060RY00078

14. Push On soft key. 15. Make sure Lamp illuminates. 16. If Lamp illuminates, the Lamp is operating correctly.

22. Push On soft key. 23. Make sure Lamp illuminates. 24. If Lamp illuminates, the Lamp is operating correctly.

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Relays Test
This test is conducted to check Fuel Pump Relay and A/C Clutch for proper operation. Tech 2 must be used for this test. Test Procedure: 1. Connect Tech 2 to the vehicle DLC. 2. Ignition SW is On. 3. Select F3: Miscellaneous Test in the Application Menu.

5. Select F0:Fuel Pump Relay.

060RX021

6. Push On soft key.

060R100078

4. Select F1:Relay Test in the Miscellaneous Test.

060RY00093

7. Control Fuel Pump Relay and check data list. 8. If the data list changes, the Fuel Pump Relay is normal. 9. Select F1:A/C Clutch Relay. 10. Run the Engine at idle.

060RY00081

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TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

4. Select F2: EVAP Test in the Miscellaneous Test.

11. Turn on Air Conditioning.

060RY00094

060RY00082

12. Turn On and Off A/C Switch. 13. Contol A/C Clutch Relay and check data list. 14. If the data list changes, the Fuel Pump Relay is normal.

5. Select F0: Purge Solenoid.

EVAP Test
This test is conducted to check EVAP system for its power operation. Tech 2 must be used for this test. Test Procedure: 1. Connect Tech 2 to the vehicle DLC. 2. Run the Engine at idle. 3. Select F3: Miscellaneous Test in the Application Menu.

060RX025

060R100078

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6. Push Decrease or Increase soft key. 11. Push On or Off soft key.

6E51

060RY00095

060RY00096

7. Control EVAP Purge Solenoid and check a data list. 8. If the data list changes, the Purge Solenoid is normal. 9. Turn engine off, turn ignition SW On. 10. Select F1:EVAP Vent Solenoid.

12. Control EVAP Vent Solenoid and check data list. 13. If the data list changes, the EVAP Vent Solenoid is normal.

Fuel System Test

This test is conducted check Fuel system for proper operation. Tech 2 must be used for this test. Test Procedure: 1. Connect Tech 2 to the vehicle DLC. 2. Ignition SW is On. 3. Select F3: Miscellaneous Test in the Application Menu.

060RX025

060R100078

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TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6. Push Disable or Enable soft key.

4. Select F3: Fuel System in the Miscellaneous Menu.

060RY00083

060RY00097

5. Select F0: Fuel Trim Enable.

7. Control Fuel Trim and check data list. 8. If data list changes, the Fuel Trim is normal. 9. Select F1: Fuel Trim Reset.

060R200071

060R200071

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

10. Push Reset soft key.

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13. Push Open Loop or Closed Loop soft key.

060RY00098

060RY00099

11. Select F2: O2-Loop status.

14. Control O2-Loop and check data list. 15. If data list changes, the O2-Loop is normal.

Instruments Test
This test is conducted check Instruments for proper operation. Tech 2 must be used for this test. Test Procedure: 1. Connect Tech 2 to the vehicle DLC. 2. Ignition SW is On. 3. Select F3: Miscellaneous Test in the Application Menu.

060R200071

12. This test is check the Closed Loop Status performance.

060R100078

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TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6. Push Decrease or Increase soft key.

4. Select F4: Instruments in the Miscellaneous Menu.

060RY00106

060RY00100

5. Select F0: Fuel Gauge level.

7. Control Fuel Level and check data list. 8. If data list and Fuel gauge meter changes, Fuel Gauge level is normal. 9. Select F1: Tachometer Control Test.

060RY00107

060RY00107

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

10. Push Inactive or active soft key.

6E55

4. Select F5: EGR Control Test in the Miscellaneous Test.

060RY00101

11. Control tachometer and data list. 12. If data list and meter changes, the tachometer control is normal.

060RY00084

5. Control EGR Valve and check data list.

EGR Control Test

This test is conducted check EGR valve for proper operation. Tech 2 must be used for this test. Test Procedure: 1. Connect Tech 2 to the vehicle DLC. 2. Run the Engine at idle. 3. Select F3: Miscellaneous Test in the Application Menu.

060RY00103

6. If data list changes, the EGR Control is normal.

Variable Intake Manifold Solenoid Test

This test is conducted check VIM Solenoid for proper operation. Tech 2 must be used for this test. Test Procedure: 1. Connect Tech 2 to the vehicle DLC.

060R100078

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TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

4. Select F6: Variable Intake Manifold Solenoid Test.

2. Ignition SW is On.

060RY00104

060RY00085

3. Select F3: Miscellaneous Test in the Application Menu.

5. Push On or Off soft key.

060RX028 060R100078

6. Control VIM Solenoid check data list. 7. If data list changes, the VIM Solenoid is normal.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E57

Injector Balance Test

This test is conducted to make sure the appropriate electric signals are being sent to injectors Nos. 16. Tech 2 must be used for this test. Test Procedure: 1. Connect Tech 2 to the vehicle DLC. 2. Run the Engine at idle. 3. Select F3: Miscellaneous Test in the Application Menu.

5. Select injector number and push injector off soft key.

060RY00105

6. Make sure of engine speed change. 7. If engine speed changes, the injector electric circuit is normal. If engine speed does not change, the injector electric circuit or the injector itself is not normal.

Plotting Snapshot Graph

060R100078

4. Select F7: Injector Balance Test in the Miscellaneous Test.

This test selects several necessary items from the data list to plot graphs and makes data comparison on a long term basis. It is an effective test particularly in emission related evaluations.

060RY00086 060RX037

For trouble diagnosis, you can collect graphic data (snap shot) directly from the vehicle. You can replay the snapshot data as needed. Therefore, accurate diagnosis is possible, even though the vehicle is not available.

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TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)

060R200070

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E59

Flow Chart for Snapshot Replay (Plotting Graph)

060R200072

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TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Primary System-Based Diagnostic

Primary System-Based Diagnostic
There are primary system-based diagnostics which evaluate system operation and its effect on vehicle emissions. The primary system-based diagnostics are listed below with a brief description of the diagnostic function: Oxygen Sensor Diagnosis The fuel control heated oxygen sensors (Bank 1 HO2S 1 and Bank 2 HO2S 1) are diagnosed for the following conditions: D Heater performance (time to activity on cold start) D Slow response D Response time (time to switch R/L or L/R) D Inactive signal (output steady at bias voltage approx. 450 mV) D Signal fixed high D Signal fixed low The catalyst monitor heated oxygen sensors (Bank 1 HO2S 2 and Bank 2 HO2S 2) are diagnosed for the following conditions: D Heater performance (time to activity on cold start). D Signal fixed low during steady state conditions or power enrichment (hard acceleration when a rich mixture should be indicated). D Signal fixed high during steady state conditions or deceleration mode (deceleration when a lean mixture should be indicated). D Inactive sensor (output steady at approx. 438 mV). If the oxygen sensor pigtail wiring, connector or terminal are damaged, the entire oxygen sensor assembly must be replaced. DO NOT attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have clean reference air provided to it. This clean air reference is obtained by way of the oxygen sensor wire(s). Any attempt to repair the wires, connector or terminals could result in the obstruction of the reference air and degrade oxygen sensor performance. Refer to On-Vehicle Service, Heated Oxygen Sensors in this section.

HO2S Heater
Heated oxygen sensors are used to minimize the amount of time required for closed loop fuel control to begin operation and to allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of time required for fuel control sensors (Bank 1 HO2S 1 and Bank2 HO2S 1) to become active. Oxygen sensor heaters are required by catalyst monitor and sensor (Bank 1 HO2S 2 and Bank 2 HO2S 2) to maintain a sufficiently high temperature which allows accurate exhaust oxygen content readings further away from the engine.

Catalyst Monitor Heated Oxygen Sensors and Diagnostic Operation

TS24067

Fuel Control Heated Oxygen Sensor

The main function of the fuel control heated oxygen sensors is to provide the control module with exhaust stream oxygen content information to allow proper fueling and maintain emissions within mandated levels. After it reaches operating temperature, the sensor will generate a voltage, inversely proportional to the amount of oxygen present in the exhaust gases. The control module uses the signal voltage from the fuel control heated oxygen sensors while in closed loop to adjust fuel injector pulse width. While in closed loop, the PCM can adjust fuel delivery to maintain an air/fuel ratio which allows the best combination of emission control and driveability. The fuel control heated oxygen sensors are also used to determine catalyst efficiency.

To control emissions of hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx), a three-way catalytic converter is used. The catalyst within the converter promotes a chemical reaction which oxidizes the HC and CO present in the exhaust gas, converting them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx, converting it to nitrogen. The PCM has the ability to monitor this process using the pre-catalyst and post-catalyst heated oxygen sensors. The pre-catalyst sensor produces an output signal which indicates the amount of oxygen present in the exhaust gas entering the three-way catalytic converter. The post-catalyst sensor produces an output signal which indicates the oxygen storage capacity of the catalyst; this in turn indicates the catalysts ability to convert exhaust gases efficiently. If the catalyst is operating efficiently, the pre-catalyst signal will be far more active than that produced by the post-catalyst sensor. In addition to catalyst monitoring, the heated oxygen sensors have a limited role in controlling fuel delivery. If the sensor signal indicates a high or low oxygen content for an extended period of time while in closed loop, the PCM will adjust the fuel delivery slightly to compensate.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

D For the 3.5L w/automatic transmission, the pre-catalyst sensors are designated Bank 1 HO2S 1 and Bank 2 HO2S 1. The post-catalyst sensors are Bank 1 HO2S 2 and Bank 2 HO2S 2. Catalyst Monitor Outputs The catalyst monitor diagnostic is sensitive to the following conditions: D Exhaust leaks D HO2S contamination D Alternate fuels Exhaust system leaks may cause the following: D Preventing a degraded catalyst from failing the diagnostic. D Causing a false failure for a normally functioning catalyst. D Preventing the diagnostic from running. Some of the contaminants that may be encountered are phosphorus, lead, silica, and sulfur. The presence of these contaminants will prevent the TWC diagnostic from functioning properly. Three-Way Catalyst Oxygen Storage Capacity The Three-Way catalyst (TWC) must be monitored for efficiency. To accomplish this, the control module monitors the pre-catalyst HO2S and post-catalyst HO2S oxygen sensors. When the TWC is operating properly, the post-catalyst oxygen sensor will have significantly less activity than the pre-catalyst oxygen sensor. The TWC stores and releases oxygen as needed during its normal reduction and oxidation process. The control module will calculate the oxygen storage capacity using the difference between the pre-catalyst and post catalyst oxygen sensors voltage levels. If the activity of the post-catalyst oxygen sensor approaches that of the pre-catalyst oxygen sensor, the catalysts efficiency is degraded. Stepped or staged testing level allow the control module to statistically filter test information. This prevents falsely passing or falsely failing the oxygen storage capacity test. The calculations performed by the on-board diagnostic system are very complex. For this reason, post catalyst oxygen sensor activity should not be used to determine oxygen storage capacity unless directed by the service manual. Two stages are used to monitor catalyst efficiency. Failure of the first stage will indicate that the catalyst requires further testing to determine catalyst efficiency. The seconds stage then looks at the inputs for the pre and post catalyst HO2S sensors more closely before determining if the catalyst is indeed degraded. This further statistical processing is done to increase the accuracy of oxygen storage capacity type monitoring. Failing the first (stage 1) test DOES NOT indicate a failed catalyst. The catalyst may be marginal or the fuel sulfur content could be very high.

6E61

Aftermarket HO2S characteristics may be different from the original equipment manufacturer sensor. This may lead to a false pass or a false fail of the catalyst monitor diagnostic. Similarly, if an aftermarket catalyst does not contain the same amount of cerium as the original part, the correlation between oxygen storage and conversion efficiency may be altered enough to set a false DTC.

Misfire Monitor Diagnostic Operation

Misfire Monitor Diagnostic Operation
Misfire is monitored as a function of the combustion quality (CQ) signals generated from the ignition current sense system. Combustion signals represent the degree of combustion in each cylinder. Misfire is detected when the combustion signal is below a predetermined value. The misfire ratio is calculated once every 100 engine cycles. For example, on a 6-cylinder engine, 600 ignition plug sparks occur every 100 cycles and if a misfire occurs 12 times during that time, the misfire is 12/600 100 = 2 %.

Misfire Counters
Whenever a cylinder misfires, the misfire diagnostic counts the misfire and notes the crankshaft position at the time the misfire occurred. These misfire counters are basically a file on each engine cylinder. A current and a history misfire counter are maintained for each cylinder. The misfire current counters (Misfire Cur #1-6) indicate the number of firing events out of the last 100 cylinder firing events which were misfires. The misfire current counter will display real time data without a misfire DTC stored. The misfire history counters (Misfire Hist #1-6) indicate the total number of cylinder firing events which were misfires. The misfire history counters will display 0 until the misfire diagnostic has failed and a DTC P0300 is set. Once the misfire DTC P0300 is set, the misfire history counters will be updated every 100 cylinder firing events. A misfire counter is maintained for each cylinder. If the misfire diagnostic reports a failure, the diagnostic executive reviews all of the misfire counters before reporting DTC. This way, the diagnostic executive reports the most current information. When crankshaft rotation is erratic, a misfire condition will be detected. Because of this erratic condition, the data that is collected by the diagnostic can sometimes incorrectly identify which cylinder is misfiring. Misfires are counted from more than one cylinder. Cylinder #1 has the majority of counted misfires. In this case, the Misfire Counters would identify cylinder #1 as the misfiring cylinder. The misfires in the other counters were just background noise caused by the erratic misfire rotation of the crankshaft. If the number of accumulated misfires is sufficient for the diagnostic to identify a true misfire, the diagnostic will set DTC P0300 Misfire Detected. Use diagnostic equipment to monitor misfire counter data on OBD II-compliant vehicles. Knowing which specific cylinder(s) misfired can lead to the root cause, even when dealing with a multiple cylinder misfire. Using the information in the misfire counters, identify which cylinders are misfiring. If the counter indicate cylinders

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TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

numbers 1 and 4 misfired, look for a circuit or component common to both cylinders number 1 and 4. Misfire counter information is located in the Eng. menu, Misfire Data sub-menu of the data list. The misfire diagnostic may indicate a fault due to a temporary fault not necessarily caused by a vehicle emission system malfunction. Examples include the following items: D Contaminated fuel D Low fuel D Fuel-fouled spark plugs D Basic engine fault

Fuel Trim System Monitor Diagnostic Operation

Fuel Trim System Monitor Diagnostic Operation
This system monitors the averages of short-term and long-term fuel trim values. If these fuel trim values stay at their limits for a calibrated period of time, a malfunction is indicated. The fuel trim diagnostic compares the averages of short-term fuel trim values and long-term fuel trim values to rich and lean thresholds. If either value is within the thresholds, a pass is recorded. If both values are outside their thresholds, a rich or lean DTC will be recorded. The fuel trim system diagnostic also conducts an intrusive test. This test determines if a rich condition is being caused by excessive fuel vapor from the EVAP canister. In order to meet OBD II requirements, the control module uses weighted fuel trim cells to determine the need to set a fuel trim DTC. A fuel trim DTC can only be set if fuel trim counts in the weighted fuel trim cells exceed specifications. This means that the vehicle could have a fuel trim problem which is causing a problem under certain conditions (i.e., engine idle high due to a small vacuum leak or rough idle due to a large vacuum leak) while it operates fine at other times. No fuel trim DTC would set (although an engine idle speed DTC or HO2S DTC may set). Use the Tech 2 to observe fuel trim counts while the problem is occurring. A fuel trim DTC may be triggered by a number of vehicle faults. Make use of all information available (other DTCs stored, rich or lean condition, etc.) when diagnosing a fuel trim fault.

Fuel Trim Cell Diagnostic Weights

No fuel trim DTC will set regardless of the fuel trim counts in cell 0 unless the fuel trim counts in the weighted cells are also outside specifications. This means that the vehicle could have a fuel trim problem which is causing a problem under certain conditions (i.e. engine idle high due to a small vacuum leak or rough due to a large vacuum leak) while it operates fine at other times. No fuel trim DTC would set (although an engine idle speed DTC or HO2S DTC may set). Use the Tech 2 to observe fuel trim counts while the problem is occurring.

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On-Board Diagnostic (OBD II) System Check

D06RY00053

Circuit Description
The on-board diagnostic system check is the starting point for any driveability complaint diagnosis. Before using this procedure, perform a careful visual/physical check of the PCM and engine grounds for cleanliness and tightness. The on-board diagnostic system check is an organized approach to identifying a problem created by an electronic engine control system malfunction.

Diagnostic Aids
An intermittent may be caused by a poor connection, rubbedthrough wire insulation or a wire broken inside the insulation. Check for poor connections or a damaged harness. Inspect the PCM harness and connector for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart: 1.The MIL (Check Engine lamp) should be ON steady with the ignition ON and the engine OFF. If not, the No MIL chart should be used to isolate the malfunction. 2.The RPL (Reduced Power lamp) should be ON steady with the ignition ON and the engine OFF. If not, the No RPLchart should be used to isolate the malfunction.

3.Checks the Class 2 data circuit and ensures that the PCM is able to transmit serial data. 4.This test ensures that the PCM is capable of controlling the MIL (Check Engine lamp) and the MIL (Check Engine lamp) driver circuit is not shorted to ground. 5.This test ensures that the PCM is capable of controlling the RPL (Reduced Power lamp) and the RPL (Reduced Power lamp) driver circuit is not shorted to ground. 7.Check the DTCs (System ,Volts Supply circuit). 8.Check the DTCs (PCM{Software} detect Errors). 11.If the engine will not start, the Cranks But Will Not Run chart should be used to diagnose the condition. 14.A Tech 2 parameter which is not within the typical range may help to isolate the area which is causing the problem. 15.This vehicle is equipped with a PCM which utilizes an electrically erasable programmable read only memory (EEPROM). When the PCM is replaced, the new PCM must be programmed. Refer to PCM Replacement and Programming Procedures in Powertrain Control Module (PCM) and Sensors of this section. 10. If the starter motor will not start, the starter control system chart should be used to diagnose the condition.

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TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

On-Board Diagnostic (OBD II) System Check

Step Action Value(s) Yes No

1. Ignition ON, engine OFF. 2. Observe the malfunction indicator lamp (MIL or Check Engine lamp). Is the MIL (Check Engine lamp)ON? Go to Step 2 1. Ignition ON, engine OFF. 2. Observe the Reduced Power lamp. Is the RPL (Reduced Power lamp) ON? Go to Step 3

Go to No MIL(Check Engine lamp) Go to No RPL(Reduce d Power lamp)

1. 2. 3. 4.

Ignition OFF. Install Tech 2. Ignition ON. Attempt to display PCM engine data with the Tech 2. Go to Step 4 Go to Step 12

Does the Tech 2 display PCM data? 4 1. Using the Tech 2 output tests function, select MIL (Check Engine lamp) control and command the MIL (Check Engine Lamp) OFF. 2. Observe the MIL (Check Engine lamp). Did the MIL (Check Engine lamp) turn OFF? 5 1. Using the Tech 2 output tests function, select MIL (Check Engine lamp) control and command the RPL (Reduced Power lamp) OFF. 2. Observe the RPL (Reduced Power lamp). Did the MIL (Reduced Power lamp) turn OFF? 6 7 Select Display DTCs with the Tech 2. Are any DTCs stored? Stored DTCs. P0562, P0563, P0601, P0602, P0604, P0606, P1625, P1635, P1639, P1640, P1650 Are the applicable DTCs stored? 8 Stored DTCs. P1514, P1515, P1516, P1523, P1125, P1290, P1295, P1299 Are the applicable DTCs stored? 9 Stored DTCs. 1. P0425, P0106, P0107, P1107, P0401, P1404, P0405, P1120, P1221, P1515, P1516, P1275, P1635, P1271, P1273, P1285, P1272 2. P0336, P0337, P1220, P1515, P1221, P1516, P1280, P1639, P1271, P1272 Are the applicable DTCs stored? 10 Attempt to crank the starter motor Did the starter motor crank? 11 Attempt to start the engine. Did the engine start and continue to run?

Go to Step 5

Go to MIL(Check Engine lamp) On Steady Go to RPL(Reduce d Power lamp) On Steady Go to Step 11

Go to Step 6 Go to Step 7

Go to applicable DTC table

Go to Step 8

Go to applicable DTC table

Go to Step 9

Go to Multiple PCM Information sensor DTCs Set

Go to Step 10 Go to Starter control system Go to Cranks But Will Not Run

Go to Step 10

Go to Step 6

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6E65

On-Board Diagnostic (OBD II) System Check (Cont'd)

Step Action Value(s) Yes No

12

Compare PCM data values displayed on the Tech 2 to the typical engine scan data values. Are the displayed values normal or close to the typical values? Go to Symptom

Refer to indicated Component System Checks

13

1. Ignition OFF, disconnect the PCM. 2. Ignition ON, engine OFF. 3. Check the Class 2 data circuit for an open, short to ground, or short to voltage. Also, check the DLC ignition feed circuit for an open or short to ground and the DLC ground circuit for an open. 4. If a problem is found, repair as necessary. Was a problem found? Go to Step 2 Go to Step 14 1. Attempt to reprogram the PCM. Refer to Powertrain Control Module (PCM) in On-Vehicle Service. 2. Attempt to display PCM data with the Tech 2. Does the Tech 2 display PCM engine data? Go to Step 2 Go to Step 15 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Go to Step 2

14

15

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TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

A/C Clutch Control Circuit Diagnosis

D06RY00159

Circuit Description
When air conditioning and blower fan are selected, and if the system has a sufficient refrigerant charge, a 12-volt signal is supplied to the A/C request input of the powertrain control module (PCM). The A/C request signal may be temporarily canceled during system operation by the electronic thermostat in the evaporator case. When the A/C request signal is received by the PCM, the PCM supplies a ground from the compressor clutch relay if the engine operating conditions are within acceptable ranges. With the A/C compressor relay energized, voltage is supplied to the compressor clutch coil. The PCM will enable the compressor clutch to engage whenever A/C has been selected with the engine running, unless any of the following conditions are present: D The throttle is greater than 90%. D The ignition voltage is below 10.5 volts. D The engine speed is greater than 4500 RPM for 5 seconds or 5400 RPM.

D The engine coolant temperature (ECT) is greater than 125 C (257 F). D The intake air temperature (IAT) is less than 5C (41F). D The power steering pressure switch signals a high pressure condition.

Diagnostic Aids
To diagnose an the intermittent fault, check for following conditions: D Poor connection at the PCMInspect connections for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harnessInspect the wiring harness for damage. If the harness appears to OK, observe the A/C clutch while moving connectors and wiring harnesses related to the A/C. A sudden clutch malfunction will indicate the source of the intermittent fault.

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6E67

A/C Clutch Diagnosis

This chart should be used for diagnosing the electrical portion of the A/C compressor clutch circuit. A Tech 2 will be used in diagnosing the system. The Tech 2 has the ability to read the A/C request input to the PCM. The Tech 2 can display when the PCM has commanded the A/C clutch ON. The Tech 2 should have the ability to override the A/C request signal and energize the A/C compressor relay.

Test Description
IMPORTANT: Do not engage the A/C compressor clutch with the engine running if an A/C mode is not selected at the A/C control switch. The numbers below refer to the step numbers on the Diagnostic Chart:

3. This a test determine is the problem is with the refrigerant system. If the switch is open, A/C pressure gauges will be used to determine if the pressure switch is faulty or if the system is partially discharged or empty. 4. Although the normal complaint will be the A/C clutch failing to engage, it is possible for a short circuit to cause the clutch to run when A/C has not been selected. This step is a test for that condition. 7. There is an extremely low probability that both relays will fail at the same time, so the substitution process is one way to check the A/C Thermostat relay. Use a known good relay to do a substitution check.

A/C Clutch Control Circuit Diagnosis

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Go to the other DTC chart(s) first Go to Air Conditioning to diagnose the cause of the open pressure switch Are any other DTCs stored?

Go to OBD System Check

Go to Step 3

1. Disconnect the electrical connector at the pressure switch located on the receiver/drier. 2. Use an ohmmeter to check continuity across the pressure switch. Is the pressure switch open?

Go to Step 4

IMPORTANT: Before continuing with the diagnosis, the following conditions must be met: D The intake air temperature must be greater than 15C. (60F). D The engine coolant temperature must be less than 119C (246F). 1. A/C OFF. 2. Start the engine and idle for 1 minute. 3. Observe the A/C compressor. Is the A/C compressor clutch engaged even though A/C has not been requested? Go to Step 37 Check the Procedure Refer to Diagnostic Aids Go to Step 5

1. 2. 3. 4. 1. 2. 3. 4.

Idle the engine. A/C ON. Blower ON. Observe the A/C compressor. Engine idling. A/C ON. Blower ON. Observe the A/C Request display on the Tech 2. (Refer to the Miscellaneous test)

Is the A/C compressor magnetic clutch engaged? 6

Go to Step 6

Does the tool A/C Request display indicate Yes?

Go to Step 26

Go to Step 7

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TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

A/C Clutch Control Circuit Diagnosis (Cont'd)

Step Action Value(s) Yes No

Temporarily substitute the A/C compressor relay in place of the A/C thermostat relay, then repeat Step 5. Did the A/C Request display indicate Yes? Go to Step 8 Verify repair Go to Step 10 Verify repair Go to Step 9 Go to Step 11 Replace the original A/C thermostat relay. Is the action complete? Does the blower operate? Repair the blower. Is the action complete? Check for a faulty 10A A/C fuse in the underdash fuse panel. Was the 10A fuse OK? Go to Step 13 Go to Step 12 Check for short circuit and make repairs if necessary. Replace the 10A A/C fuse. Is the action complete? Verify repair 1. Remove the glove box to gain access to the A/C thermostat. 2. Disconnect the thermostat connector. 3. Attach a fused jumper between ground and the thermostat wire. 4. A/C ON. 5. Blower ON. Dose A/C request indicate YES on the Tech 2? Go to Step 14 Go to Step 17 1. Ignition ON. 2. Use a DVM to check voltage at the electronic A/C thermostat. Was voltage equal to the specified value? B+ Go to Step 17 Go to Step 15 Check for open wire between the thermostat and the A/C switch. Was the wire open? Go to Step 16 Go to Step 17 Repair the open wire between the thermostat and the A/C switch. Is the action complete? Verify repair Check for an open circuit between A/C thermostat relay and PCM A/C request terminal (F45). Was there an open circuit? Go to Step 18 Go to Step 19 Repair the open circuit between the PCM and A/C thermostat relay. Is the action complete? Verify repair 1. Ignition ON. 2. Use a DVM to check voltage at the A/C pressure switch. Was voltage equal to the specified value? B+ Go to Step 21 Go to Step 20 Repair the open circuit between the 10A A/C fuse and the pressure switch. Is the action complete? Verify repair

8 9 10 11

12

13

14

15

16

17

18

19

20

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E69

A/C Clutch Control Circuit Diagnosis (Cont'd)

Step Action Value(s) Yes No

21

Use an ohmmeter to check continuity between the pressure switch and the A/C thermostat relay. Was the circuit open? Go to Step 22 Go to Step 23 Repair the open circuit between the pressure switch and the A/C thermostat relay. Is the action complete? Verify repair Go to Step 24 Verify repair Go to Step 25 Check for damaged pin or terminal at F45 of the PCM. Was a damaged pin or terminal found? Repair the damaged pin or terminal. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

22

23 24 25

26

1. Remove the A/C compressor relay. 2. Ignition ON. 3. Use a DVM to check voltage at both of the wires at the A/C compressor relay socket. Is the voltage equal to the specified value? B+ Go to Step 28 Go to Step 27 Repair the faulty wire between the A/C fuse and the A/C compressor relay . Is the action complete? Verify repair 1. 2. 3. 4. 5. A/C compressor relay removed. Engine idling. A/C ON. Blower ON. Use a DVM to measure voltage between the wire at the A/C compressor relay socket and battery. B+ Go to Step 32 Go to Step 29

27

28

Did the DVM indicate the specified value? 29 Check for an open wire between PCM terminal F4 and the A/C compressor relay. Was the wire open? 30 Repair the open wire between the PCM and the A/C compressor relay. Is the action complete? 31 Check for a damaged pin or terminal at F4 of the PCM. Was a damaged pin or a terminal found?

Go to Step 30

Go to Step 31

Verify repair Go to Step 24

Go to Step 25

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TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

A/C Clutch Control Circuit Diagnosis (Cont'd)

Step Action Value(s) Yes No

32

1. A/C compressor relay removed. 2. Connect a fused jumper at the A/C compressor relay socket with either wire. 3. Engine idling. 4. A/C ON. 5. Blower ON. Did the compressor magnetic clutch engage? Go to Step 33 Verify repair Go to Step 34 Repair the A/C compressor relay. Is the action complete? Check for an open circuit between the A/C compressor relay and the A/C clutch. Was an open circuit found? Go to Step 35 Go to Step 36 Repair the open circuit between the compressor Clutch and the A/C compressor relay. Is the action complete? Verify repair Service the compressor clutch or replace the compressor due to a faulty internal overheat switch. Is the action complete? Verify repair 1. Remove the A/C compressor relay. 2. Idle the engine. Is the compressor clutch still engaged when A/C is not selected? Go to Step 38 Go to Step 39

33 34

35

36

37

38

Repair the short to voltage between the A/C clutch and A/C compressor relay. Is the action complete? Verify repair 1. Reinstall the A/C compressor relay. 2. Remove the A/C thermostat relay. 3. Engine idling. Is the compressor clutch still engaged when A/C is not selected? Go to Step 40 Go to Step 42

39

40

Use a DVM to check for a short to ground between the A/C compressor relay and F4 of the PCM. Was a short detected? Go to Step 41 Go to Step 25 Repair the short to ground between the PCM and A/C compressor relay. Is the action complete? Verify repair Repair the short to ground between the A/C thermostat relay and the electronic thermostat. Is the action complete? Verify repair

41

42

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E71

Electronic Ignition System Diagnosis

If the engine cranks but will not run or immediately stalls, the Engine Cranks But Will Not Start chart must be used to determine if the failure is in the ignition system or the fuel system. If DTC P0300 through P0306, P0341, or P0336 is set, the appropriate diagnostic trouble code chart must be used for diagnosis. If a misfire is being experienced with no DTC set, refer to the Symptoms section for diagnosis.

Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure

EVAP Canister Purge Solenoid and EVAP Vent Solenoid Valve

A continuous purge condition with no purge commanded by the PCM will set a DTC P1441. Refer to the DTC charts for further information.

Visual Check of The Evaporative Emission Canister

D If the canister is cracked or damaged, replace the canister. D If fuel is leaking from the canister, replace the canister and check hoses and hose routing.

T32003

Fuel Metering System Check

Some failures of the fuel metering system will result in an Engine Cranks But Will Not Run symptom. If this condition exists, refer to the Cranks But Will Not Run chart. This chart will determine if the problem is caused by the ignition system, the PCM, or the fuel pump electrical circuit. Refer to Fuel System Electrical Test for the fuel system wiring schematic. If there is a fuel delivery problem, refer to Fuel System Diagnosis, which diagnoses the fuel injectors, the fuel pressure regulator, and the fuel pump. If a malfunction occurs in the fuel metering system, it usually results in either a rich HO2S signal or a lean HO2S signal. This condition is indicated by the HO2S voltage, which causes the PCM to change the fuel calculation (fuel injector pulse width) based on the HO2S reading. Changes made to the fuel calculation will be indicated by a change in the long term fuel trim values which can be monitored with a Tech 2. Ideal long term fuel trim values are around 0%; for a lean HO2S signal, the PCM will add fuel, resulting in a fuel trim value above 0%. Some variations in fuel trim values are normal because all engines are not exactly the same. If the evaporative emission canister purge is ON, the fuel trim may be as low as 38%. If the fuel trim values are greater than +23%, refer to DTC P0131, DTC P0151, DTC P0171, and DTC 1171 for items which can cause a lean HO2S signal.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart: 2. Relieve the fuel pressure by connecting the J 34730-1 Fuel Pressure Gauge to the fuel pressure connection on the fuel rail. CAUTION: In order to reduce the risk of fire and personal injury, wrap a shop towel around the fuel pressure connection. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete. Place the fuel pressure gauge bleed hose in an approved gasoline container. With the ignition switch OFF, open the valve on the fuel pressure gauge. 3. Record the lowest voltage displayed by the DVM after the first second of the test. (During the first second, voltage displayed by the DVM may be inaccurate due to the initial current surge.) Injector Specifications: Resistance (Ohms) 11.8 12.6 Voltage Specification at 10C-35C (50F-95F) 5.7 6.6

Fuel System Pressure Test

A fuel system pressure test is part of several of the diagnostic charts and symptom checks. To perform this test, refer to Fuel Systems Diagnosis.

D The voltage displayed by the DVM should be within the specified range. D The voltage displayed by the DVM may increase throughout the test as the fuel injector windings warm and the resistance of the fuel injector windings changes.

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TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

7. The Fuel Injector Balance Test portion of this chart (Step 7 through Step 11) checks the mechanical (fuel delivery) portion of the fuel injector. An engine cool-down period of 10 minutes is necessary in order to avoid irregular fuel pressure readings due to Hot Soak fuel boiling.

D An erratic voltage reading (large fluctuations in voltage that do not stabilize) indicates an intermittent connection within the fuel injector. 5. Injector Specifications: Highest Acceptable Voltage Reading Above/Below 35C/10C (95F/50F) 9.5 Volts Acceptable Subtracted Value

0.6 Volts

Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11)

R262001

CYLINDER 1st Reading (1) 2nd Reading (2) Amount of Drop (1st Reading2nd Reading) Av.drop = 166 kPa/24 psi 10 kPa/1.5 psi = 156 176 kPa or 22.5 25.5 psi

1 296 kPa (43 psi) 131 kPa (19 psi) 165 kPa (24 psi) OK

2 296 kPa (43 psi) 117 kPa (17 psi) 179 kPa (26 psi) Faulty, Rich (Too Much Fuel Drop)

3 296 kPa (43 psi) 124 kPa (18 psi) 172 kPa (25 psi) OK

4 296 kPa (43 psi) 145 kPa (21 psi) 151 kPa (22 psi) Faulty, Lean (Too Little Fuel Drop)

5 296 kPa (43 psi) 131 kPa (19 psi) 165 kPa (24 psi) OK

6 296 kPa (43 psi) 130 kPa (19 psi) 166 kPa (24 psi) OK

NOTE: These figures are examples only.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E73

Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11)
Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Turn the engine OFF. NOTE: In order to prevent flooding of a single cylinder and possible engine damage, relieve the fuel pressure before performing the fuel injector coil test procedure. 2. Relieve the fuel pressure. Refer to Test Description Number 2. 3. Connect the J 39021-5V Fuel Injector Tester to B+ and ground, and to the J 39021-90 Injector Switch Box. 4. Connect the injector switch box to the grey fuel injector harness connector located on the front of the EVAP canister bracket. 5. Set the amperage supply selector switch on the fuel injector tester to the Coil Test 0.5 amp position. 6. Connect the leads from the J 39200 Digital Voltmeter (DVM) to the injector tester. Refer to the illustrations associated with the test description. 7. Set the DVM to the tenths scale (0.0). 8. Observe the engine coolant temperature. Is the engine coolant temperature within the specified values?

Go to OBD System Check

10C (50F) to 35C (95F)

Go to Step 3

Go to Step 5

1. Set injector switch box injector #1. 2. Press the Push to Start Test button on the fuel injector tester. 3. Observe the voltage reading on the DVM. IMPORTANT: The voltage reading may rise during the test. 4. Record the lowest voltage observed after the first second of the test. 5. Set the injector switch box to the next injector and repeat steps 2, 3, and 4. Did any fuel injector have an erratic voltage reading (large fluctuations in voltage that did not stabilize) or a voltage reading outside of the specified values?

5.7-6.6 V

Go to Step 4

Go to Step 7

Replace the faulty fuel injector(s). Refer to Fuel Injector. Is the action complete? Go to Step 7

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TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11) (Cont'd)
Step Action Value(s) Yes No

1. Set injector switch box injector #1. 2. Press the Push to Start Test button on the fuel injector tester. 3. Observe the voltage reading on the DVM. IMPORTANT: The voltage reading may rise during the test. 4. Record the lowest voltage observed after the first second of the test. 5. Set the injector switch box to the next injector and repeat steps 2, 3, and 4. Did any fuel injector have an erratic voltage reading (large fluctuations in voltage that did not stabilize) or a voltage reading above the specified value?

9.5 V

Go to Step 4

Go to Step 6

1. Identify the highest voltage reading recorded (other than those above 9.5 V). 2. Subtract the voltage reading of each injector from the highest voltage selected in step 1. Repeat until you have a subtracted value for each injector. For any injector, is the subtracted Value in step 2 greater than the specified value? 0.6 V Go to Step 4 Go to Step 7

CAUTION: In order to reduce the risk of fire and personal injury, wrap a shop towel around the fuel pressure connection. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete. 1. Connect the J 34730-1 Fuel Pressure Gauge to the fuel pressure test port. 2. Energize the fuel pump using the Tech 2. 3. Place the bleed hose of the fuel pressure gauge into an approved gasoline container. 4. Bleed the air out of the fuel pressure gauge. 5. With the fuel pump running, observe the reading on the fuel pressure gauge. Is the fuel pressure within the specified values?

296-376 kPa (43-55 psi)

Go to Step 8

Go to Fuel System Diagnosis Go to Fuel System Diagnosis

Turn the fuel pump OFF. Does the fuel pressure remain constant? Go to Step 9

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Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11) (Cont'd)
Step Action Value(s) Yes No

1. Connect the J 39021-5V Fuel Injector Tester and J 39021-90 Injector Switch Box the fuel injector harness connector. 2. Set the amperage supply selector switch on the fuel injector tester to the Balance Test 0.52.5 amp position. 3. Using the Tech 2 turn the fuel pump ON then OFF in order to pressurize the fuel system. 4. Record the fuel pressure indicated by the fuel pressure gauge after the fuel pressure stabilizes. This is the first pressure reading. 5. Energize the fuel injector by depressing the Push to Start Test button on the fuel injector tester. 6. Record the fuel pressure indicated by the fuel pressure gauge after the fuel pressure gauge needle has stopped moving. This is the second pressure reading. 7. Repeat steps 1 through 6 for each fuel injector. 8. Subtract the second pressure reading from the first pressure reading for one fuel injector. The result is the pressure drop value. 9. Obtain a pressure drop value for each fuel injector. 10.Add all of the individual pressure drop values. This is the total pressure drop. 11. Divide the total pressure drop by the number of fuel injectors. This is the average pressure drop. Does any fuel injector have a pressure drop value that is either higher than the average pressure drop or lower than the average pressure drop by the specified value? 10 kPa (1.5 psi) Go to OBD System Check

Go to Step 10

10

Re-test any fuel injector that does not meet the specification. Refer to the procedure in step 9. NOTE: Do not repeat any portion of this test before running the engine in order to prevent the engine from flooding. Does any fuel injector still have a pressure drop value that is either higher than the average pressure drop or lower than the average pressure drop by the specified value?

10 kPa (1.5 psi)

Go to Step 11

Go to Symptoms

11

Replace the faulty fuel injector(s). Injector. Is the action complete?

Refer to Fuel Verify repair

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TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

The PCM provides the following sensors with a 5volt reference and a sensor ground signal: 1 D The exhaust gas recirculating (EGR) pintle position sensor D The manifold absolute pressure (MAP) sensor D The throttle position (TP) sensor 1 D The acceleration position (AP) sensor 1 D The acceleration position (AP) sensor 3 D The Vapor Pressure Sensor 2 D The Crank position (CKP) sensor D The throttle position (TP) sensor 2 D The acceleration position (AP) sensor 2 The PCM monitors the separate feedback signals from these sensors in order to determine their operating status.

Powertrain Control Module (PCM) Diagnosis

To read and clear diagnostic trouble codes, use a Tech 2. IMPORTANT: Use of a Tech 2 is recommended to clear diagnostic trouble codes from the PCM memory. Diagnostic trouble codes can also be cleared by turning the ignition OFF and disconnecting the battery power from the PCM for 30 seconds. Turning off the ignition and disconnecting the battery power from the PCM will cause all diagnostic information in the PCM memory to be cleared. Therefore, all the diagnostic tests will have to be re-run. Since the PCM can have a failure which may affect only one circuit, following the diagnostic procedures in this section will determine which circuit has a problem and where it is. If a diagnostic chart indicates that the PCM connections or the PCM is the cause of a problem, and the PCM is replaced, but this does not correct the problem, one of the following may be the reason: D There is a problem with the PCM terminal connections. The terminals may have to be removed from the connector in order to check them properly. D EEPROM program is not correct for the application. Incorrect components or reprogramming the PCM with the wrong EEPROM program may cause a malfunction and may or may not set a DTC. D The problem is intermittent. This means that the problem is not present at the time the system is being checked. In this case, refer to the Symptoms portion of the manual and make a careful physical inspection of all component and wiring associated with the affected system. D There is a shorted solenoid, relay coil, or harness. Solenoids and relays are turned ON and OFF by the PCM using internal electronic switches called drivers. A shorted solenoid, relay coil, or harness will not damage the PCM but will cause the solenoid or relay to be inoperative.

Diagnostic Aids
IMPORTANT: Be sure to inspect PCM and engine grounds for being secure and clean. A short to voltage in one of the sensor input circuits may cause one or more of the following DTCs to be set: D P0425 D P0108, P1106 D P0406 D P1120, P1515, P1221, P1516, P1635 D P1275, P1639, P1271, P1273 D P1285, P1272, P1273 D P0336, P0337 D P1220, P1515, P1221, P1515, P1516 D P1280, P1271, P1272 IMPORTANT: If a sensor input circuit has been shorted to voltage, ensure that the sensor is not damaged. A damaged sensor will continue to indicate a high or low voltage after the affected circuit has been repaired. If the sensor has been damaged, replace it. An open in the sensor ground circuit between the PCM and the splice will cause one or more of the following DTCs to be set: D P0425 D P0108, P1106 D P0406 D P1120, P1515, P1221, P1516, P1635 D P1275, P1639, P1271, P1273 D P1285, P1272, P1273 D P0336, P0337 D P1220, P1515, P1221, P1515, P1516 D P1280, P1271, P1272 A short to ground in the 5volt reference A or B circuit will cause one or more of the following DTCs to be set: D P0453 D P0106, P0107, P1107 D P0401, P1404, P0405 D P1120, P1515, P1221, P1516, P1635

Multiple PCM Information Sensor DTCs Set

Circuit Description
The powertrain control module (PCM) monitors various sensors to determine the engine operating conditions. The PCM controls fuel delivery, spark advance, transmission operation, and emission control device operation based on the sensor inputs. The PCM provides a sensor ground to all of the sensors. The PCM applies 5 volts through a pullup resistor, and determines the status of the following sensors by monitoring the voltage present between the 5volt supply and the resistor: D The engine coolant temperature (ECT) sensor D The intake air temperature (IAT) sensor D The transmission fluid temperature (TFT) sensor

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

D P1275, P1639, P1271, P1273 D P1285, P1272, P1273 D P0336, P0337 D P1220, P1515, P1221, P1515, P1516 D P1280, P1271, P1272 Check for the following conditions: D Poor connection at PCM. Inspect the harness connectors for backedout terminals, improper mating, broken locks, improperly formed or damage terminals, and a poor terminaltowire connection.

6E77

D Damaged harness. Inspect the wiring harness for damage. If the harness is not damaged, observe an affected sensor fs displayed value on the Tech 2 with the ignition ON and the engine OFF while you move the connectors and the wiring harnesses related to the following sensors: D Vapor Pressure (Fuel Tank Pressure) Sensor D MAP Sensor D EGR D TPS1/TPS2 D APS1/APS2/APS3 D CKP

Multiple PCM Information Sensor DTCs Set

Step Action Value(s) Yes No

Was the On-Board (OBD) System Check performed? Go to Step 2

Go to OBD System Check

1. Turn the ignition OFF, disconnect the PCM. 2. Turn the ignition ON, check the 5 volt reference 1 and 2 circuit for the following conditions: D A poor connection at the PCM. D An open between the PCM connector and the splice. D A short to ground. D A short to voltage. Is there an open or short? Go to Step 3 Verify repair Go to Step 4 Repair the open or short. Is the action complete? Check the sensor ground circuit for the following conditions: D A poor connection at the PCM or the affected sensors. D An open between the PCM connector and the affected sensors. Is there an open or a poor connection? Go to Step 5 Verify repair Go to applicable DTC table Go to Step 6 Repair the open or the poor connection. Is the action complete? Following below the DTCs stored: P1635, P1639 Measure the resistance below the items: D Between EGR sensor supply circuit and Vapor Pressure Sensor supply circuit. D Between MAP sensor supply circuit and Vapor Pressure Sensor supply circuit. D Between Vapor Pressure Sensor supply circuit and PCM harness connector. (5Volt supply circuit) Is the resistance near the specified value? Go to Step 9 Go to Step 8

3 4

5 6

Go to Step 7

6E78

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Multiple PCM Information Sensor DTCs Set (Cont'd)

Step Action Value(s) Yes No

Locate and repair the open circuit in the MAP or EGR or Vapor Pressure sensor supply circuit. Is the action complete? Verify repair 1. Disconnect the MAP, Vapor pressure sensor and EGR connector. 2. Ignition ON. 3. Measure the resistance of the blow areas: D MAP sensor GND circuit. D EGR GND circuit. D Vapor pressure sensor GND circuit. Does the voltage resistance near the specified value? Go to Step 11 Go to Step 10 Locate and repair the short circuit in the MAP or EGR or Vapor Pressure sensor signal or GND circuit. Is the action complete? Verify repair 1. Disconnect the CKP sensor connector. 2. Ignition ON. 3. Measure the voltage of the blow areas: D CKP sensor GND circuit and shield circuit. Does the voltage resistance near the specified value? Go to Step 13 Go to Step 12 Locate and repair the short circuit in the CKP sensor signal or GND circuit. Is the action complete? Verify repair Go to applicable DTC table Are more of the following items for DTCs stored? EGR, Vapor Pressure Sensor, MAP, CKP, TPS, APS Replace the PCM. The replacement PCM must be programmed. Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?

10

11

12

13

Go to Step 14

14

Go to OBD System Check

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E79

Exhaust Gas Recirculation (EGR) Diagnosis

An EGR flow check diagnosis of the linear EGR system is covered by DTC P0401. Pintle position error diagnosis is covered by DTC P0402, P0404, P1404, P0405, P0406. If EGR diagnostic trouble codes P0401 and/or P0402, P0404, P1404, P0405, P0406 are encountered, refer to the DTC charts.

Engine Tech 2 Data Definitions and Ranges

A/C CLUTCH Tech 2 Displays ON or OFF Indicates whether the PCM has commanded the A/C clutch ON. Used in A/C system diagnostic. A/C REQUEST Tech 2 Displays YES or NO Indicates the state of the A/C request input circuit from the HVAC controls. The PCM uses the A/C request signal to determine whether A/C compressor operation is being requested. AIR/FUEL RATIO Tech 2 Range 0.0-25.5 Air/fuel ratio indicates the PCM commanded value. In closed loop, the air/fuel ratio should normally be displayed around 14.6-14.7. A lower air/fuel ratio indicates a richer commanded mixture, which may be seen during power enrichment or TWC protection modes. A higher air/fuel ratio indicates a leaner commanded mixture. This can be seen during deceleration fuel mode. AP1 Tech 2 Range 0%-100% AP (accelerator pedal) angle is computed by the PCM from the AP sensor voltage. AP angle should display 11-15% at idle and 85-89% at wide open throttle. AP2 Tech 2 Range 0%-100% AP (accelerator pedal) angle is computed by the PCM from the AP sensor voltage. AP angle should display 85-89% at idle and 11-15% at wide open throttle. AP3 Tech 2 Range 0%-100% AP (accelerator pedal) angle is computed by the PCM from the AP sensor voltage. AP angle should display 85-89% at idle and 32-36% at wide open throttle. BAROMETRIC PRESSURE Tech 2 Range 10-105 kPa/0.00-5.00 Volts The barometric pressure reading is determined from the MAP sensor signal monitored during key up and wide open throttle (WOT) conditions. The barometric pressure is used to compensate for altitude differences and is normally displayed around 61-104 depending on altitude and barometric pressure. CHECK TRANS LAMP AUTO TRANSMISSION Indicates the need to check for a DTC with the Tech 2 when the lamp is flashing 0.2 seconds ON and 0.2 seconds OFF. DESIRED EGR POS. Tech 2 Range 0%-100% Represents the EGR pintle position that the PCM is commanding. DESIRED IDLE Tech 2 Range 0-3187 RPM The idle speed that the PCM is commanding. The PCM will compensate for various engine loads based on engine coolant temperature, to keep the engine at the desired speed.

ECT (Engine Coolant Temperature) Tech 2 Range 40C to 151C (40F to 304F) The engine coolant temperature (ECT) is mounted in the coolant stream and sends engine temperature information to the PCM. The PCM applies 5 volts to the ECT sensor circuit. The sensor is a thermistor which changes internal resistance as temperature changes. When the sensor is cold (high resistance), the PCM monitors a high signal voltage and interprets that as a cold engine. As the sensor warms (decreasing resistance), the voltage signal will decrease and the PCM will interpret the lower voltage as a warm engine. EGR DUTY CYCLE Tech 2 Range 0%-100% Represents the EGR valve driver PWM signal from the PCM. A duty cycle of 0% indicates that no EGR flow is being commanded; a 100% duty cycle indicates maximum EGR flow commanded. EGR FEEDBACK Tech 2 Range 0.00-5.00 Volts Indicates the EGR pintle position sensor signal voltage being monitored by the PCM. A low voltage indicates a fully extended pintle (closed valve); a voltage near 5 volts indicates a retracted pintle (open valve). ENGINE LOAD Tech 2 Range 0%-100% Engine load is calculated by the PCM from engine speed and MAF sensor readings. Engine load should increase with an increase in RPM or air flow. ENGINE RUN TIME Tech 2 Range 00:00:00-99:99:99 Hrs:Min:Sec Indicates the time elapsed since the engine was started. If the engine is stopped, engine run time will be reset to 00:00:00. ENGINE SPEED Range 0-9999 RPM Engine speed is computed by the PCM from the 58X reference input. It should remain close to desired idle under various engine loads with engine idling. EVAP PURGE PWM Tech 2 Range 0%-100% Represents the PCM commanded PWM duty cycle of the EVAP purge solenoid valve. 0% displayed indicates no purge; 100% displayed indicates full purge. FUEL PUMP Tech 2 Displays ON or OFF Indicates the PCM commanded state of the fuel pump relay driver circuit. HO2S BANK 1, SEN. 1 Tech 2 Range 0-1132 mV Represents the fuel control exhaust oxygen sensor output voltage. Should fluctuate constantly within a range between 10 mV (lean exhaust) and 1000 mV (rich exhaust) while operating in closed loop. HO2S BANK 1, SEN. 2 Tech 2 Range 0-1000mV Monitors the exhaust oxygen sensor output voltage. The PCM monitors the operating efficiency of catalytic converter by comparing the output voltages of sensor 1 and sensor 2 in this bank. If the catalytic converter is operating efficiently, the output voltage of sensor 1 will give a greater fluctuation than that of sensor 2. If the PCM detects an abnormal level of voltage fluctuation from sensor 2, a DTC P0420 will be set, indicating that the catalytic converter for this bank is no longer operating efficiently.

6E80

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

INJ. PULSE BANK 1/INJ. PULSE BANK 2 Tech 2 Range 0-1000 msec. Indicates the amount of time the PCM is commanding each injector ON during each engine cycle. A longer injector pulse width will cause more fuel to be delivered. Injector pulse width should increase with increased engine load. LONG TERM FUEL TRIM BANK 1/BANK 2 The long term fuel trim is derived from the short term fuel trim values and represents a long term correction of fuel delivery for the bank in question. A value of 0% indicates that fuel delivery requires no compensation to maintain the PCM commanded air/fuel ratio. A negative value significantly below 0% indicates that the fuel system is rich and fuel delivery is being reduced (decreased injector pulse width). A positive value significantly greater than 0% indicates that a lean condition exists and the PCM is compensating by adding fuel (increased injector pulse width). Because long term fuel trim tends to follow short term fuel trim, a value in the negative range due to canister purge at idle should not be considered unusual. Fuel trim values at maximum authority may indicate an excessively rich or lean system. Fuel System STATUS Tech 2 Displays OPEN or CLOSED CLOSED indicates that the PCM is controlling fuel delivery according to oxygen sensor voltage. In OPEN the PCM ignores the oxygen sensor voltage and bases the amount of fuel to be delivered on TP sensor, engine coolant, and MAF sensor inputs only. MAF Tech 2 Range 0.0-512 gm/s MAF (mass air flow) is the MAF input frequency converted to grams of air per second. This indicates the amount of air entering the engine. MAP Tech 2 Range 10-105 kPa (0.00-4.97 Volts) The manifold absolute pressure (MAP) sensor measures the change in the intake manifold pressure from engine load, EGR flow, and speed changes. As intake manifold pressure increases, intake vacuum decreases, resulting in a higher MAP sensor voltage and kPa reading. The MAP sensor signal is used to monitor intake manifold pressure changes during the EGR flow test, to update the BARO reading, and as an enabling factor for several of the diagnostics. MIL Tech 2 Displays ON or OFF Indicates the PCM commanded state of the malfunction indicator lamp. MISFIRE CUR. CYL. #1 /#2 /#3 /#4 / #5 / #6 Tech 2 Range 0-255 Counts The misfire current counters increase at a rate according to the number of the possible misfires being detected on each cylinder. The counters may normally display some activity, but the activity should be nearly equal for all the cylinders.

HO2S BANK2, SEN. 1 Tech 2 Range 0-1132 mV Represents the fuel control exhaust oxygen sensor output voltage. Should fluctuate constantly within a range between 10mV (lean exhaust) and 1000 mV (rich exhaust) while operating in closed loop. HO2S BANK 2, SEN. 2Tech 2 Range 0-1000 mV Monitors the exhaust oxygen sensor output voltage. The PCM monitors the operating efficiency of catalytic converter by comparing the output voltages of sensor 1 and sensor 2 in this bank. If the catalytic converter is operating efficiently, the output voltage of sensor 1 will have a greater fluctuation than that of sensor 2. If the PCM detects an abnormal level of voltage fluctuation from sensor 2, a DTC P0430 will be set, indicating that the catalytic converter for this bank is no longer operating efficiently. HO2S BANK 1, SEN. 1Tech 2 Displays NOT READY or READY Indicates the status of the exhaust oxygen sensor. The Tech 2 will indicate that the exhaust oxygen sensor is ready when the PCM detects a fluctuating HO2S voltage sufficient to allow closed loop operation. This will not occur unless the exhaust oxygen sensor is warmed up. HO2S BANK 2, SEN. 1 Tech 2 Displays NOT READY or READY Indicates the status of the exhaust oxygen sensor. The Tech 2 will indicate that the exhaust oxygen sensor is ready when the PCM detects a fluctuating HO2S voltage sufficient to allow closed loop operation. This will not occur unless the exhaust oxygen sensor is warmed up. HO2S WARM UP TIME BANK 1, SEN. 1/BANK 1, SEN 2/BANK 2 SEN. 1/BANK 2 SEN. 2 Tech 2 Range 00:00:00-99:99:99 HRS:MIN:SEC Indicates warm-up time for each HO2S. The HO2S warm-up time is used for the HO2S heater test. The PCM will run the heater test only after a cold start (determined by engine coolant and intake air temperature at the time of start-up) and only once during an ignition cycle. When the engine is started the PCM will monitor the HO2S voltage. When the HO2S voltage indicates a sufficiently active sensor, the PCM looks at how much time has elapsed since start-up. If the PCM determines that tool much time was required for the HO2S to become active, a DTC will set. If the engine was warm when started, HO2S warm-up will the display 00:00:00. IAT (INTAKE AIR TEMPERATURE) Tech 2 Range 40C to 151C (40F to 304F) The PCM converts the resistance of the intake air temperature sensor to degrees. Intake air temperature (IAT) is used by the PCM to adjust fuel delivery and spark timing according to incoming air density. IGNITION 1 Tech 2 Range 0-25.5 Volts This represents the system voltage measured by the PCM at its ignition feed.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

MISFIRE CUR. CYL. #1 /#2 /#3 /#4 / #5 / #6 Tech 2 Range 0-65535 Counts The misfire history counters display the relative level of misfire that has been detected on each cylinder. The misfire history counters will not update or show any activity until a misfire DTC (P0300) has become active. MISFIRE FAILURES SINCE FIRST FAIL Tech 2 Range 0-65535 Counts Indicates the number of 200 crankshaft revolution sample periods during which the level of misfire was sufficiently high to report a fail. MISFIRE PASSES SINCE FIRST FAIL Tech 2 Range 0-65535 Counts Indicates the number of 200 crankshaft revolution sample periods during which the level of misfire was sufficiently low to report a pass. POWER ENRICHMENT Tech 2 Displays ACTIVE or INACTIVE ACTIVE displayed indicates that the PCM has detected conditions appropriate to operate in power enrichment mode. The PCM will command power enrichment mode when a large increase in throttle position and load is detected. While in power enrichment mode, the PCM will increase the amount of fuel delivered by entering open loop and increasing the injector pulse width. This is done to prevent a possible sag or hesitation from occurring during acceleration. SPARK Tech 2 Range 64 to 64 Displays the amount of spark advance being commanded by the PCM on the IC circuit. START-UP ECT Tech 2 Range 40C to 151C (40F to 304F) Indicates the engine coolant temperature at the time that the vehicle was started. Used by the HO2S diagnostic to determine if the last start-up was a cold start. START-UP IAT Tech 2 Range 40C to 151C (40F to 304F) Indicates the intake air temperature at the time that the vehicle was started. Used by the HO2S diagnostic to determine if the last start-up was a cold start. TOTAL MISFIRE CURRENT COUNT Tech 2 Range 0-255 Indicates the total number of cylinder firing events that were detected as being misfires during the last 200 crankshaft revolution sample period. TP1 Tech 2 Range 0%-100% TP (throttle position) angle is computed by the PCM from the TP sensor voltage. TP angle should display 6-12% at idle and 79-83% at wide open throttle. TP2 Tech 2 Range 0%-100% TP (throttle position) angle is computed by the PCM from the TP sensor voltage. TP angle should display 88-94% at idle and 19-23% at wide open throttle. CATALYST PROTECTION MODE Tech 2 Displays YES or NO YES displayed indicates that the PCM has detected conditions appropriate to operate in TWC protection mode. The PCM will decrease the air/fuel ratio to a value that depends on mass air flow (higher mass air flow = lower air/fuel ratio).

6E81

UPSHIFT LAMP (MANUAL TRANSMISSION) VEHICLE SPEED Tech 2 Range 0-255 km/h (0-155 mph) The vehicle speed sensor signal is converted into km/h and mph for display. WEAK CYLINDER Tech 2 Displays Cylinder Number This indicates that the PCM has detected crankshaft speed variations that indicate 2% or more cylinder firing events are misfires.

Typical Scan Data Values

Use the Typical Scan Data Values Table only after the On-Board Diagnostic System Check has been completed, no DTC(s) were noted, and you have determined that the on-board diagnostics are functioning properly. Tech 2 values from a properly-running engine may be used for comparison with the engine you are diagnosing. The typical scan data values represent values that would be seen on a normally-running engine. NOTE: A Tech 2 that displays faulty data should not be used, and the problem should be reported to the Tech 2 manufacturer. Use of a faulty Tech 2 can result in misdiagnosis and unnecessary replacement of parts. Only the parameters listed below are referred to in this service manual for use in diagnosis. For further information on using the Tech 2 to diagnose the PCM and related sensors, refer to the applicable reference section listed below. If all values are within the typical range described below, refer to the Symptoms section for diagnosis.

Test Conditions
Engine running, lower radiator hose hot, transmission in park or neutral, closed loop, accessories off, brake not applied and air conditioning off.

6E82

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

3.5L V-6 Engine (Automatic and Manual Transmission) Tech 2 Parameter A/C Clutch Relay A/C Request Data List Units Displayed Typical Data Values (IDLE) Off Typical Data Values (2500 RPM) Off Refer To

Engine

On/Off

General Description and Operation, A/C Clutch Circuit Operation General Description and Operation, A/C Request Signal General Description and Operation, Fuel System Metering Purpose General Description and Operation General Description and Operation General Description and Operation General Description and Operation

Engine

Yes/No

No

No

Air/Fuel Ratio

Engine

Ratio: _ to 1

14.614.7

14.614.7

APP Sensor1 APP Sensor2 APP Sensor3 Barometric Pressure

Engine Engine Engine Engine

Percent Percent Percent kPa

1115 8589 8589 61-104 (depends on altitude and barometric pressure) Open 0V Off

1624 7482 7684 61-104 (depends on altitude and barometric pressure) Open 0V Off

Brake Light Switch Check Trans Lamp (Auto Trans) Cruise Main Switch Cruise Set Switch Cruise Cancel Switch Cruise Resume Switch Decel Fuel Cutoff Desired EGR Position Desired Idle Speed ECT (Engine Coolant Temp)

Engine Engine

Open 0V/Closed 12V On/Off

Refer to Section 5 4L30-E Automatic Transmission Diagnosis Refer to Section 10 Refer to Section 10 Refer to Section 10 Refer to Section 10

Engine Engine Engine Engine

Active/Inactive Active/Inactive Active/Inactive Active/Inactive

Inactive Inactive Inactive Inactive

Inactive Inactive Inactive Inactive

Engine

Active/Inactive

Inactive

Inactive

General Description and Operation, Deceleration Mode General Description and Operation, EGR Pintle Position Sensor General Description and Operation General Description and Operation, Engine Coolant Temperature (ECT) Sensor General Description and Operation, EGR Pintle Position Sensor

Engine

Percent

0%

0%

Engine Engine

RPM Degrees C, Degrees F

700 80-100C (176-212F)

800 80-100C (176-212F)

EGR Closed Pintle Position

Engine

Steps

20-40

20-40

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Tech 2 Parameter EGR Duty Cycle Data List Units Displayed Typical Data Values (IDLE) 0% Typical Data Values (2500 RPM) 0% Refer To

6E83

Engine

Percent

General Description and Operation, Linear EGR Operation and Results of Incorrect Operation General Description and Operation, Mass Air Flow (MAF) Sensor

EGR Feedback EGR Normalized Engine Load

Engine Engine Engine

Volts Percent Percent

0.45-0.80 0% 2.0% - 5.5%

0.45-0.80 0% 8.0% - 16.0%

Time From Start Engine Speed

Engine

Sec

Varies. Resets at each engine start. Within 50 to +100 of Desired Idle 0%

Varies. Resets at each engine start. Actual engine speed 0%

Engine

RPM

Diagnosis, EVAP Emission Canister Purge Valve Check Diagnosis, EVAP Canister Purge Solenoid and EVAP Vacuum Switch and Visual Check; DTCs: P1441, P1442 General Description

EVAP Purge Solenoid EVAP Vent Valve

Engine

Percent

Engine

On/Off

Off

Off

Fuel System Status Fuel Level Fuel Level Sensor Fuel Tank (Vapor) Pressure Sensor Fuel Pump HO2S Bank 1 Sen.1 (millivolts) HO2S Bank 1 Sen.2 (millivolts) (Auto Trans) HO2S Bank 1 Sen.2 (millivolts) (Manual Trans) HO2S Bank 1 Sen.3 (millivolts) (Manual Trans)

Engine

Open Loop/Closed Loop Percent Volts Volts in. H2O

Closed Loop

Closed Loop

Engine Engine Engine

1.02 1.86 On 50-950 changing quickly 200-700 changing slowly On

1.02 2.57

Engine Fuel Engine Fuel General Description and Operation

Engine O2 Sensor Data O2 Sensor Data O2 Sensor Data

On/Off Millivolts

Engine Fuel General Description and Operation, Fuel control HO2S General Description and Operation, Fuel Metering System General Description and Operation, Fuel Metering System

50-950, always changing quickly 250-650 changing slowly

Millivolts

Millivolts

50-950 changing quickly

50-950 changing quickly

O2 Sensor Data

Millivolts

200-700 changing slowly

250-650 changing slowly

General Description and Operation, Catalyst Monitor Heated Oxygen Sensor (Manual Trans)

6E84

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Data List Units Displayed Typical Data Values (IDLE) 50-950 changing quickly 200-700 changing slowly Typical Data Values (2500 RPM) 50-950 changing quickly 250-650 changing slowly Refer To

Tech 2 Parameter HO2S Bank 2 Sen.1 (millivolts) HO2S Bank 2 Sen.2 (millivolts) (Auto trans) HO2S Bank 1 Sen.1 (ready/not ready) HO2S Bank 2 Sen.1 (ready/not ready) HO2S Warm-Up Time Bank 1 Sen.1 HO2S Warm-Up Time Bank 1 Sen.2 HO2S Warm-Up Time Bank 2 Sen.1 HO2S Warm-Up Time Bank 2 Sen.2 IAT (Intake Air Temp)

O2 Sensor Data O2 Sensor Data O2 Sensor Data O2 Sensor Data O2 Sensor Data O2 Sensor Data O2 Sensor Data O2 Sensor Data Engine

Millivolts

General Description and Operation, Fuel Control HO2S General Description and Operation, Fuel Metering System General Description and Operation, Fuel Control HO2S; DTC: P0135 General Description and Operation, Fuel Control HO2S General Description and Operation, Fuel Control HO2S General Description and Operation, Fuel Control HO2S General Description and Operation, Fuel Control HO2S General Description and Operation, Catalyst Monitor Heated Oxygen Sensor (Auto Trans) General Description and Operation, Intake Air Temperature (IAT) Sensor Refer to Section 8 General Description and Operation, Electronic Ignition System General Description, Fuel Metering, Fuel Injector General Description, Fuel Metering, Fuel Injector General Description and ION Sensing Module General Description and ION Sensing Module General Description and ION Sensing Module General Description Diagnosis, Fuel Trim System Monitor; DTCs: P0171, P0172

Millivolts

Ready Yes/No

Ready Yes

Ready Yes

Ready Yes/No

Ready Yes

Ready Yes

Seconds

25-45

25-45

Seconds

60-100

60-100

Seconds

25-45

25-45

Seconds

60-100

60-100

Degrees C, Degrees F

0-100C, depends on underhood temperature Closed 0V 12.8-14.1

0-80C, depends on underhood temperature Closed 0V 12.8-14.1

Illumination Switch Ignition Voltage Inj. Pulse Bank 1 Inj. Pulse Bank 2 Knock Present Knock Signal Knock Sensor Retard Knock Counter Long Term FT Bank 1 (Long Term Fuel Trim)

Engine Engine

Closed 0V/Open 12V Volts

Engine Engine Engine Engine Engine Engine Misfire

Milliseconds Milliseconds No/Yes Percent CA Counts Counts and Percentage

2.0-4.0 2.0-4.0 No 14 0 100 to 150 counts, 22% to +17%

2.5-4.0 2.5-4.0 No 14 0 100 to 150 counts, 22% to +17%

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Tech 2 Parameter Long Term FT Bank 2 (Long Term Fuel Trim) MAF (Mass Air Flow) MAP kPa (Manifold Absolute Pressure) MIL Misfire Cur. Cyl #1 Misfire Cur. Cyl #2 Misfire Cur. Cyl #3 Misfire Cur. Cyl #4 Misfire Cur. Cyl #5 Misfire Cur. Cyl #6 Misfire Hist. Cyl #1 Misfire Hist. Cyl #2 Misfire Hist. Cyl #3 Misfire Hist. Cyl #4 Misfire Hist. Cyl #5 Misfire Hist. Cyl #6 Misfire Failures Since First Fail Misfire Passes Since First Fail PNP (Park/Neutral Position) Power Enrichment PSP Switch (Power Steering Pressure) Data List Units Displayed Typical Data Values (IDLE) 100 to 150 counts, 22% to +17% 3.0-7.0 Typical Data Values (2500 RPM) 100 to 150 counts, 22% to +17% 12-20 Refer To

6E85

Misfire

Counts and Percentage

Diagnosis, Fuel Trim System Monitor; DTCs: P0171 General Description and Operation, MAF; DTCs: P101, P0102, P0103 General Description and Operation, Manifold Absolute Pressure (MAP) Sensor; DTCs: P0106, P0107, P0108 On-Board Diagnostic System Check DTC P0300 DTC P0300 DTC P0300 DTC P0300 DTC P0300 DTC P0300 DTC P0300 DTC P0300 DTC P0300 DTC P0300 DTC P0300 DTC P0300 DTC P0300 DTC P0300 4L30-E Automatic Transmission Diagnosis General Description and Operation, Acceleration Mode Refer to 2A Section

Engine

Grams per second Kilopascals Volts

Engine

25-35 0.8-1.3 Off 0-2 0-2 0-2 0-2 0-2 0-2 0 0 0 0 0 0 0 0 P-N

20-30 0.5-1.0 Off 0-2 0-2 0-2 0-2 0-2 0-2 0 0 0 0 0 0 0 0 P-N

Engine Misfire Misfire Misfire Misfire Misfire Misfire Misfire Misfire Misfire Misfire Misfire Misfire Misfire Misfire Engine

On/Off Counts Counts Counts Counts Counts Counts Counts Counts Counts Counts Counts Counts Counts Counts P-N / R-D-3-2-L NO/YES

Engine

NO

NO

Engine

Normal/Hi

Normal Pressure

Normal Pressure

6E86

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Data List Units Displayed Typical Data Values (IDLE) 15-22 Typical Data Values (2500 RPM) 34-44 Refer To

Tech 2 Parameter Spark (Advance) Start-Up ECT (Engine Coolant Temp) Start-Up IAT (Intake Air Temp) TCC Cruise Brake Switch Total Misfire Current Count TP Sensor 1 (Throttle Position Sensor 1) TP Sensor 2 (Throttle Position Sensor 2) Throttle at Idle

Engine

Degrees Before Top Dead Center Degrees C, Degrees F

General Description and Operation, Electronic Ignition System General Description and Operation, Engine Coolant Temperature (ECT) Sensor General Description and Operation, Intake Air Temperature (IAT) Sensor Refer to Section 10 DTC P0300 General Description and Operation, Throttle Position (TP) Sensor General Description and Operation, Throttle Position (TP) Sensor General Description and Operation, Throttle Position (TP) Sensor Manual Transmission 4L30-E Automatic Transmission Diagnosis DTC P0300

Engine

Depends on engine coolant temperature at time of start-up Depends on intake air temperature at time of start-up Active 0-5 612

Depends on engine coolant temperature at time of start-up Depends on intake air temperature at time of start-up Active 0-5 1216

Engine

Degrees C, Degrees F

Engine Misfire Engine

Active/Inactive Counts Percentage

Engine

Percentage

8894

8690

Engine

No/Yes

Yes

No

Upshift Lamp (manual trans) Vehicle Speed Weak Cylinder

Engine Engine Misfire

On/Off MPH / km/h Cylinder #

Off 0

Off 0

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E87

No Malfunction Indicator Lamp (MIL)

D06R200083

Circuit Description
The Check Engine lamp (MIL) should always be illuminated and steady with the ignition ON and the engine stopped. Ignition feed voltage is supplied to the MIL bulb through the meter fuse. The powertrain control module (PCM) turns the MIL ON by grounding the MIL driver circuit.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. A No MIL condition accompanied by a no-start condition suggests a faulty PCM ignition feed or battery feed circuit. 9. Using a test light connected to B+, probe each of the PCM ground terminals to ensure that a good ground is present. Refer to PCM Terminal End View for terminal locations of the PCM ground circuits. 12.In this step, temporarily substitute a known good relay for the PCM relay. The horn relay is nearby, and it can be verified as good simply by honking the horn. Replace the horn relay after completing this step. 17.This vehicle is equipped with a PCM which utilizes an electrically erasable programmable read only memory (EEPROM). When the PCM is replaced, the new PCM must be programmed. Refer to PCM Replacement and Programming Procedures Powertrain Control Module (PCM) and Sensors.

Diagnostic Aids
An intermittent MIL may be cased by a poor connection, rubbed-through wire insulation, or a wire broken inside the insulation. Check for the following items: D Inspect the PCM harness and connections for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness. D If the engine runs OK, check for a faulty light bulb, an open in the MIL driver circuit, or an open in the instrument cluster ignition feed. D If the engine cranks but will not run, check for an open PCM ignition or battery feed, or a poor PCM to engine ground.

6E88

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

No Malfunction Indicator Lamp (MIL)

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Go to Step 3 Attempt to start the engine. Does the engine start?

Go to OBD System Check Go to Step 6

2 3

Check the meter fuse for the instrument cluster ignition feed circuit. Is the fuse OK? Go to Step 4 Go to Step 16 Ignition ON, probe the ignition feed circuit at the cluster connector with a test light to ground. Is the test light ON? Go to Step 5 Go to Step 13 1. Ignition OFF. 2. Disconnect the PCM. 3. Jumper the MIL driver circuit at the PCM connector to ground. 4. Ignition ON. Is the MIL ON? Go to Step 10 Go to Step 11 Check the PCM ignition feed and battery feed fuses (15 A engine fuse and 15 A PCM fuse). Are both fuses OK? Go to Step 7 Go to Step 15 1. 2. 3. 4. Ignition OFF. Disconnect the PCM. Ignition ON. Probe the ignition feed circuit at the PCM harness connector with a test light to ground. Go to Step 8 Go to Step 12

Is the test light ON? 8 Probe the battery feed circuit at the PCM harness connector with a test light to ground. Is the test light ON? 9 10 11 Check for a faulty PCM ground connection. Was a problem found? Check for damaged terminals at the PCM. Was a problem found? Check for an open MIL driver circuit between the PCM and the MIL. Was a problem found? 12 Substitute a known good relay for the PCM main relay. Was the malfunction fixed? 13 14 Repair the open in the ignition feed circuit. Is the action complete? Locate and repair the open PCM battery feed circuit. Is the action complete?

Go to Step 9 Verify repair Verify repair

Go to Step 14 Go to Step 10 Go to Step 17

Verify repair

Go to Step 18

Verify repair Verify repair Verify repair

Go to Step 13

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E89

No Malfunction Indicator Lamp (MIL) (Cont'd)

Step Action Value(s) Yes No

15

Locate and repair the short to ground in the PCM ignition feed circuit or PCM battery feed circuit. Is the action complete? Verify repair Locate and repair the short to ground in the ignition feed circuit to the instrument cluster, and replace the fuse. Is the action complete? Verify repair Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to PCM in ON-Vehicle Service for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair Go to Instrument Panel in Electrical Diagnosis

16

17

18

Check the MIL driver circuit for a poor connection at the instrument panel connector. Was a problem found? Verify repair

6E90

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Malfunction Indicator Lamp (MIL) ON Steady

D06R200083

Circuit description
The malfunction indicator lamp (MIL) should always be illuminated and steady with ignition ON and the engine stopped. Ignition feed voltage is supplied directly to the MIL indicator. The powertrain control module (PCM) turns the MIL ON by grounding the MIL driver circuit. The MIL should not remain ON with the engine running and no DTC(s) set. A steady MIL with the engine running and no DTC(s) suggests a short to ground in the MIL driver circuit.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. If the MIL does not remain ON when the PCM is disconnected, the MIL driver wiring is not faulty. 3. If the MIL driver circuit is OK, the instrument panel cluster is faulty. 6. This vehicle is equipped with a PCM which utilizes an electrically erasable programmable read only memory (EEPROM). When the PCM is replaced, the new PCM must be programmed. Refer to PCM Replacement and Programming Procedures in Powertrain Control Module (PCM) and Sensors.

Diagnostic Aids
An intermittent may be caused by a poor connection, rubbed-through wire insulation, or a wire broken inside the insulation. Check for the following items: D Poor connection or damaged harness Inspect the PCM harness and connectors for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E91

Malfunction Indicator Lamp (MIL) ON Steady

Step Action Value(s) Yes No

Was the On-Board diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition OFF, disconnect PCM. 2. Ignition ON, observe the MIL (Service Engine Soon lamp). Is the MIL ON? Go to Step 3

Go to OBD System Check

Go to Step 5

1. Ignition OFF, disconnect the instrument panel cluster. 2. Check the MIL driver circuit between the PCM and the instrument panel cluster for a short to ground. 3. If a problem is found, repair as necessary. Was the MIL driver circuit shorted to ground? Replace the instrument panel cluster. Is the action complete?

Go to OBD System Check Go to OBD System Check

Go to Step 4

1. Ignition OFF, reconnect the PCM. 2. Ignition ON, reprogram the EEPROM. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. 3. Using the Tech 2 output controls function, select MIL dash lamp control and command the MIL OFF. (Refer to the Miscellaneous test) Did the MIL turn OFF? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?

Go to OBD System Check

Go to Step 6

Go to OBD System Check

6E92

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

No Reduced Power Lamp (RPL)

D06R200083

Circuit Description
The Reduced Power Lamp (RPL) should be turned OFF afrer ON for 3 seconds with the ignition ON and the engine stopped. Ignition feed voltage is supplied to the RPL bulb through the meter fuse. The powertrain control module (PCM) turns the RPL ON by grounding the RPL driver circuit.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. A No RPL condition accompanied by a no-start condition suggests a faulty PCM ignition feed or battery feed circuit. 9. Using a test light connected to B+, probe each of the PCM ground terminals to ensure that a good ground is present. Refer to PCM Terminal End View for terminal locations of the PCM ground circuits. 12.In this step, temporarily substitute a known good relay for the PCM relay. The horn relay is nearby, and it can be verified as good simply by honking the horn. Replace the horn relay after completing this step. 17.This vehicle is equipped with a PCM which utilizes an electrically erasable programmable read only memory (EEPROM). When the PCM is replaced, the new PCM must be programmed. Refer to PCM Replacement and Programming Procedures Powertrain Control Module (PCM) and Sensors.

Diagnostic Aids
An intermittent RPL may be cased by a poor connection, rubbed-through wire insulation, or a wire broken inside the insulation. Check for the following items: D Inspect the PCM harness and connections for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness. D If the engine runs OK, check for a faulty light bulb, an open in the RPL driver circuit, or an open in the instrument cluster ignition feed. D If the engine cranks but will not run, check for an open PCM ignition or battery feed, or a poor PCM to engine ground.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E93

No Reduced Power Lamp (RPL)

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Go to Step 3 Attempt to start the engine. Does the engine start?

Go to OBD System Check Go to Step 6

2 3

Check the meter fuse for the instrument cluster ignition feed circuit. Is the fuse OK? Go to Step 4 Go to Step 16 Ignition ON, probe the ignition feed circuit at the cluster connector with a test light to ground. Is the test light ON? Go to Step 5 Go to Step 13 1. Ignition OFF. 2. Disconnect the PCM. 3. Jumper the RPL driver circuit at the PCM connector to ground. 4. Ignition ON. Is the RPL ON? Go to Step 10 Go to Step 11 Check the PCM ignition feed and battery feed fuses (15 A engine fuse and 15 A PCM fuse). Are both fuses OK? Go to Step 7 Go to Step 15 1. 2. 3. 4. Ignition OFF. Disconnect the PCM. Ignition ON. Probe the ignition feed circuit at the PCM harness connector with a test light to ground. Go to Step 8 Go to Step 12

Is the test light ON? 8 Probe the battery feed circuit at the PCM harness connector with a test light to ground. Is the test light ON? 9 10 11 Check for a faulty PCM ground connection. Was a problem found? Check for damaged terminals at the PCM. Was a problem found? Check for an open RPL driver circuit between the PCM and the RPL. Was a problem found? 12 Substitute a known good relay for the PCM main relay. Was the malfunction fixed? 13 14 Repair the open in the ignition feed circuit. Is the action complete? Locate and repair the open PCM battery feed circuit. Is the action complete?

Go to Step 9 Verify repair Verify repair

Go to Step 14 Go to Step 10 Go to Step 17

Verify repair

Go to Step 18

Verify repair Verify repair Verify repair

Go to Step 13

6E94

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

No Reduced Power Lamp (RPL) (Cont'd)

Step Action Value(s) Yes No

15

Locate and repair the short to ground in the PCM ignition feed circuit or PCM battery feed circuit. Is the action complete? Verify repair Locate and repair the short to ground in the ignition feed circuit to the instrument cluster, and replace the fuse. Is the action complete? Verify repair Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to PCM in ON-Vehicle Service for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair Go to Instrument Panel in Electrical Diagnosis

16

17

18

Check the RPL driver circuit for a poor connection at the instrument panel connector. Was a problem found? Verify repair

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E95

Reduced Power Lamp (RPL) ON Steady

D06R200083

Circuit description
The Reduced Power Lamp (RPL) should be truned OFF after ON for 3 seconds with ignition ON and the engine stopped. Ignition feed voltage is supplied directly to the RPL indicator. The powertrain control module (PCM) turns the RPL ON by grounding the RPL driver circuit. The RPL should not remain ON with the engine running and no DTC(s) set. A steady RPL with the engine running and no DTC(s) suggests a short to ground in the RPL driver circuit.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. If the RPL does not remain ON when the PCM is disconnected, the RPL driver wiring is not faulty. 3. If the RPL driver circuit is OK, the instrument panel cluster is faulty. 6. This vehicle is equipped with a PCM which utilizes an electrically erasable programmable read only memory (EEPROM). When the PCM is replaced, the new PCM must be programmed. Refer to PCM Replacement and Programming Procedures in Powertrain Control Module (PCM) and Sensors.

Diagnostic Aids
An intermittent may be caused by a poor connection, rubbed-through wire insulation, or a wire broken inside the insulation. Check for the following items: D Poor connection or damaged harness Inspect the PCM harness and connectors for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness.

6E96

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Reduced Power Lamp (RPL) ON Steady

Step Action Value(s) Yes No

Was the On-Board diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition OFF, disconnect PCM. 2. Ignition ON, observe the RPL. Is the RPL ON? Go to Step 3

Go to OBD System Check

Go to Step 5

1. Ignition OFF, disconnect the instrument panel cluster. 2. Check the RPL driver circuit between the PCM and the instrument panel cluster for a short to ground. 3. If a problem is found, repair as necessary. Was the RPL driver circuit shorted to ground? Replace the instrument panel cluster. Is the action complete?

Go to OBD System Check Go to OBD System Check

Go to Step 4

1. Ignition OFF, reconnect the PCM. 2. Ignition ON, reprogram the EEPROM. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. 3. Using the Tech 2 output controls function, select RPL dash lamp control and command the RPL OFF. (Refer to the Miscellaneous test) Did the RPL turn OFF? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?

Go to OBD System Check

Go to Step 6

Go to OBD System Check

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E97

Engine Cranks But Will Not Run

D06R200031

6E98

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

D06R200032

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E99

Circuit Description
The electronic Ignition system uses a coil -at-plug method of spark distribution. In this type of ignition system, the powertrain control module (PCM) triggers the correct driver outside the Ignition Current Sense System (ICSS), which then triggers the correct ignition coil based on the 58X signal received from the crankshaft position sensor (CKP). The spark plug connected to the coil fires when the ICSS opens the ground circuit for the coils primary circuit. During crank, the PCM monitors the CKP 58X signal. The CKP signal is used to determine which cylinder will fire first. After the CKP 58X signal has been processed by the PCM, it will command all six injectors to allow a priming shot of fuel for all the cylinders. After the priming, the injectors are left OFF during the next six 58X reference pulses from the CKP. This allows each cylinder a chance to use the fuel from the priming shot. During this waiting been received by the PCM. The ION sensor signal allows the PCM to operate the injectors sequentially based on camshaft position. If the camshaft position signal is not present at start - up, the PCM will begin sequential fuel delivery with a 1 -in-6 chance that fuel delivery is correct. The engine will run without a ION sensor signal, but will set a DTC code.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 5. An obvious cause of low fuel pressure would be an empty fuel tank. 6. The engine will easily start and run if a few injectors are disabled. It is not necessary to test all injectors at this time since this step is only a test to verify that all of the injectors have not been disabled by fuel contamination. 7. A blinking test light verifies that the PCM is monitoring the 58X crankshaft reference signal and is capable of activating the injectors. If there is an open or shorted driver circuit, DTCs 201 206 and a misfire DTC 300 306 should be set. 19. By using a spark tester, each ignition coils ability to produce 25,000 volts is verified. 25. If there is an open or shorted driver circuit, DTCs 201 206 and a misfire DTC 301 306 should be set. All six injector driver circuits can be checked at one time without removing the intake manifold if a J 39021 95 test light is available. This is the alternative procedure: D With the ignition OFF, disconnect the gray connector located at the rear of the air filter, attached to a bracket on the purge canister. D Connect test light J 39021 95 to the connector. Do any of the light constantly illuminate or fail to blink when the engine is cranked? If so, repair the short or open circuit, or replace the PCM if indicated. This procedure only tests the driver circuit as far as the test connection, so step 31 is added to test the circuit all the way to the injector.

Diagnostic Aids
An intermittent problem may be caused by a poor connection, rubbed - through wire insulation or a wire broken inside the insulation. Check for the following items: D Poor connection or damaged harness-Inspect the PCM harness and connectors for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness. D Faulty engine coolant temperature sensor-Using a Tech 2, compare engine coolant temperature with intake air temperature on a completely cool engine. Engine coolant temperature should be within 10 C of intake air temperature. If not, replace the ECT sensor.

Engine Cranks But Will Not Run

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Check the ignition coil fuse, the engine fuse, and the PCM fuse. Was a fuse blown? Go to Step 3 Verify repair

Go to OBD System Check

Go to Step 4

Check for a short to ground and replace the fuse. Is the action complete?

6E100

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Engine Cranks But Will Not Run (Cont'd)

Step Action Value(s) Yes No

1. Ignition OFF, install a fuel pressure gauge at the test fitting on the fuel supply line in the engine compartment. (Use a shop cloth to absorb any fuel leakage while making the connection.) 2. Ignition ON, observe the fuel pressure. Is the fuel pressure within the specified values, and 285 - 375 kPa does it hold steady? (43 55 psi) Go to Step 6 Go to Fuel System Electrical Test Go to Step 5 Go to Fuel System Diagnosis

Is any fuel pressure indicated?

Install the switch box J 390212 at the injector test connector and activate an injector. Did the fuel pressure drop when the injector was activated? Go to Step 7 Go to Step 18

Install an injector test light at the #2 cylinder injector harness connector. Does the light blink when the engine is cranked? Go to Step 8 Go to Step 24 1. Ignition OFF. 2. Disconnect the 11-pin connector at the ION sensing module. 3. With a test light to B + , probe each of the 6 exposed ION sensing module pins, one at a time, while the engine is cranked. (Use the gray narrow Metri - Pak flexible female connector from the J - 35616 kit to make the pin accessible.) Does the light flash at each pin when the engine is cranked? Go to Step 12 Go to Step 9

1. Remove the 4-pin connector at the ION sensing module. 2. Ignition ON. 3. Use a test light at the harness connector to verify that the module is being supplied with B + and ground. Was a problem found? Go to Step 10 Go to Step 11 Repair the open ignition feed circuit or ground circuit to the ION sensing module. Is the action complete? Verify repair Verify repair Repair the ION sensing module. Is the action complete? 1. Reconnect the ION sensing module 11-pin connector. 2. Remove the electrical connector from each coil. 3. With a test light to B+, probe each of the coil connectors at the wire which runs to the ION sensing module. Does the light flash at each coil connector when the engine is cranked? Go to Step 14 Go to Step 13

10

11 12

13

Check for an open circuit between the coil and ION sensing module. Is the action complete? Verify repair

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E101

Engine Cranks But Will Not Run (Cont'd)

Step Action Value(s) Yes No

14

1. Ignition ON. 2. While the coil connectors are disconnected, touch each coil connectors ignition feed terminal with a grounded test light (the ignition feed wire is YEL tracer). Did the test light illuminate? Go to Step 16 Verify repair Go to Step 15 Repair the open ignition feed circuit. Is the action complete? While the coil connectors are disconnected, touch each connectors secondary ground terminal with a test light to B +. (The ground wires are black.) Did the test light illuminate at each coil connector? Go to Step 18 Verify repair Go to Step 17 Repair the open secondary ground circuit. Is the action complete? 1. Test the fuel for contamination. 2. If a problem is found, clean the fuel system and correct the contaminated fuel condition as necessary. Replace the fuel filter and replace any injectors that are not delivering fuel (see Injector Balance Test). Was a problem found? Verify repair Go to Step 19 1. Remove any ignition coil and install a spark tester at the spark plug end of the coil. 2. Observe the tester while the engine is cranking. Was a crisp, blue spark observed? Only one or two sparks followed by no result is considered the same as No Spark.

15 16

17 18

19

Go to Step 21

Go to Step 20

20

Replace the ignition coil, and return to Step 19 to test the remaining coils. Is the action complete? Verify repair Repeat Step 19 for each coil. Remove only one coil at a time, and reinstall each coil on its spark plug after testing, but do not refasten coils with screws at this time. After all coils have passed the spark test, does the engine start?

21

Refasten all coils with their screws

Go to Step 22

22

1. Remove the spark plugs from all cylinders. 2. Visually inspect the spark plug electrodes. 3. Replace any spark plugs with loose or missing electrodes or cracked insulators. Did your inspection reveal any spark plugs exhibiting excessive fouling?

Correct the fouling condition

Go to Step 23

6E102

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Engine Cranks But Will Not Run (Cont'd)

Step Action Value(s) Yes No

23

Refer to Engine Mechanical Diagnosis to diagnose the following conditions: D Faulty or incorrect camshaft drive belts D Leaking or sticky valves or rings D Excessive valve deposits D Weak valve springs D Incorrect valve timing D Leaking head gasket Is the action complete? Verify repair Go to Step 25 Observe the Engine Speed data display on the Tech 2 while cranking the engine. Is the engine RPM indicated? Go to Step 25 Go to Step 34 1. Disconnect the 7-pin gray connector at the rear of the air filter beneath the point where the air duct attaches to the MAF sensor. 2. Ignition ON. 3. Using a test light connected to ground, probe the ignition terminal at the PCM (female) side of the 7-pin connector. Is the test light ON? Go to Step 26 Go to Step 32 1. At the PCM (female) side of the connector, connect a test light between the ignition + terminal and one of the injector driver circuits at the same connector. 2. Ignition ON. 3. Observe the test light, and repeat the test for each injector driver circuit. Did the test light stay on when checking any of the 6 injector driver circuits? Go to Step 27 Go to Step 29

24

25

26

27

1. Ignition OFF, disconnect the PCM. 2. Ignition ON, observe the test light. Is the test light ON? Go to Step 28 Go to Step 33 Locate and repair the short to ground in the injector driver circuit. Is the action complete? Verify repair 1. Using the same test location as in step 26, connect a test light between the ignition terminal and one of the driver circuits. 2. Crank the engine and observe the test light. 3. Repeat for each injector driver circuit. Did the light blink during the test for each circuit? Go to Step 31 Verify repair Go to Step 30 Go to Step 33 Check for an open injector driver circuit. Was a problem found?

28

29

30

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E103

Engine Cranks But Will Not Run (Cont'd)

Step Action Value(s) Yes No

31

1. At the injector (male) side of the gray connector mentioned in step 25, connect an ohmmeter between the ignition pin and one of the driver circuit pins. 2. Check for continuity in the circuit. 3. Repeat for each injector circuit. The readings should be approximately equal to the specified value for injector resistance. Was a problem found? 12.5 m PCM must be Verify repair Verify repair Go to Step 8 Repair the ignition feed circuit. Is the action complete? Replace the PCM. IMPORTANT: The programmed. replacement

32 33

Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? 34 1. Raise the vehicle and disconnect the CKP sensor harness. 2. Ignition ON. 3. With a test light to ground, probe the harness ignition feed terminal. Did the light illuminate? 35 Check the ignition feed wire between the sensor and the PCM for a short to ground or open circuit. Is the action complete? 36 1. Ignition ON. 2. At the CKP harness connector, connect a test light between the ignition and ground terminals. Did the light illuminate? 37 Check the sensor ground circuit for an open or short to voltage. Is the action complete? 38 Check the signal circuit between the sensor and the PCM for a short to ground, short to voltage, or an open. Was a problem found? 39 Replace the CKP position sensor. Is the action complete? Verify repair Go to Step 33 Verify repair Go to Step 39 Verify repair Go to Step 38 Go to Step 37 Verify repair Go to Step 36 Go to Step 35 Verify repair

6E104

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Fuel System Electrical Test

D06R200031

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E105

Circuit Description
When the ignition switch is first turned ON, the powertrain control module (PCM) energizes the fuel pump relay which applies power to the in-tank fuel pump. The fuel pump relay will remain ON as long as the engine is running or cranking and the PCM is receiving 58X crankshaft position pulses. If no 58X crankshaft position pulses are present, the PCM de-energizes the fuel pump relay within 2 seconds after the ignition is turned ON or the engine is stopped. The fuel pump delivers fuel to the fuel rail and injectors, then to the fuel pressure regulator. The fuel pressure regulator controls fuel pressure by allowing excess fuel to be returned to the fuel tank. With the engine stopped and ignition ON, the fuel pump can be turned ON by using a command by the Tech 2.

Fuel Pressure Relief Procedure

1. Remove the fuel cap. 2. Remove the fuel pump relay from the underhood relay center. 3. Start the engine and allow it to stall. 4. Crank the engine for an additional 3 seconds.

Fuel Gauge Installation

1. Remove the shoulder fitting cap. 2. Install fuel gauge J 34730-1 to the fuel feed line located in front of and above the right side valve train cover . 3. Reinstall the fuel pump relay.

Diagnostic Aids
An intermittent may be caused by a poor connection, rubbed-through wire insulation, or a wire broken inside the insulation. Check for the following items: D Poor connection or damaged harness Inspect the PCM harness and connectors for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. If the fuel pump is operating but incorrect pressure is noted, the fuel pump wiring is OK and the Fuel System Pressure Test chart should be used for diagnosis. CAUTION: To reduce the risk of fire and personal injury: D It is necessary to relieve fuel system pressure before connecting a fuel pressure gauge. Refer to Fuel Pressure Relief Procedure, below. D A small amount of fuel may be released when disconnecting the fuel lines. Cover fuel line fittings with a shop towel before disconnecting, to catch any fuel that may leak out. Place the towel in an approved container when the procedure is completed.

6E106

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Fuel System Electrical Test

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Read the Caution above. 2. Relieve the fuel system pressure and install the fuel pump pressure gauge to the test fitting. 3. Ignition ON, Engine is Off. 4. Use a Tech 2 to command the fuel pump ON. (Refer to the Miscellaneous Test.) Is there an immediate pressure build-up which indicates the pump is running? Go to Step 3

Go to OBD System Check

Go to Step 4

1. Verify that the pump is not running by removing the fuel filler cap and listening. 2. Command the pump ON with the Tech 2. Did the pump turn OFF after 2 seconds? 1. Ignition OFF. 2. Remove the fuel pump relay. 3. Using a test light connected to ground, probe the battery feed to the relay. Did the light illuminate?

Test completed

Go to Step 12

Go to Step 6 Verify repair

Go to Step 5

5 6

Repair short or open battery feed to fuel pump relay. Is the action complete? 1. Connect a test light between the two wires that connect to the fuel pump relay pull-in coil. 2. Ignition ON. Did the test light illuminate for 2 seconds and then turn off? Go to Step 12 Go to Step 7

1. With a test light connected to battery (), probe the fuel pump relay connector at the wire which runs from the relay pull-in coil to the PCM. 2. Ignition ON. Did the test light illuminate for 2 seconds and then turn off? Go to Step 8 Go to Step 9

Locate and repair open in the fuel pump relay ground circuit. Is the action complete? Verify repair Check for short or open between the PCM and the fuel pump relay. Was a problem found? Verify repair Go to Step 10 1. Check the fuel pump relay circuit for a poor terminal connection at the PCM. 2. If a problem is found, replace terminal as necessary. Was a problem found? Verify repair Go to Step 11

10

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E107

Fuel System Electrical Test (Cont'd)

Step Action Value(s) Yes No

11

Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

12

1. Reconnect the fuel pump relay. 2. Disconnect the fuel pump electrical connector at the fuel tank. 3. Using a test light connected to ground, probe the fuel pump feed wire (harness side). 4. Command the fuel pump ON with a Tech 2. Did the light illuminate for 2 seconds? Go to Step 15 Go to Step 13 1. Honk the horn to verify that the horn relay is functioning. 2. Substitute the horn relay for the fuel pump relay. 3. Leave the test light connected as in step 12. 4. Command the fuel pump ON with the Tech 2. Did the test light illuminate for 2 seconds when the fuel pump was commanded ON? Go to Step 17 Go to Step 14

13

14

1. Re-connect the horn relay in its proper location. 2. Check for a short circuit, blown fuse or open circuit between the relay and the fuel tank. Is the action complete? Verify repair 1. With the fuel pump electrical connector at the fuel tank disconnected, connect a test light between the feed wire and the ground wire (harness side). 2. Command the fuel pump ON with a Tech 2. Did the test light illuminate for 2 seconds? Go to Step 18 Verify repair Go to Step 16 Repair the open circuit in the fuel pump ground wire. Is the action complete? 1. Re-connect the horn relay in its proper location. 2. Replace the fuel pump relay. Is the action complete? Verify repair Verify repair Replace the fuel pump. Is the action complete?

15

16 17

18

6E108

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Electric Throttle Control (ETC) System Check

D06R200033

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E109

Circuit Description
D The powertrain control module (PCM) controls engine speed by adjusting the position of the throttle control valve (DC motor). The throttle motor is a DC motor driven by one coil. The PCM applies current to the DC motor coil in PWM (%) to adjust the throttle valve into a passage in the throttle body to allow air flow. This method allows highly accurate control of engine speed and quick response to changes in engine load. D The acceleration position (AP) sensor circuit provides a voltage signal relative to acceleration pedal angle. The acceleration pedal angle will vary about 13% at idle position to about 87% at wide open throttle(WOT). APS signal is used to determine which DC motor will adjust throttle position. After the APS signal has been processed by the PCM, it will command DC motor to allow movement of throttle position.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart: 2. Visually/physically inspect for the following throttle valve conditions. 3. Visually/physically inspect for the following acceleration pedal conditions. 5. Check the following circuits for throttle valve and DC moter. Check the following TP sensor resistance and DC motor. 6. Check the following circuits for acceleration pedal. Check the following AP sensor resistance. 7. Following DTC: Error for ETC system.

Diagnostic Aids
D An intermittent may be caused by a poor connection, rubbed-through wire insulation or a wire broken inside the insulation. Check for poor connections or a damaged harness. Inspect the PCM harness and connector for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness. D Throttle body Check for objects blocking the DC motor or throttle bore, excessive deposits in the ETC passage and on the valve spring, and excessive deposits in the throttle bore and on the throttle valve plate. D Acceleration pedal Check for objects blocking the AP sensor or pedal arm with spring, excessive deposits in the acceleration pedal arm and on the acceleration pedal and lacking the pedal stopper rabber.

6E110

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Electric Throttle Control (ETC) System Check

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Visually/physically inspect for the following conditions: D Throttle body tampering. D Restricted intake throttle system. Check for a possible collapsed air intake duct, restricted air filter element, or foreign objects blocking the air intake system. D Throttle body: Check for objects blocking the throttle passage or throttle bore, excessive deposits in the throttle passage and on the throttle valve, and excessive deposits in the throttle bore and on the throttle plate. D Throttle body with lever: When check for objects to send round the throttle spring lever that lever is smooth movement by less than 9 lbm{1.0 Nm}, and spring lever has not excessive play. D Throttle function: Check for the throttle function. When ignition switch ON that throttle lever is smooth operated by step on the acceleration pedal. Did any of the above require a repair? Visually/physically inspect for the following conditions: D Acceleration pedal tampering. D Acceleration pedal : Check for objects blocking the spring or pedal arm. D Acceleration pedal : For check for objects to move the acceleration pedal that pedal is smooth movement, and acceleration pedal arm has not excessive play. Did any of the above require a repair? 1. Check for a poor connection at the throttle body harness connector. 2. Check for a poor connection at the acceleration position sensor harness connector. 3. If a problem is found, replace faulty terminals as necessary. Was a problem found? Verify repair

Go to OBD System Check

Refer to appropriate section for on-vehicle service

Go to Step 3

Refer to appropriate section for on-vehicle service

Go to Step 4

Go to Step 5

Check the following circuits for an open, short to voltage, short to ground, or poor connection at the PCM: D Throttle position sensor 1 circuit. D Throttle position sensor 2 circuit. TPS, DC D Throttle DC motor circuit. mortor 17km TPS, DC D Throttle position sensor resistance. mortor D Throttle DC motor resistance. change If a problem is found, repair as necessary. resistance 0.3100m Was a problem found?

Verify repair

Go to Step 6

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E111

Electric Throttle Control (ETC) System Check (Cont'd)

Step Action Value(s) Yes No

Check the following circuits for an open, short to voltage, short to ground, or poor connection at the PCM: D Acceleration position sensor 1 circuit. D Acceleration position sensor 2 circuit. VccGND D Acceleration position sensor 3 circuit. AP1 2.64km D Acceleration position sensor resistance. AP2 2.64km If a problem is found, repair as necessary. AP3 Was the prblem found? 4.26.4km Following below the DTCs stored: P1120, P1220, P1221, P1271, P1272, P1273, P1275, P1280, P1285, P1514, P1515, P1516, P1523 1. 2. 3. 4. 5. Closed throttle APS1 = 1115% APS2 = 8589% APS3 = 8589% NOTE: The value check of TPS must be performed in TPS1 = less than 15 seconds. 612% TPS2 Was a problem found? = 8894% Wide open throttle APS1 = 8589% APS2 = 1115% APS3 = 3236% TPS1 = 7983% TPS2 = 1923% 1. Replace the faulty sensor. 2. Recheck the value for APS and TPS Refer to the procedure in step 8. Was the problem found? Warming up the engine until the ECT rise at 80C Ignition OFF. Insall the Tech 2. Ignition ON but not engine run. Check the value for APS and TPS.

Verify repair Go to applicable DTC table

Go to Step 7

Go to Step 8

Go to Step 9

System O.K.

Go to Step 10

Verify repair

10

Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to OnVehicle Service in Powertrain Control Module and Sensors for Procedures. And also refer to letest Service Bulletin. Check to see if the Latest software is releasec or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Verify repair

6E112

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Fuel System Diagnosis

060R200214

Legend (1) Vent Solenoid (2) EVAP Purge Solenoid (3) Throttle Body (4) Fuel Filler Neck (5) Fuel Tank (6) Rollover Valve (7) EVAP Canister (8) Ignition Feed (9) Ignition Feed

(10) (11) (12) (13) (14) (15) (16) (17) (18) (19)

EVAP Purge Solenoid Drive Signal from PCM Vent Solenoid Driver Signal from PCM Vent Filter Fuel Tank Pressure Sensor Fuel Tank Pressure Signal to PCM 5 volt Reference A Circuit from PCM Sensor Ground Circuit from PCM Fuel Level Sensor Fuel Level Signal to PCM 5 Volt Return

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E113

Circuit Description
When the ignition switch is turned ON, the powertrain control module (PCM) will turn ON the in-tank fuel pump. The in-tank fuel pump will remain ON as long as the engine is cranking or running and the PCM is receiving 58X crankshaft position pulses. If there are no 58X crankshaft position pulses, the PCM will turn the in-tank fuel pump OFF 2 seconds after the ignition switch is turned ON or 2 seconds after the engine stops running. The in-tank fuel pump is an electric pump within an integral reservoir. The in-tank fuel pump supplies fuel through an in-line fuel filter to the fuel rail assembly. The fuel pump is designed to provide fuel at a pressure above the pressure needed by the fuel injectors. A fuel pressure regulator, attached to the fuel rail, keeps the fuel available to the fuel injectors at a regulated pressure. Unused fuel is returned to the fuel tank by a separate fuel return line.

16.Check the spark plug associated with a particular fuel injector for fouling or saturation in order to determine if that particular fuel injector is leaking. If checking the spark plug associated with a particular fuel injector for fouling or saturation does not determine that a particular fuel injector is leaking, use the following procedure: D Remove the fuel rail, but leave the fuel lines and injectors connected to the fuel rail. Refer to Fuel Rail Assembly in On-Vehicle Service. D Lift the fuel rail just enough to leave the fuel injector nozzles in the fuel injector ports. CAUTION: In order to reduce the risk of fire and personal injury that may result from fuel spraying on the engine, verify that the fuel rail is positioned over the fuel injector ports and verify that the fuel injector retaining clips are intact. D Pressurize the fuel system by connecting a 10 amp fused jumper between B+ and the fuel pump relay connector. D Visually and physically inspect the fuel injector nozzles for leaks. 17.A rich condition may result from the fuel pressure being above 376 kPa (55 psi). A rich condition may cause a DTC P0132 or a DTC P0172 to set. Driveability conditions associated with rich conditions can include hard starting (followed by black smoke) and a strong sulfur smell in the exhaust. 20.This test determines if the high fuel pressure is due to a restricted fuel return line or if the high fuel pressure is due to a faulty fuel pressure regulator. 21.A lean condition may result from fuel pressure below 333 kPa (48 psi). A lean condition may cause a DTC P0131 or a DTC P0171 to set. Driveability conditions associated with lean conditions can include hard starting (when the engine is cold ), hesitation, poor driveability, lack of power, surging , and misfiring. 22.Restricting the fuel return line causes the fuel pressure to rise above the regulated fuel pressure. Command the fuel pump ON with the Tech 2. The fuel pressure should rise above 376 kPa (55 psi) as the fuel return line becomes partially closed. NOTE: Do not allow the fuel pressure to exceed 414 kPa (60 psi). Fuel pressure in excess of 414 kPa (60 psi) may damage the fuel pressure regulator. CAUTION: To reduce the risk of fire and personal injury: D It is necessary to relieve fuel system pressure before connecting a fuel pressure gauge. Refer to Fuel Pressure Relief Procedure, below. D A small amount of fuel may be released when disconnecting the fuel lines. Cover fuel line fittings with a shop towel before disconnecting, to catch any fuel that may leak out. Place the towel in an approved container when the procedure is completed.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. Connect the fuel pressure gauge to the fuel feed line as shown in the fuel system illustration. Wrap a shop towel around the fuel pressure connection in order to absorb any fuel leakage that may occur when installing the fuel pressure gauge. With the ignition switch ON and the fuel pump running, the fuel pressure indicated by the fuel pressure gauge should be 333-376 kPa (48-55 psi). This pressure is controlled by the amount of pressure the spring inside the fuel pressure regulator can provide. 3. A fuel system that cannot maintain a constant fuel pressure has a leak in one or more of the following areas: D The fuel pump check valve. D The fuel pump flex line. D The valve or valve seat within the fuel pressure regulator. D The fuel injector(s). 4. Fuel pressure that drops off during acceleration, cruise, or hard cornering may case a lean condition. A lean condition can cause a loss of power, surging, or misfire. A lean condition can be diagnosed using a Tech 2. If an extremely lean condition occurs, the oxygen sensor(s) will stop toggling. The oxygen sensor output voltage(s) will drop below 500 mV. Also, the fuel injector pulse width will increase. IMPORTANT: Make sure the fuel system is not operating in the Fuel Cut-Off Mode. When the engine is at idle, the manifold pressure is low (high vacuum). This low pressure (high vacuum) is applied to the fuel pressure regulator diaphragm. The low pressure (high vacuum) will offset the pressure being applied to the fuel pressure regulator diaphragm by the spring inside the fuel pressure regulator. When this happens, the result is lower fuel pressure. The fuel pressure at idle will vary slightly as the barometric pressure changes, but the fuel pressure at idle should always be less than the fuel pressure noted in step 2 with the engine OFF.

6E114

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Fuel Pressure Relief Procedure

1. Remove the fuel cap. 2. Remove the fuel pump relay from the underhood relay center. 3. Start the engine and allow it to stall. 4. Crank the engine for an additional 3 seconds.

Fuel Gauge Installation

1. Remove the shoulder fitting cap. 2. Install fuel gauge J 34730-1 to the fuel feed line located in front of and above the right side valve train cover. 3. Reinstall the fuel pump relay.

Fuel System Diagnosis

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Turn the ignition OFF. 2. Turn the air conditioning system OFF. 3. Relieve fuel system pressure and install the fuel pressure gauge. 4. Turn the ignition ON. NOTE: The fuel pump will run for approximately 2 seconds. Use the Tech 2 to command the fuel pump ON. (Refer to the Miscellaneous Test.) 5. Observe the fuel pressure indicated by the fuel pressure gauge with the fuel pump running. Is the fuel pressure within the specified limits? 290-376 kPa (42-55 psi)

Go to OBD System Check

Go to Step 3

Go to Step 17

NOTE: The fuel pressure will drop when the fuel pump stops running, then it should stabilize and remain constant. Does the fuel pressure indicated by the fuel pressure gauge remain constant? Go to Step 4 Go to Step 12

1. When the vehicle is at normal operation temperature, turn the ignition ON to build fuel pressure and observe the measurement on the gauge. 2. Start the engine and observe the fuel pressure gauge. Did the reading drop by the amount specified after the engine was started? 21-105 kPa (3-15 psi) Go to Step 5 Go to Step 6 Go to Step 9 Check for improper fuel

5 6

Is fuel pressure dropping off during acceleration, cruise, or hard cornering? Visually and physically inspect the following items for a restriction: D The in-pipe fuel filter. D The fuel feed line. Was a restriction found?

Verify repair

Go to Step 7

Remove the fuel tank and visually and physically inspect the following items: D The fuel pump strainer for a restriction. D The fuel line for a leak. D Verify that the correct fuel pump is in the vehicle. Was a problem found in any of these areas? Verify repair Go to Step 8

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E115

Fuel System Diagnosis (Cont'd)

Step Action Value(s) Yes No

8 9

Replace the fuel pump. Is the action complete? 1. Disconnect the vacuum hose from the fuel pressure regulator. 2. With the engine idling, apply 12-14 inches of vacuum to the fuel pressure regulator. Does the fuel pressure indicated by the fuel pressure gauge drop by the amount specified? 21-105 kPa (3-15 psi) Go to Step 10 Go to Step 11 Verify repair

10

Locate and repair the loss of vacuum to the fuel pressure regulator. Is the action complete? Verify repair Verify repair Replace the fuel pressure regulator. Is the action complete? 1. Run the fuel pump with the Tech 2. 2. After pressure has built up, turn off the pump and clamp the supply hose shut with suitable locking pliers which will not damage the hose. Does the fuel pressure indicated by the fuel pressure gauge remain constant? Go to Step 13 Go to Step 15

11 12

13

Visually inspect the fuel supply line and repair any leaks. Was a problem found? Verify repair Go to Step 14 Remove the fuel tank and inspect for leaky hose or in-tank fuel line. Was a problem found? Verify repair Go to Step 8 1. If the pliers are still clamped to the fuel supply hose, remove the locking pliers. 2. With suitable locking pliers, which will not damage the hose, clamp the fuel return line to prevent fuel from returning to the fuel tank. 3. Run the fuel pump with the Tech 2. 4. After pressure has built up, remove power to the pump. Does the fuel pressure indicated by the fuel pressure gauge remain constant? 376 kPa (55 psi) Go to Step 11 Verify repair Go to Step 18 Go to Step 16 Go to Step 21

14

15

16 17

Locate and replace any leaking fuel injector(s). Is the action complete? Is the fuel pressure indicated by the fuel pressure gauge above the specified limit?

6E116

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Fuel System Diagnosis (Cont'd)

Step Action Value(s) Yes No

18

1. Relieve the fuel pressure. Refer to the Fuel Pressure Relief. 2. Disconnect the fuel return line from the fuel rail. 3. Attach a length of flexible hose to the fuel rail return outlet passage. 4. Place the open end of the flexible hose into an approved gasoline container. 5. Run the fuel pump with the Tech 2. 6. Observe the fuel pressure indicated by the fuel pressure gauge with the fuel pump running. Is the fuel pressure within the specified limits? Locate and correct the restriction in the fuel return line. Is the action complete?

290-376 kPa (42-55 psi)

Go to Step 19 Verify repair

Go to Step 20

19 20

Visually and physically inspect the fuel rail outlet passages for a restriction. Was a restriction found? 0 kPa (0 psi) Verify repair Go to Step 22 Go to Step 11 Go to Step 23 Is the fuel pressure indicated by the fuel pressure gauge above the specified value? 1. Command the fuel pump ON with the Tech 2. 2. Using suitable pliers which will not damage the fuel hose, gradually apply pressure with the pliers to pinch the flexible fuel return hose closed. CAUTION: Do not let the fuel pressure exceed the second specified value. Does the fuel pressure indicated by the fuel pressure gauge rise above the first specified value? 376 kPa (55 psi) 414 kPa (60 psi)

21 22

Go to Step 11

Go to Step 7

23

1. Command the fuel pump ON with the Tech 2. 2. Remove the fuel filler cap and listen for the sound of the fuel pump running. 3. Turn the pump off. Was the fuel pump running? Go to Step 7

Go to Fuel System Electrical Test Chart

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E117

Exhaust Gas Recirculation (EGR) System Check

D06R200087

Circuit Description
A properly operation exhaust gas recirculation (EGR) system will directly affect the air/fuel requirements of the engine. Since the exhaust gas introduced into the air/fuel mixture is an inert gas (contains very little or no oxygen), less fuel is required to maintain a correct air/fuel ratio. Introducing exhaust gas into the combustion chamber lowers combustion temperatures and reduces the formation of oxides of nitrogen (NOx) in the exhaust gas. Lower combustion temperatures also prevent detonation. If the EGR pintle were to stay closed, the inert exhaust gas would be replaced with air and the air/fuel mixture would be leaner. The powertrain control module (PCM) would compensate for the lean condition by adding fuel, resulting in higher long term fuel trim values.

Diagnostic Aids
The EGR valve chart is a check of the EGR system. An EGR pintle constantly in the closed position could cause detonation and high emissions of NOx. It could also result in high long term fuel trim values in the open throttle cell, but not in the closed throttle cell. An EGR pintle constantly in the open position would cause a rough idle. Also, an EGR mounted incorrectly (rotated 180) could cause rough idle. Check for the following items: D EGR passages Check for restricted or blocked EGR passages. D Manifold absolute pressure sensor A manifold absolute pressure sensor may shift in calibration enough to affect fuel delivery. Refer to Manifold Absolute Pressure Output Check.

6E118

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Exhaust Gas Recirculation (EGR) System Check

Step Action Value(s) Yes No

1 2 3

Check the EGR valve for looseness. Is the EGR valve Loose? Tighten the EGR valve. Is the action complete? 1. Place the transmission selector in Park or Neutral. 2. Start the engine and idle until warm. 3. Using a Tech 2, command EGR 50% ON. (Refer to the Miscellaneous Test.) Does the engine idle rough and lose RPMs? 1. Engine OFF. 2. Ignition ON. 3. Using a test light to ground, check the EGR harness between the EGR valve and the ignition feed. Does the test light illuminate? Go to Step 6 Verify repair Go to Step 5 Go to Step 6 Repair the EGR harness ignition feed. Was the problem corrected? 1. Remove the EGR valve. 2. Visually and physically inspect the EGR valve pintle, valve passages and adapter for excessive deposits, obstructions or any restrictions. Does the EGR valve have excessive deposits, obstructions or any restrictions? Go to Step 7 Go to Step 8 Verify repair EGR system working properly. No problem found. Go to Step 2 Go to Step 3

Go to Step 4

5 6

Clean or replace EGR system components as necessary. Was the problem corrected? Verify repair Go to Step 8 1. Ground the EGR valve metal case to battery (). 2. Using a Tech 2, command EGR ON and observe the EGR valve pintle for movement. Does the EGR valve pintle move according to command? Go to Step 9 Go to DTC P1406 chart

1. Remove the EGR inlet and outlet pipes from the intake and exhaust manifolds. 2. Visually and physically inspect manifold EGR ports and EGR inlet and outlet pipes for blockage or restriction caused by excessive deposits or other damage. Do the manifold EGR ports or inlet and outlet pipes have excessive deposits, obstructions, or any restrictions?

Go to Step 10

EGR system working properly. No problem found.

10

Clean or replace EGR system components as necessary. Is the action complete? Verify repair

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E119

Manifold Absolute Pressure (MAP) Output Check

D06R200048

Circuit Description
The manifold absolute pressure (MAP) sensor measures the changes in the intake MAP which result from engine load (intake manifold vacuum) and engine speed changes; and converts these into a voltage output. The powertrain control module (PCM) sends a 5-volt reference voltage to the MAP sensor. As the MAP changes, the output voltage of the sensor also changes. By monitoring the sensor output voltage, the PCM knows the MAP. A lower pressure (low voltage) output voltage will be about 1-2 volts at idle. Higher pressure (high voltage) output voltage will be about 4-4.8 volts at wide open throttle. The MAP sensor is also used, under certain conditions, to measure barometric pressure, allowing the PCM to make adjustments for different altitudes. The PCM uses the MAP sensor to diagnose proper operation of the EGR system, in addition to other functions.

Test Description
IMPORTANT: Be sure to used the same diagnostic test equipment for all measurements. The number(s) below refer to the step number(s) on the Diagnostic Chart. 2. Applying 34 kPa (10 inch Hg) vacuum to the MAP sensor should cause the voltage to be 1.5-2.1 volts less than the voltage at step 1. Upon applying vacuum to the sensor, the change in voltage should be instantaneous. A slow voltage change indicates a faulty sensor. 3. Check the vacuum hose to the sensor for leaking or restriction, Be sure that no other vacuum devices are connected to the MAP hose. IMPORTANT: Make sure the electrical connector remains securely fastened. 4. Disconnect the sensor from the bracket. Twist the sensor with your hand to check for an intermittent connection. Output changes greater than 0.10 volt indicate a bad sensor.

6E120

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Manifold Absolute Pressure (MAP) Output Check

Step Action Value(s) Yes No

1. Turn the ignition OFF and leave it OFF for 15 seconds. 2. Ignition ON. Dont crank engine. 3. The Tech 2 should indicate a manifold absolute pressure (MAP) sensor voltage. 4. Compare this scan reading to scan reading of a known good vehicle obtained using the exact same procedure as in Steps 1-4. Is the voltage reading the same +/0.40 volt? Go to Step 2 Go to Step 5 1. Disconnect the vacuum hose at the MAP sensor and plug the hose. 2. Connect a hand vacuum pump to the MAP sensor. 3. Start the engine. 4. Apply 34 kPa (10 in.Hg) of vacuum and note the voltage change. Is the voltage change 1.5-2.1 volts less than Step 1? Go to Step 3 Go to Step 5 Verify repair Go to Step 6 Verify repair Verify repair Go to Step 4 Go to Step 4 Go to Step 7 Check the sensor cover for leakage or restriction. Does the hose supply vacuum to the MAP sensor only? Repair the hose blockage. Is the action complete? Check the sensor connection. Is the sensor connection good? Refer to On-Vehicle Service, MAP Sensor. Is the action complete? Repair the poor connection. Is the action complete?

3 4 5 6 7

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E121

Evaporative (EVAP) Emissions Canister Purge Valve Check

D06R200084

Circuit Description
Canister purge is controlled by a solenoid valve that allows manifold vacuum to purge the canister. The powertrain control module (PCM) supplies a ground to energize the solenoid valve (purge ON). The EVAP purge solenoid control is turned ON and OFF several times a second. The duty cycle (pulse width or ON time) is determined by engine operating conditions including load, throttle position, coolant temperature and ambient temperature. The duty cycle is calculated by the PCM and the purge solenoid is enabled when the appropriate conditions have been met: D The engine run time after start is more than 60 seconds. D The engine coolant temperature is above 30C (86F). D The fuel control system is operating in the closed-loop mode.

Diagnostic Aids
D Make a visual check of vacuum hoses. D Check the throttle body for cracks. D Check the malfunction indicator lamp for a possible mechanical problem.

Test Description
The number(s) below refer to the step number(s) on the Diagnostic Chart. 1. Check to see if the solenoid is open or closed. The solenoid is normally de-energized in this step, so it should be closed. 2. This step checks to determine if the solenoid was open due to an electrical circuit problem or a defective solenoid. 3. This should normally energize the solenoid, opening the valve and allowing the vacuum to drop (purge ON).

6E122

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Evaporative (EVAP) Emissions Canister Purge Valve Check

Step Action Value(s) Yes No

1. Ignition OFF. 2. Ignition ON, engine OFF. 3. At the throttle body, disconnect the hose that goes to the purge solenoid. 4. Using a hand vacuum pump with an attached vacuum gauge J 23738-A, apply vacuum (10 in. Hg or 34 kPa) to the solenoid. Does the solenoid hold the vacuum? Go to Step 3 Go to Step 2 1. Disconnect the solenoid electrical connector. 2. As in Step 1, apply vacuum (10 in. Hg or 34 kPa) to the solenoid. Does the solenoid hold the vacuum? Go to Step 4 Go to Step 7 1. At the throttle body, put a cap over the vacuum port where the hose was disconnected for testing. This is to prevent a vacuum leak when the engine is started. 2. Ignition OFF. 3. Install the Tech 2. 4. Apply vacuum to the purge solenoid with the hand vacuum pump. 5. Start the engine, run at 2500 RPM. 6. Using the Tech 2, select Powertrain, 3.5V6 6VE1, F3: Misc. Tests, F2: EVAP Purge, F0: EVAP Purge. (Refer to the Misellaneous Test.) 7. Turn the purge solenoid ON. Did the vacuum drop when the purge was turned on? Go to Step 8 Go to Step 5 Verify repair Go to Step 9 Go to Step 6

4 5 6

Check for a short to ground in the S7 Pin wire. Is there a short? Repair the short to ground. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Servicein Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

Replace the faulty purge solenoid. Refer to On-Vehicle Service, EVAP Canister Purge Solenoid. Is the action complete? Verify repair

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E123

Evaporative (EVAP) Emissions Canister Purge Valve Check (Cont'd)

Step Action Value(s) Yes No

1. Turn the ignition OFF. 2. At the throttle body, install a vacuum gauge where the hose from the purge solenoid was disconnected for testing. 3. Start the engine. 4. Stabilize the engine speed at about 2500 RPM. 5. Momentarily snap the throttle open and let it return to idle. Is there approximately 10 in. Hg (34 kPa) of vacuum available at the EVAP emission canister purge solenoid?

No problem found in the EVAP emission canister purge valve check

Check the Procedure Refer to Diagnostic Aids

1. Disconnect the solenoid electrical connector. 2. Connect a test lamp between the harness terminals. Does the test lamp light? Go to Step 7 Go to Step 10 Probe terminal A and terminal B with a test lamp to ground. Does the test lamp light on both terminals? Go to Step 11 Verify repair Go to Step 13 Go to Step 12 Go to Step 14 Repair the short to voltage in the S7 Pin wire. Is the action complete? Does one of the terminals light the test lamp? Check for an open in the S7 Pin wire between the purge solenoid and the PCM. Was there an open circuit? Go to Step 15 Verify repair Verify repair Go to Step 6 Repair the open in the BLK/YEL wire. Is the action complete? Repair the open in the S7 Pin wire. Is the action complete?

10

11 12 13

14 15

6E124

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

PCM Diagnostic Trouble Codes

The following table lists the diagnostic trouble codes supported by this vehicle application. If any DTCs not listed here are displayed by a Tech 2, the Tech 2 data may be faulty; notify the Tech 2 manufacturer of any DTCs displayed that are not included in the following table. PCM Diagnostic Trouble Codes DTC Description Type Illuminate MIL (Check Engine Lamp) Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Illuminate RPL (Reduced Power Lamp) No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No

P0101 P0102 P0103 P0106 P0107 P0108 P0112 P0113 P0117 P0118 P0125 P0131 P0132 P0133 P0134 P0135 P0137 P0138 P0140 P0141 P0151 P0152 P0153 P0154 P0155 P0157 P0158 P0160 P0161 P0171 P0172 P0174 P0175 P0201

MAF System Performance MAF Sensor Circuit Low Frequency MAF Sensor Circuit High Frequency MAP Rationality/Performance MAP Circuit Low Input Voltage MAP Circuit High Input Voltage IAT Circuit Low Input Voltage IAT Circuit High Input Voltage ECT Circuit Low Input Voltage ECT Circuit High Input Voltage ECT Insufficient for Closed Loop Fuel Control O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1) O2 Sensor Circuit High Voltage (Bank 1 Sensor 1) O2 Sensor Circuit Slow Response (Bank 1 Sensor 1) O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1) O2 Sensor Heater Circuit (Bank 1 Sensor 1) O2 Sensor Circuit Low Voltage (Bank 1 Sensor 2) O2 Sensor Circuit High Voltage (Bank 1 Sensor 2) O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 2) O2 Sensor Heater Circuit (Bank 1 Sensor 2) O2 Sensor Circuit Low Voltage (Bank 2 Sensor 1) O2 Sensor Circuit High Voltage (Bank 2 Sensor 1) O2 Sensor Circuit Slow Response (Bank 2 Sensor 1) O2 Sensor Circuit No Activity Detected (Bank 2 Sensor 1) O2 Sensor Heater Circuit (Bank 2 Sensor 1) O2 Sensor Circuit Low Voltage (Bank 2 Sensor 2) O2 Sensor Circuit High Voltage (Bank 2 Sensor 2) O2 Sensor Circuit No Activity Detected (Bank 2 Sensor 2) O2 Sensor Heater Circuit (Bank 2 Sensor 2) O2 Sensor System too Lean (Bank 1) O2 Sensor System too Rich (Bank 1) O2 Sensor System too Lean (Bank 2) O2 Sensor System too Rich (Bank 2) Injector 1 Control Circuit

B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B B A

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC Description Type Illuminate MIL (Check Engine Lamp) Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes No No Yes No No Yes Yes Yes No Yes Yes No Yes Yes Yes No

6E125
Illuminate RPL (Reduced Power Lamp) No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No

P0202 P0203 P0204 P0205 P0206 P0300 P0325 P0336 P0337 P0351 P0352 P0353 P0354 P0355 P0356 P0401 P0402 P0404 P0405 P0406 P0420 P0430 P0440 P0442 P0444 P0445 P0446 P0447 P0448 P0452 P0453 P0456 P0461 P0462 P0463 P0464 P0502 P0506 P0507 P0562

Injector 2 Control Circuit Injector 3 Control Circuit Injector 4 Control Circuit Injector 5 Control Circuit Injector 6 Control Circuit Engine Misfire Detected ION Sensing Module CKP Sensor Circuit Range/Performance (58X) CKP Sensor Circuit No signal (58X) Ignition 1 Control Circuit Ignition 2 Control Circuit Ignition 3 Control Circuit Ignition 4 Control Circuit Ignition 5 Control Circuit Ignition 6 Control Circuit EGR Flow Insufficient EGR Flow Excessive EGR Range/Performance (Open Valve) EGR Sensor Circuit Low Voltage EGR Sensor Circuit High Voltage Catalyst System Low Efficiency (Bank 1) Catalyst System Low Efficiency (Bank 2) EVAP Control System EVAP Control System Small Leak Detected EVAP Purge Control Circuit Open EVAP Purge Control Circuit Short EVAP Canister Vent Control Malfunction EVAP Vent Solenoid Circuit Open EVAP Vent Solenoid Circuit Short EVAP Control System Tank Pressure Sensor Low Input EVAP Control System Tank Pressure Sensor High Input EVAP Control System Very Small Leak Detected Fuel Level Sensor Circuit Range/Performance Fuel Level Sensor Circuit Low Input Voltage Fuel Level Sensor Circuit High Input Voltage Fuel Level Sensor Noisy Signal No VSS Signal Idle Speed Control RPM too Low Idle Speed Control RPM too High System Voltage is Low

A A A A A B B B B A A A A A A B B B B B A A B B D D B D D B B B D B B D B B B D

6E126
DTC

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Description Type Illuminate MIL (Check Engine Lamp) Yes No No No No No Yes No No No No No No No No No No No Yes Yes Yes Yes Yes Yes No No No Yes No No No No Yes Yes Yes Yes Yes Yes Yes Illuminate RPL (Reduced Power Lamp) No No No No No No No No No No No No No No No No No No No Yes No No No No No No No No No No No No No No No Yes Yes Yes No

P0563 P0565 P0566 P0567 P0568 P0571 P0601 P0602 P0604 P0606 P0660 P0662 P1106 P1107 P1111 P1112 P1114 P1115 P1120 P1125 P1133 P1134 P1153 P1154 P1167 P1169 P1171 P1220 P1221 P1271 P1272 P1273 P1275 P1280 P1285 P1290 P1295 P1299 P1310

System Voltage is High Cruise Main Switch Circuit Error Cruise Cancel Switch Circuit Error Cruise Resume Switch Circuit Error Cruise Set Switch Circuit Error No Brake Switch Signal PCM/ECM Memory Checksum PCM/ECM Programming error PCM/ECM RAM error PCM/ECM Internal Performance VIM Solenoid Circuit Open VIM Solenoid Circuit Short MAP Circuit Intermittent High Voltage) MAP Circuit Intermittent Low Input Voltage IAT Circuit Intermittent High Voltage IAT Circuit Intermittent Low Input Voltage ECT Circuit Intermittent Low Voltage ECT Circuit Intermittent High Voltage TPS1 Circuit ETC Limit Performance Mode O2 Sensor Too Few Rich/Lean and Lean/Rich Switches (Bank 1 Sensor 1) O2 Sensor Transition Switch Time ratio (Bank 1 Sensor 1) O2 Sensor Too Few Rich/Lean and Lean/Rich Switches (Bank 2 Sensor 1) O2 Sensor Transition Switch Time ratio (Bank 2 Sensor 1) Fuel supply System RICH During Decel Fuel Cut Off (Bank 1) Fuel supply System RICH During Decel Fuel Cut Off (Bank 2) Fuel supply System Lean During Power Enrichment TPS2 Circuit TPS1TPS2 Correlation (Circuit Performance) APS1APS2 Correlation (Circuit Performance) APS2APS3 Correlation (Circuit Performance) APS1APS3 Correlation (Circuit Performance) APS1 Circuit APS2 Circuit APS3 Circuit ETC Forced Idle Mode ETC Power Management Mode ETC Forced Engine Shutdown in Mode ION Sensing Module Diagnostic

B D D D D D A D D D D D D D D D D D B A B B B B D D D B D D D D B B B A A A A

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC Description Type Illuminate MIL (Check Engine Lamp) Yes Yes Yes Yes Yes Yes Yes Yes Yes No No No No No No No

6E127
Illuminate RPL (Reduced Power Lamp) No No No No No No No No No No No No No No No No

P1311 P1312 P1326 P1340 P1404 P1441 P1514 P1515 P1516 P1523 P1574 P1635 P1636 P1639 P1640 P1650

ION Sensing Module SEC 1 Line Circuit Fault ION Sensing Module SEC 2 Line Circuit Fault ION Sensing Module Combustion Quality circuit ION Sensing Module Cylinder Synchronization EGR Range/Performance (Closed Valve) EVAP Control System Continuous Open Purge Flow TPSMAF Correlation CommandAcrual TPS Correlation CommandAcrual TPS Correlation Error Throttle Actuator Control Return Performance Brake Switch No Operation Reference Voltage #1 Circuit PCM RAM Stack Reference Voltage #2 Circuit ODM Output circuit Fault QDM Output Circuit Fault

A A A B B B A A A D D D D D D D

6E128

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0101 MAF System Performance

D06R200047

Circuit Description
The mass air flow (MAF) sensor measures the amount of air which passes through it into the engine during a given time. The powertrain control module (PCM) uses the mass air flow information to monitor engine operating conditions for fuel delivery calculations. A large quantity of air entering the engine indicates an acceleration or high load situation, while a small quantity or air indicates deceleration or idle. The MAF sensor produces a frequency signal which can be monitored using a Tech 2. The frequency will vary within a range of around 3 to 7g/s at idle. DTC P0101 will be set if the signal from the MAF sensor does not match a predicted value based on throttle position and engine RPM.

D The PCM will store condition which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0101 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault. D DTC P0101 can be cleared using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Diagnostic Aids
An intermittent may be caused by the following: D Poor connections. D Misrouted harness. D Rubbed through wire insulation. D Broken wire inside the insulation. D The duct work at the MAF sensor for leaks. D An engine vacuum leak. D The PCV system for vacuum leaks. D An incorrect PCV valve. D The engine oil dip stick not fully seated. D The engine oil fill cap loose or missing. Check for the following conditions: D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken

Conditions for setting the DTC

D D D D The engine is running. No TP sensor and MAP sensor DTCs are set. No MAF frequency DTCs are set. System voltage is between 11.5 volts and 16 volts.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected fault. D The PCM calculates an air flow value based on idle air control valve position, throttle position, RPM and barometric pressure.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harness- Inspect the wiring harness for damage. If the harness appears to be OK, observe the Mass Air Flow (MAF) display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. D Plugged intake air duct or filter element D A wideopen throttle acceleration from a stop should cause the mass air flow displayed on a Tech 2 to increase from about 36 g/s at idle to 100 g/s or greater at the time of the 12 shift. If not, check for a restriction.

6E129

A change in the display will indicate the location of the fault. If DTC P0101 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P001 Diagnostic Chart may isolate the cause of the fault.

DTC P0101 MAF System Performance

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition OFF. 2. Disconnect the Mass Air Flow (MAF) Sensor harness connector from the MAF Sensor. 3. Place an unpowered test lamp between the 12 volt signal circuit and the ground circuit, both at the MAF Sensor connector. 4. Ignition ON, EngineOFF. Did the test lamp illuminate? Go to Step 6

Go to OBD System Check

Go to Step 3

1. Ignition ON, Engine OFF. 2. Using a Digital Voltmeter (DVM), check the 12 volt signal circuit for the correct voltage. Did the DVM indicate a value within the following range? 11.5 to 12.5 Volt Go to Step 5 Go to Step 4

1. Ignition OFF. 2. Check the 12 volt signal circuit for the following conditions: D An open circuit D A short to ground Was the problem found? Verify repair Check the MAF ground circuit for the following conditions: D An open circuit D A short to voltage Was a problem found? Verify repair 1. Ignition OFF. 2. Check the MAF Sensor signal circuit between the PCM and the MAF Sensor for the following conditions: D An open circuit D A short to ground D A short to battery voltage Was a problem found? Verify repair Go to Step 7

6E130

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0101 MAF System Performance (Cont'd)

Step Action Value(s) Yes No

1. Connect the MAF Sensor wiring harness connector to the MAF Sensor. 2. Connect the Tech 2 to the vehicle. 3. Place the Transmission in Park/Neutral, and fully apply the Parking Brake. 4. Start the engine. 5. Select the Mass Air Flow (MAF) parameter on the Tech 2. With the engine idling, does the Tech 2 display the following value(s)? 3 to 7 g/s Go to Step 8 Go to Step 9

1. 2. 3. 4.

Ignition OFF. Disconnect the MAF sensor connector. Ignition ON, engine idling. Using a Tech 2, monitor MAF Frequency. 0 g/s Go to Step 10 Verify repair Go to Step 9

Does the Tech 2 indication a MAF Frequency at the specified value? 9 10 Replace the MAF Sensor. Is the action complete? Replace the PCM. IMPORTANT: The PCM must be reprogrammed. Refer to PCM reprogramming. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?

Verify repair

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E131

Diagnostic Trouble Code (DTC) P0102 MAF Sensor Circuit Low Frequency

D06R200047

Circuit Description
The mass air flow (MAF) sensor measures the amount of air which passes through it into the engine during a given time. The powertrain control module (PCM) uses the mass air flow information to monitor engine operating conditions for fuel delivery calculations. A large quantity of air entering the engine indicates an acceleration or high load situation, while a small quantity of air indicates deceleration or idle. The MAF sensor produces a frequency signal which can be monitored using a Tech 2. The frequency will vary within a range of around 3 to 7g/s at idle. DTC P0102 will be set if the signal from the MAF sensor is below the possible range of a normally operating MAF sensor.

D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0102 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0102 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Misrouted harness Inspect the MAF sensor harness to ensure that it is not routed too close to high voltage wires. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the Tech 2 while moving connectors and wiring harnesses related to the MAF sensor. A change in the display will indicate the location of the fault. D Plugged intake air duct or filter element A wide-open throttle acceleration from a stop should cause the

Conditions for Setting the DTC

D The engine is running above 500 RPM for more than 10 seconds. D System voltage is above 11.5 volts. D MAF signal frequency is below 1.6g/s for a total of 50-percent of the last 1000 samples monitored. A sample is taken every cylinder event.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected fault. D The PCM calculates an air flow value based on idle air control valve position, throttle position, RPM and barometric pressure.

6E132

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

2. This step verifies that the problem is present at idle. 4. A voltage reading of less than 4 or over 5 volts at the MAF sensor signal circuit indicates a fault in the wiring or a poor connection. 5. This verifies that ignition feed voltage and a good ground are available at the MAF sensor.

mass air flow displayed on a Tech 2 to increase from about 3-6 g/second at idle to 100 g/second or greater at the time of the 1-2 shift. If not, check for a restriction. If DTC P0102 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart.

DTC P0102 MAF Sensor Circuit Low Frequency

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Start the engine. 2. With the engine idling, monitor MAF Frequency display on the Tech 2. Is the MAF Frequency below the specified value? 3-7 g/s Go to Step 3

Go to OBD System Check

Go to Step 5

1. Ignition ON, engine OFF. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Records conditions as noted. 4. Using a Tech 2, monitor DTC info for DTC P0102. Does the Tech 2 indicate DTC P0102 failed this ignition? Go to Step 4

Check the Procedure Refer to Diagnostic Aids

1. 2. 3. 4.

Ignition OFF. Disconnect the MAF sensor connector. Ignition ON, engine OFF. Using a DVM, measure voltage between the MAF sensor signal circuit and battery ground. 11.512 V Go to Step 5 Go to Step 8

Is the voltage near the specified value? 5 Connect a test light between the MAF sensor ignition feed and ground circuits at the MAF sensor harness connector. Is the test light ON? 6 Connect a test light between the MAF sensor ignition feed circuit and battery ground. Is the test light ON? 7 1. Check for a poor connection at the MAF sensor. 2. If a poor connection is found, replace the faulty terminal(s). Was a poor connection found? 8 1. Ignition OFF. 2. Disconnect the MAF sensor. 3. Disconnect the PCM connector for the MAF signal circuit. 4. Ignition ON, engine OFF. 5. With the DVM, measure the voltage between the MAF signal terminal at the PCM and battery ground. Is the voltage under the specified value?

Go to Step 7

Go to Step 6

Go to Step 11

Go to Step 7

Verify repair

Go to Step 12

0V

Go to Step 9

Go to Step 10

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E133

DTC P0102 MAF Sensor Circuit Low Frequency (Cont'd)

Step Action Value(s) Yes No

1. 2. 3. 4.

Ignition OFF. Disconnect the PCM connector. Ignition ON. Check the MAF sensor signal circuit for a short to 5 volts. Verify repair Ignition OFF. Disconnect the PCM connector. Ignition ON. Check the MAF sensor signal circuit between the PCM and the MAF sensor for an open, short to ground, or short to the MAF ground circuit. Verify repair Go to Step 13

Is the action complete? 10 1. 2. 3. 4.

Is the action complete? 11 Locate and repair the open in the ground circuit to the MAF sensor. Is the action complete? 12 Locate and repair the open in the ignition feed circuit to the MAF sensor. Is the action complete? 13 14 Replace the MAF sensor. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?

Verify repair

Verify repair Verify repair

Go to Step 14

Verify repair

6E134

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0103 MAF Sensor Circuit High Frequency

D06R200047

Circuit Description
The mass air flow (MAF) sensor measures the amount of air which passes through it into the engine during a given time. The powertrain control module (PCM) uses the mass air flow information to monitor engine operating conditions for fuel delivery calculations. A large quantity of air entering the engine indicates an acceleration or high load situation, while a small quantity of air indicates deceleration or idle. The MAF sensor produces a frequency signal which can be monitored using a Tech 2. The frequency will vary within a range of around 3 to 7g/s at idle. DTC P0103 will be set if the signal from the MAF sensor is above the possible range of a normally operating MAF sensor.

D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0103 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0103 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Diagnostic Aids
If DTC P0103 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set.

Conditions for Setting the DTC

D The engine is running above 500 RPM for more than 10 seconds. D System voltage is above 11.5 volts. D MAF signal frequency is above 40g/s for a total of 50 percent of the last 200 samples monitored. A sample is taken every cylinder event.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. This step verifies that the problem is present at idle. 4. A frequency reading with the MAF sensor connector disconnected indicates an electromagnetic interference (EMI) related fault.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected the fault. D The PCM calculates an airflow value based on idle air control valve position, throttle position, RPM and barometric pressure.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E135

DTC P0103 MAF Sensor Circuit High Frequency

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition ON, engine OFF. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Records conditions as noted. 4. Using a Tech 2, monitor DTC info for DTC P0103. Does the Tech 2 indicate DTC P0103 failed this ignition? Go to Step 3

Go to OBD System Check

Check the Procedure Refer to Diagnostic Aids

1. Start the engine. 2. With the engine idling, monitor MAF Frequency display on the Tech 2. Is MAF Frequency above the specified value? 37g/s Go to Step 4 Go to Step 7 1. 2. 3. 4. Ignition OFF. Disconnect the MAF sensor connector. Ignition ON, engine idling. Using a Tech 2, monitor MAF Frequency. 0g/s Go to Step 5 Verify repair Go to Step 6 Go to Step 7

Does the Tech 2 indicate a MAF Frequency at the specified value? 5 6 Replace the MAF sensor. Is the action complete? 1. Check the MAF harness for incorrect routing near high voltage components (solenoids, relays, motors). 2. If incorrect routing is found, correct the harness routing. Was a problem found? 7 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?

Verify repair

Go to Step 7

Verify repair

6E136

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0106 MAP System Performance

D06R200048

Circuit Description
The manifold absolute pressure (MAP) sensor responds to changes in intake manifold pressure (vacuum). The MAP sensor signal voltage to the powertrain control module (PCM) varies from below 2 volts at idle (high vacuum) to above 4 volts at wide-open throttle (low vacuum) at sea level. The MAP sensor is used to determine manifold pressure changes while the linear exhaust gas recirculation (EGR) flow test diagnostic is being run (refer to DTC P0401), engine vacuum level for some other diagnostics, and barometric pressure (BARO). The PCM compares the MAP sensor signal to a calculated MAP based on throttle position and various engine load factors. If the PCM detects a MAP signal that varies excessively above or below the calculated value, DTC P0106 will set.

D The MAP value must vary for a total of 10 seconds over a 20-second period of time that the samples were monitored. D The failure must occur for 2 consecutive trips.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator lamp (MIL) after the second consecutive trip in which the fault is detected. D The PCM will default to a BARO value of 79.3 kPa. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0106 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0106 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D D D D D D D D No TP sensor DTCs are present. Engine speed is steady, changing less then 100 RPM. Engine speed is between 1000 rpm and 4000 rpm. Throttle position is steady, throttle angle changes less than 1%. EGR flow rate is steady, changing less than 4%. No change in brake switch, A/C clutch, TCC or power steering pressure switch status. Above conditions are met for longer than 1 second. Actual MAP value varies more than 10 kPa.

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the MAP display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0106 cannot be duplicated, the information included in the Failure Records data can be useful in

6E137

determining vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P1107 Diagnostic Chart may isolate the cause of the fault.

DTC P0106 MAP System Performance

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition ON, engine OFF. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Records conditions as noted. 4. Using a Tech 2, monitor DTC info for DTC P0106. Does the Tech 2 indicate DTC P0106 failed? Go to Step 4

Go to OBD System Check

Go to Step 3

1. Check for the following conditions: D Vacuum hoses disconnected, damaged, or incorrectly routed D Intake manifold vacuum leaks D Vacuum leaks at throttle body D Vacuum leaks at EGR valve flange and pipes D Crankcase ventilation valve faulty, missing or incorrectly installed. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair 1. Disconnect the MAP sensor electrical connector. 2. Observe the MAP value displayed on the Tech 2. Is the MAP value near the specified value? 11 kPa Go to Step 5

Check the Procedure Refer to Diagnostic Aids

Go to Step 13

1. Connect a test light between B+ and the MAP sensor signal circuit at the MAP sensor harness connector. 2. Observe the MAP value displayed on the Tech 2. Is the MAP value near the specified value? 100 kPa Go to Step 6 Go to Step 9 1. Jumper the 5 volt reference circuit and the MAP signal circuit together at the MAP sensor harness connector. 2. Observe the MAP value displayed on the Tech 2. Is the MAP value near the specified value? 100 kPa Go to Step 7 Go to Step 8 1. Ignition OFF. 2. Disconnect the PCM and check the sensor ground circuit for high resistance, an open between the PCM and the MAP sensor, or for a poor connection at the PCM. 3. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 11

6E138

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0106 MAP System Performance (Cont'd)

Step Action Value(s) Yes No

1. Check the 5 volt reference circuit for high resistance, an open between the PCM and the MAP sensor, or a poor connection at the PCM. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 10 1. Ignition OFF. 2. Disconnect the PCM, and check the MAP sensor signal circuit for high resistance, an open, a short to ground, or a short to the sensor ground circuit. 3. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 10 1. Check the MAP sensor signal circuit for a poor connection at the PCM. 2. If a problem is found, repair as necessary. Did the terminal require replacement? Verify repair Go to Step 14 1. Check for a poor connection at the MAP sensor. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Verify repair Go to Step 12 Replace the MAP sensor. Is the action complete? 1. Ignition OFF, disconnected the PCM. 2. Ignition ON, check the MAP signal circuit for a short to voltage or a short to the 5 volt reference circuit. 3. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 14 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

10

11

12 13

14

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E139

Diagnostic Trouble Code (DTC) P0107 MAP Sensor Circuit Low Voltage

D06R200048

Circuit Description
The manifold absolute pressure (MAP) sensor responds to changes in intake manifold pressure (vacuum). The MAP sensor signal voltage to the powertrain control module (PCM) varies from below 2 volts at idle (high vacuum) to above 4 volts with the ignition ON, engine not running or at wide-open throttle (low vacuum). The MAP sensor is used to determine manifold pressure changes while the exhaust gas recirculation (EGR) flow test diagnostic is being run (refer to DTC P0401), to determine engine vacuum level for some other diagnostics and to determine barometric pressure (BARO). The PCM monitors the MAP signals for voltages outside the normal range of the MAP sensor. If the PCM detects a MAP signal voltage that is excessively low, DTC P0107 will be set.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected fault. D The PCM will default to a BARO value of 79.3 kPa. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0107 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0107 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D No TP sensor DTCs present. D Engine is running. D Throttle angle is above 1% if engine speed is less than 1000 RPM. D Throttle angle is above 2% if engine speed is above 1000 RPM. D The MAP sensor indicates manifold absolute pressure at or below 11 kPa for a total of approximately 10 seconds over a 16-second period. D Ignition voltage more than 11 volts.

Diagnostic Aids
Check for the following conditions: D Check for intermittent codes. D The MAP sensor shares a 5 Volt reference with the EGR Sensor. If these codes are also set, it could indicate a problem with the 5 Volt reference circuit . D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the

6E140

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

determining vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P0107 Diagnostic Chart may isolate the cause of the fault.

MAP display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0107 cannot be duplicated, the information included in the Failure Records data can be useful in

DTC P0107 MAP Sensor Circuit Low Voltage

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition ON, engine OFF. 2. With the throttle closed, observe the MAP value displayed on the Tech 2. Is the MAP value near the specified value? 1. Ignition ON, engine OFF. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Records conditions as noted. 4. Using a Tech 2, monitor DTC info for DTC P0107. Does the Tech 2 indicate DTC P0107 failed? Go to Step 4 1. Ignition OFF. 2. Disconnect the MAP sensor electrical connector. 3. Jumper the 5 volt reference circuit and the MAP signal together at the MAP sensor harness connector. 4. Ignition ON. 5. Observe the MAP value displayed on the Tech 2. Is the MAP value near the specified value? (If no, start with diagnosis chart for other sensors in the circuit and see if 5V returns.)

Go to OBD System Check

5V 100kPa at sea level

Go to Step 4

Go to Step 3

Check the Procedure Refer to Diagnostic Aids

0 V 11 kPa

Go to Step 10

Go to Step 5

1. Disconnect the jumper. 2. Connect a test light between B+ and the MAP sensor signal circuit at the MAP sensor harness connector. 3. Observe the MAP value displayed on the Tech 2. Is the MAP value near the specified value. 5 V 100 kPa Go to Step 6 Go to Step 8 1. Ignition OFF. 2. Disconnect the PCM and check the 5 volt reference circuit for an open or short to ground. 3. If the 5 volt reference circuit is open or shorted to ground, repair it as necessary. Was the 5 volt reference circuit open or shorted to ground? Verify repair Go to Step 7

Check the 5 volt reference circuit for a poor connection at the PCM and replace the terminal if necessary. Did the terminal require replacement? Verify repair Go to Step 11

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E141

DTC P0107 MAP Sensor Circuit Low Voltage (Cont'd)

Step Action Value(s) Yes No

1. Ignition OFF. 2. Disconnect the PCM, and check the MAP signal circuit for an open, short to ground, or short to the sensor ground circuit. 3. If the MAP sensor signal circuit is open or shorted to ground, repair it as necessary. Was the MAP signal circuit open or shorted to ground? Verify repair Go to Step 9 Check the MAP sensor signal circuit for a poor connection at the PCM and the MAP sensor; replace the terminal if necessary. Did the terminal require replacement? Verify repair Verify repair Go to Step 11 Replace the MAP sensor. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

10 11

6E142

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0108 MAP Sensor Circuit High Voltage

D06R200048

Circuit Description
The manifold absolute pressure (MAP) sensor responds to changes in intake manifold pressure (vacuum). The MAP sensor signal voltage to the powertrain control module (PCM) varies from below 2 volts at idle (high vacuum) to above 4 volts with the key ON, engine not running or at wide-open throttle (low vacuum). The MAP sensor is used to determine manifold pressure changes while the linear EGR flow test diagnostic is being run (refer to DTC P0401), to determine engine vacuum level for some other diagnostics and to determine barometric pressure (BARO). The PCM monitors the MAP signals for voltages outside the normal range of the MAP sensor. If the PCM detects a MAP signal voltage that is excessively high, DTC P0108 will be set.

D The PCM will default to a BARO value of 79.3 kPa. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0108 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0108 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Diagnostic Aids
Check for the following conditions: D The MAP sensor shares a 5 Volt reference with the EGR sensor. If these codes are also set, it could indicate a problem with the 5 Volt reference circuit. D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the MAP display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault.

Conditions for Setting the DTC

D No TP sensor DTCs present. D Engine is running for more than 10 seconds. D Throttle position is below 3% if engine speed is below 1000 RPM. D Throttle position is below 10% if engine speed is above 1000 RPM. D The MAP sensor indicates an intermittent manifold absolute pressure above 80 kPa for a total of approximately 10 seconds over a 16-second period.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected fault.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

If DTC P0108 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P1108 Diagnostic Chart may isolate the cause of the fault.

6E143

DTC P0108 MAP Sensor Circuit High Voltage

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. If the engine idle is rough, unstable or incorrect, repair the idle problem before using this chart. Refer to Symptoms section. 2. With the engine idling, note the MAP value on the Tech 2. Is the MAP reading above the specified value? 2535 kPa Go to Step 4

Go to OBD System Check

Go to Step 3

1. Ignition ON, engine OFF. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Records conditions as noted. 4. Using a Tech 2, monitor DTC info for DTC P0108. Does the Tech 2 indicate DTC P0108 failed this ignition? Go to Step 4

Check the Procedure Refer to Diagnostic Aids

1. 2. 3. 4.

Ignition OFF. Disconnect the MAP sensor electrical connector. Ignition ON. Note the MAP sensor voltage displayed on the Tech 2. (If no, start with diagnostic chart for other sensors in the circuit and see if 5V returns.) 11 kPa 0.0 V Go to Step 5 Go to Step 7 Go to Step 6 Go to Step 9

Is the MAP sensor voltage at the specified value? 5 6 Probe the sensor ground circuit with a test light to B+. Is the test light ON? 1. Check the MAP signal circuit for a short to voltage or a short to the 5 volt reference circuit. 2. If the MAP sensor signal circuit is shorted, repair circuit as necessary. Was the MAP sensor signal circuit shorted? 7 1. Check for a poor sensor ground terminal connection at the MAP sensor electrical connector. 2. If a problem is found, replace the faulty terminal. Did the terminal require replacement? 8 Check for a plugged or leaking vacuum supply to the MAP sensor. Is the vacuum supply plugged or leaking? 9 1. Check for a poor sensor ground terminal connection at the PCM. 2. If a problem is found, replace the faulty terminal. Did the terminal require replacement?

Verify repair

Go to Step 11

Verify repair

Go to Step 8

Verify repair

Go to Step 12

Verify repair

Go to Step 10

6E144

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0108 MAP Sensor Circuit High Voltage (Cont'd)

Step Action Value(s) Yes No

10

1. Check the continuity of the MAP sensor ground circuit. 2. If the MAP sensor ground circuit measures over 5 ohms, repair open or poor connection. Was a condition found and corrected? Verify repair Go to Step 11 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify Repair Verify repair

11

12

Replace the MAP sensor. Is the action complete?

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E145

Diagnostic Trouble Code (DTC) P0112 IAT Sensor Circuit Low Voltage

D06RY00168

Circuit Description
The intake air temperature (IAT) sensor is a thermistor which measures the temperature of the air entering the engine. The powertrain control module (PCM) applies 5 volts through a pull-up resistor to the IAT sensor. When the intake air is cold, the sensor resistance is high and the PCM will monitor a high signal voltage on the IAT signal circuit. If the intake air is warm, the sensor resistance is lower, causing the PCM to monitor a lower voltage. DTC P0112 will set when the PCM detects an excessively low signal voltage on the intake air temperature sensor signal circuit.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0112 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0112 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-bout terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the IAT display on the Tech 2 while moving connectors and wiring harnesses related to the IAT sensor. A change in the IAT display will indicate the location of the fault. If DTC P0112 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set.

Conditions for Setting the DTC

D The engine has been running for over 15 seconds. D Vehicle speed is greater than 30 mph (48 km/h) . D IAT signal voltage indicates and intake air temperature greater than 148C (298F) (about 5 volts) for a total of 12.5 seconds over a 25-second period of time.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected fault. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

6E146

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart: 2. Verifies that the fault is present. 3. If DTC P0112 can be repeated only by duplicating the Failure Records condition, refer to the Temperature vs. Resistance Value table. The table may be used to test the IAT sensor at various temperatures to evaluate the possibility of a shifted sensor that may be stored above or below a certain temperature. If this is the case, replace the IAT sensor. If the IAT sensor appears to be OK, the fault is intermittent; refer to Diagnostic Aids.

Intake Air Temperature Sensor

C F OHMS Temperature vs. Resistance Values (approximate) 100 80 60 45 35 25 15 5 5 15 30 40 212 176 140 113 95 77 59 41 23 5 22 40 177 332 667 1188 1802 2796 4450 7280 12300 21450 52700 100700

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E147

DTC P0112IAT Sensor Circuit Low Voltage

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition ON, engine OFF. 2. Using a Tech 2, monitor the intake air temperature (IAT). Is the intake air temperature greater than the specified value? 148C (283F) Go to Step 4

Go to OBD System Check

Go to Step 3

1. Ignition ON, engine OFF. Review and record Tech 2 Failure Records data. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor the DTC info for DTC P0112. Does the Tech 2 indicate DTC P0112 failed this ignition? Refer to Test Description

Check the Procedure Refer to Diagnostic Aids

1. 2. 3. 4.

Ignition OFF. Disconnect the IAT sensor electrical connector. Ignition ON. Observe the intake air temperature on the Tech 2.

Is the intake air temperature below the specified value? 5 1. Ignition OFF. 2. Disconnect the PCM electrical connectors. 3. Check the IAT sensor signal circuit for a short to ground. Is the IAT sensor signal circuit shorted to ground? 6 7 Replace the IAT sensor. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?

38C (36F)

Go to Step 6

Go to Step 5

Verify repair Verify repair

Go to Step 7

Verify repair

6E148

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0113 IAT Sensor Circuit High Voltage

D06RY00168

Circuit Description
The intake air temperature (IAT) sensor is a thermistor which measures the temperature of the air entering the engine. The powertrain control module (PCM) applies 5 volts through a pull-up resistor to the IAT sensor. When the intake air is cold, the sensor resistance is high and the PCM will monitor a high signal voltage on the IAT signal circuit. If the intake air is warm, the sensor resistance is lower causing the PCM to monitor a lower voltage. DTC P0113 will set when the PCM detects an excessively high signal voltage on the intake air temperature sensor signal circuit.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0113 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0113 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Diagnostic Aids
Check for the following conditions: D The IAT sensor shares a ground with the EGR position sensor and the TP sensor. Check the ground if these DTCs are set. D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the IAT display on the Tech 2 while moving connectors and wiring harnesses related to the IAT sensor. A change in the IAT display will indicate the location of the fault. If DTC P0113 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set.

Conditions for Setting the DTC

D D D D D The engine has been running for over 30 seconds. Vehicle speed is less than 20 mph (32 km/h). ECT signal temperature is above 60C (140F). Mass air flow is less then 20 g/second. IAT signal voltage indicates an intake air temperature less than 39C (38F) for total of 12.5 seconds over a 25-second period.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected fault. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E149

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart: 2. Verifies that the fault is present. 3. If DTC P0113 can be repeated only by duplicating the Failure Records conditions, refer to the Temperature vs. Resistance Values table. The table may be used to test the IAT sensor at various temperatures to evaluate the possibility of a shifted sensor that may be open above or below a certain temperature. If this is the case, replace the IAT sensor. If the IAT sensor appears to be OK, the fault is intermittent; refer to Diagnostic Aids.

Intake Air Temperature Sensor

C F OHMS Temperature vs. Resistance Values (approximate) 100 80 60 45 35 25 15 5 5 15 30 40 212 176 140 113 95 77 59 41 23 5 22 40 177 332 667 1188 1802 2796 4450 7280 12300 21450 52700 100700

DTC P0113 IAT Sensor Circuit High Voltage

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Ignition ON, engine OFF. Observe the Intake Air Temp display on the Tech 2. Is the Intake Air Temp below the specified value? 1. Ignition ON, engine OFF. 2. Review and record Tech 2 Failure Records data parameters. 3. Operate the vehicle within Failure Records conditions as noted. 4. Using a Tech 2, monitor DTC info for DTC P0113. Does the Tech 2 indicate DTC P0113 failed? 1. Ignition OFF. 2. Disconnect the IAT sensor electrical connector. 3. Jumper the IAT signal circuit and the sensor ground circuit together at the IAT sensor harness connector. 4. Ignition ON. 5. Observe the Intake Air Temp display on the Tech 2. Is the Intake Air Temp at the specified value? 1. Jumper the IAT signal circuit at the IAT sensor harness connector to chassis ground. 2. Observe the Intake Air Temp display on the Tech 2. Is the Intake Air Temp at the specified value?

Go to OBD System Check

38C (36F)

Go to Step 4

Go to Step 3

Refer to Test Description

Check the Procedure Refer to Diagnostic Aids

140C (284F)

Go to Step 6

Go to Step 5

140C (284F)

Go to Step 7

Go to Step 8

6E150

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0113 IAT Sensor Circuit High Voltage (Cont'd)

Step Action Value(s) Yes No

Check for poor connections at the IAT sensor and replace terminals if necessary. Did any terminals require replacement? Verify repair Go to Step 10 1. Ignition OFF. 2. Disconnect the PCM, and check the IAT sensor ground circuit for an open. 3. If the IAT sensor ground circuit is open, repair it as necessary. Was the IAT sensor ground circuit open? Verify repair Go to Step 9 1. Ignition OFF. 2. Disconnect the PCM, and check the IAT signal circuit for an open. 3. If the IAT sensor signal circuit is open, repair it as necessary. Was the IAT signal circuit open? Verify repair Go to Step 9 Check for a poor sensor ground or IAT signal circuit terminal connection at the PCM and replace terminal(s) if necessary. Did any of the terminals need to be replaced? Verify repair Verify repair Go to Step 11 Replace the IAT sensor. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

10 11

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E151

Diagnostic Trouble Code (DTC) P0117 ECT Sensor Circuit Low Voltage

D06R200049

Circuit Description
The engine coolant temperature (ECT) sensor is a thermistor mounted on a coolant crossover pipe at the front of the engine. The powertrain control module (PCM) applies a voltage (about 5 volts) through a pull-up resistor to the ECT signal circuit. When the engine coolant is cold, the sensor (thermistor) resistance is high, therefore the PCM will measure a high signal voltage. As the engine coolant warms, the sensor resistance becomes lower, and the ECT signal voltage measured at the PCM drops. With a fully warmed-up engine, the ECT signal voltage should measure about 1.5 to 2.0 volts.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0117 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0117 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the ECT display on the Tech 2 while moving connectors and wiring harnesses related to the ECT sensor. A change in the ECT display will indicate the location of the fault. If DTC P0117 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P1114 Diagnostic Chart may isolate the cause of the fault.

Conditions for Setting the DTC

D Engine running time is longer than 120 seconds. D The ECT sensor signal indicates an engine coolant temperature greater than 150C (302F) (about 0.10 V) for a total of 50 seconds over a 100second period.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected fault. D The PCM will substitute the ECT reading with a default engine coolant temperature value. The default value is based on start-up intake air temperature and running time. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

6E152

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. Verifies that the fault is present. 3. If DTC P0117 can be repeated only by duplicating the Failure Records conditions, refer to the Temperature vs. Resistance Values table. The table may be used to test the ECT sensor at various temperatures to evaluate the possibility of a shifted sensor that may be shorted above or below a certain temperature. If this is the case, replace the ECT sensor. If the ECT sensor appears to be OK, the fault is intermittent; refer to Diagnostic Aids.

Engine Coolant Temperature Sensor

C F OHMS Temperature vs. Resistance Values (approximate) 100 80 60 45 35 25 15 5 5 15 30 40 212 176 140 113 95 77 59 41 23 5 22 40 177 332 667 1188 1802 2796 4450 7280 12300 21450 52700 100700

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E153

DTC P0117 ECT Sensor Low Voltage

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition ON, engine OFF. 2. Observe the Eng Cool Temp display on the Tech 2. Is the Eng Cool Temp below the specified value? 1. Ignition ON, engine OFF. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Records conditions as noted. 4. Using a Tech 2, monitor DTC info for DTC P0117. Does the Tech 2 indicate DTC P0117 failed this ignition? 39C (38F) Go to Step 4

Go to OBD System Check

139C (282F)

Go to Step 4

Go to Step 3

Check the Procedure Refer to Diagnostic Aids

1. Disconnect the ECT sensor electrical connector. 2. Observe the Eng Cool Temp display on the Tech 2. Is the Eng Cool Temp at the specified value? 1. Ignition OFF. 2. Disconnect the PCM and check the ECT signal circuit for a short to ground or a short to the sensor ground circuit. 3. If the ECT signal circuit is shorted. repair it as necessary. Was the ECT signal circuit shorted to ground?

Go to Step 6

Go to Step 5

Verify repair Verify repair

Go to Step 7

6 7

Replace the ECT sensor. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

6E154

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0118 ECT Sensor Circuit High Voltage

D06R200049

Circuit Description
The engine coolant temperature (ECT) sensor is a thermistor mounted in on a coolant crossover pipe at the front of the engine. The powertrain control module (PCM) applies a voltage (about 5 volts) through a pull-up resistor to the ECT signal circuit. When the engine coolant is cold, the sensor (thermistor) resistance is high, therefore the PCM will measure a high signal voltage. As the engine coolant warms, the sensor resistance becomes less, and the ECT signal voltage measured at the PCM drops. With a fully warmed-up engine, the ECT signal voltage should measure about 1.5 to 2.0 volts.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0118 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0118 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Diagnostic Aids
Check for the following conditions: The ECT shares a ground with the Transmission Fluid Temperature sensor, the Fuel Tank Pressure sensor, and the MAP sensor. Check the ground if these DTCs are also set. D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the ECT display on the Tech 2 while moving connectors and wiring harnesses related to the ECT sensor. A change in the ECT display will indicate the location of the fault. If DTC P0118 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently,

Conditions for Setting the DTC

D Engine running time is longer than 90 seconds. D The ECT sensor signal indicates an engine coolant temperature of 39C (38F) or less (about 5 volts) for a total of 50 seconds over a 100-second period.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected fault. D The PCM will substitute the ECT reading with a default engine coolant temperature value. The default value is based on start-up intake air temperature and running time. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

performing the DTC P1115 Diagnostic Chart may isolate the cause of the fault.

6E155

Engine Coolant Temperature Sensor

C F OHMS Temperature vs. Resistance Values (approximate) 100 80 60 45 35 25 15 5 5 15 30 40 212 176 140 113 95 77 59 41 23 5 22 40 177 332 667 1188 1802 2796 4450 7280 12300 21450 52700 100700

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. Verifies that the fault is present. 3. If DTC P0118 can be repeated only by duplicating the Failure Records conditions, refer to the Temperature vs. Resistance Value table. The table may be used to test the ECT sensor at various temperatures to evaluate the possibility of a shifted sensor that may be shorted above or below a certain temperature. If this is the case, replace the ECT sensor. If the ECT sensor appears to be OK, the fault is intermittent; refer to Diagnostic Aids.

DTC P0118 ECT Sensor Circuit High Voltage

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition ON, engine OFF. 2. Observe the Eng Cool Temp display on the Tech 2. Is the Eng Cool Temp below the specified value? 1. Ignition ON, engine OFF. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Records conditions as noted. 4. Using a Tech 2, monitor the DTC info for DTC P0118. Does the Tech 2 indicate DTC P0118 failed? 1. Disconnect the ECT sensor electrical connector. 2. Jumper the ECT signal circuit and the sensor ground circuit together at the ECT sensor harness connector. 3. Observe the Eng Cool Temp display on the Tech 2. Is the Eng Cool Temp at the specified value? 1. Jumper the ECT signal circuit at the ECT sensor harness connector to chassis ground. 2. Observe the Eng Cool Temp display on the Tech 2. Is the Eng Cool Temp at the specified value? Check for poor connections at the ECT sensor and replace terminals if necessary. Did any terminals require replacement? Verify repair

Go to OBD System Check

39C (38F)

Go to Step 4

Go to Step 3

Refer to Test Description

Check the Procedure Refer to Diagnostic Aids

140C (284F)

Go to Step 6

Go to Step 5

140C (284F)

Go to Step 7

Go to Step 8

Go to Step 10

6E156

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0118 ECT Sensor Circuit High Voltage (Cont'd)

Step Action Value(s) Yes No

1. Ignition OFF. 2. Disconnect the PCM, and check the ECT sensor ground circuit for an open. 3. If the ECT sensor ground circuit is open, repair it as necessary. Was the ECT sensor ground circuit open? Verify repair Go to Step 9 1. Ignition OFF. 2. Disconnect the PCM, and check the ECT signal circuit for an open. 3. If the ECT sensor signal circuit is open, repair it as necessary. Was the ECT signal circuit open? Verify repair Go to Step 9 Check for a poor sensor ground or ECT signal circuit terminal connection at the PCM and replace terminal(s) if necessary. Did any of the terminals need to be replaced? Verify repair Verify repair Go to Step 11 Replace the ECT sensor. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

10 11

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E157

Diagnostic Trouble Code (DTC) P0125 ECT Excessive Time to Closed Loop Fuel Control

D06R200049

Circuit Description
To provide the best possible combination of driveability, fuel economy, and emission control, a closed loop air/fuel metering system is used. When the vehicle is first started, the powertrain control module (PCM) controls fuel delivery in open loop, ignoring the heated oxygen sensor (HO2S) signals and calculating air/fuel ratio based on inputs from the engine coolant temperature, throttle position, and mass air flow sensors. The PCM will begin using the Bank 1 HO2S 1 and Bank 2 HO2S 1 signals for controlling fuel delivery under closed loop conditions when the following conditions have been met: D The HO2S output signals are varying, indicating that the sensors are hot enough to operate properly. D The engine coolant temperature sensor indicates coolant temperature above 50C (122F). D Time since start-up is at least 16 seconds for a warm engine or 23 seconds for a cold engine.

D For a warm engine (intake air temperature is greater than 10C/50F), engine coolant temperature sufficient to allow closed loop operation (50C/122F) is not achieved within 2 minutes of start-up. For a cold engine (intake air temperature between (7C and 10C), engine coolant temperature sufficient to allow closed loop operation (50C/122F) is not achieved within 10 minutes of start-up. D The above condition fails 20 consecutive times.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected fault. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0125 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0125 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D D D D No active IAT, MAF or ECT DTC(s) are present. Engine is running. Vehicle speed is greater than 5 mph (8 km/h) . Intake air temperature is greater than 10C (14F) 0C (32F). D Startup engine coolant temperature is between 10C (14F) and 28C (82F).

6E158

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Aids
DTC P0125 set indicates a faulty ECT sensor. Comparing the engine coolant temperature displayed on a Tech 2 with actual coolant temperature measured with a thermometer may isolate this condition. If the displayed engine coolant temperature is not close to the actual coolant temperature, replace the ECT sensor. Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0125 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage wince the DTC was last set.

Engine Coolant Temperature

C F OHMS Temperature vs. Resistance Values (approximate) 100 80 60 45 35 25 15 5 5 15 30 40 212 176 140 113 95 77 59 41 23 5 22 40 177 332 667 1188 1802 2796 4450 7280 12300 21450 52700 100700

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. Comparing the engine coolant temperature displayed on a Tech 2 with actual coolant temperature measured with a thermometer may isolate this condition. If the displayed engine coolant temperature is not close to the actual coolant temperature, replace the ECT sensor. If the temperatures are close, the fault is intermittent; refer to Diagnostic Aids.

DTC P0125 ECT Excessive Time to Closed Loop Fuel Control

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Go to applicable ECT sensor DTC chart Are any ECT sensor DTCs set?

Go to OBD System Check

Go to Step 3

1. Allow the engine to cool completely. 2. Check the cooling system coolant level (refer to Cooling and Radiator). Is the coolant level OK? Go to Step 4 Check the Procedure Refer to Diagnostic Aids Go to Step 9 1. Start the engine. 2. With the engine idling, monitor ENG COOL TEMP display on the Tech 2. Does ENG COOL TEMP increase to above the specified value within 2 minutes? 21C (70F)

Go to Step 5

Check for proper operation of the thermostat (refer to Cooling and Radiator). Is the thermostat operating correctly? Go to Step 6 Go to Step 9

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

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DTC P0125 ECT Excessive Time to Closed Loop Fuel Control (Cont'd)
Step Action Value(s) Yes No

Compare engine coolant temperature displayed on the Tech 2 to the actual coolant temperature measured with a thermometer. (Observe normal precautions when opening the cooling system.) Is the Tech 2 engine coolant temperature indication close to the measured temperature? Go to Step 9 Go to Step 7

1. Ignition OFF. 2. Disconnect the PCM. 3. Using a DVM, measure the resistance of the ECT at the PCM connector. 4. Compare the DVM reading with the chart in Test Description. Is the chart value approximately equal to the thermometer reading? Go to Step 12 Go to Step 8

Check for high resistance in wiring related to the ECT sensor. Also, check for poor connections at the ECT sensor and the PCM. Was a problem found? Go to Step 10 Go to Step 11 Refer to Cooling and Radiator for cooling system diagnosis and repair condition as necessary. Is the action complete? Verify repair Replace the faulty terminal(s) or repair faulty wiring as necessary. Is the action complete? Verify repair Verify repair Replace the ECT sensor. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

10

11 12

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Diagnostic Trouble Code (DTC) P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1

D06R200013

Circuit Description
The powertrain control module (PCM) supplies a bias voltage of about 450 mV between the heated oxygen sensor (HO2S) signal high and signal low circuits. When measured with a 10 megaohm digital voltmeter, this may display as low as 350 mV. The oxygen sensor varies the voltage within a range of about 1000 mV when the exhaust is rich, down through about 10 mV when exhaust is lean. The PCM constantly monitors the HO2S signal during closed loop operation and compensates for a rich or lean condition by decreasing or increasing injector pulse width as necessary. If the Bank 1 HO2S 1 voltage remains excessively low for an extended period of time, DTC P0131 will be set.

D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data. D Open loop fuel control will be in effect.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0131 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0131 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D D D D No related DTCs. Vehicle is operating in closed loop. Engine coolant temperature is above 60C (140F). Closed loop commanded air/fuel ratio is between 14.5 and 14.8. D Bank 1 HO2S 1 signal voltage remains below 22 mV during normal closed loop operation for a total of 77 seconds over a 90-second period of time.

Diagnostic Aids
Check for the following conditions: D Heated oxygen sensor wiring The sensor pigtail may be routed incorrectly and contacting the exhaust system. D Poor PCM to engine block grounds. D Fuel pressure The system will go lean if pressure is too low. The PCM can compensate for some decrease. However, If fuel pressure is too low, a DTC P0131 may be set. Refer to Fuel System Diagnosis. D Lean injector(s) Perform Injector Balance Test. D Vacuum leaks Check for disconnected or damaged vacuum hoses and for vacuum leaks at the intake manifold, throttle body, EGR system, and PCV system.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected fault.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

D Exhaust leaks An exhaust leak may cause outside air to be pulled into the exhaust gas stream past the HO2S, causing the system to appear lean. Check for exhaust leaks that may cause a false lean condition to be indicated. D MAF sensor The system can go lean if the MAF sensor signal indicates an engine airflow measurement that is not correct. Disconnect the MAF sensor to see if the lean condition is corrected. If so, replace the MAF sensor. D Fuel contamination Water, even in small amounts, can be delivered to the fuel injectors. The water can cause a lean exhaust to be indicated. Excessive alcohol in the fuel can also cause this condition. Refer to Fuel System Diagnosis for the procedure to check for fuel contamination.

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D If none of the above conditions are present, replace the affected HO2S.

Test Description
Number(s) below refer to step numbers on the diagnostic chart. 3. DTC P0131 failing during operation may indicate a condition described in the Diagnostic Aids above. If the DTC P0131 test passes while the Failure Records conditions are being duplicated, an intermittent condition is indicated. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Install the Tech 2. 2. Run the engine at normal operating temperature. 3. Operate the vehicle within the parameters specified under Conditions for Setting the DTC criteria included in Diagnostic Support. 4. Using a Tech 2, monitor Bank 1 HO2S 1 voltage. Does the Bank 1 HO2S 1 voltage remain below the specified value? 22 mV Go to Step 4

Go to OBD System Check

Go to Step 3

1. Ignition ON, engine OFF, review and record Tech 2 Failure Records data and note parameters. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor DTC info for DTC P0131 until the DTC P0131 test runs. Note test result. Does Tech 2 indicate DTC P0131 failed this ignition? Go to Step 4 1. Turn the ignition OFF. 2. Disconnect the PCM. 3. Check the Bank 1 HO2S 1 high and low circuits for a short to ground or a short to the heater ground circuit. Are the Bank 1 HO2S 1 signal circuits shorted to ground? Go to Step 5 Verify repair

Check the Procedure Refer to Diagnostic Aids

Go to Step 6

5 6

Repair the Bank 1 HO2S 1 signal circuit. Is the action complete? 1. Turn the ignition OFF, HO2S 1 and PCM disconnected. 2. Check for short circuit between the high and low signal circuits. Was there continuity between the high and low circuits? Go to Step 7 Verify repair Go to Step 8 Repair the short between the high and low circuits. Is the action complete?

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TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1 (Cont'd)

Step Action Value(s) Yes No

1. Ignition OFF. 2. Reconnect the disconnected. 3. Ignition ON.

PCM,

leave

the

sensor

Does the Tech 2 indicate Bank 1 HO2S 1 voltage between the specified values? 9 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?

425-475 mV

Check the Procedure Refer to Diagnostic Aids

Go to Step 9

Verify repair

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6E163

Diagnostic Trouble Code (DTC) P0132 HO2S Circuit High Voltage Bank 1 Sensor 1

D06R200013

Circuit Description
The powertrain control module (PCM) supplies a bias voltage of about 450 mV between the heated oxygen sensor (HO2S) signal and low circuits. When measured with a 10 megaohm digital voltmeter, this may display as low as 320 mV. The oxygen sensor varies the voltage within a range of about 1000 mV when exhaust is rich, down through about 10 mV when exhaust is lean. The PCM constantly monitors the HO2S signal during closed loop operation and compensates for a rich or lean condition by decreasing or increasing injector pulse width as necessary. If the Bank 1 HO2S 1 voltage remains excessively high for an extended period of time, DTC P0132 will be set.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected fault. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data. D Open loop fuel control will be in effect.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0132 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0132 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D No related DTCs. D Engine coolant temperature is above 60C (140F) D Closed loop commanded air/fuel ratio is between 14.5 and 14.8. D Bank 1 HO2S 1 signal voltage remains above 952 mV during normal closed loop operation for a total of 77 seconds over a 90-second period. OR D Bank 1 HO2S 1 signal voltage remains above 500 mV during deceleration fuel cutoff mode operation for 3 seconds.

Diagnostic Aids
Check the following items: D Fuel pressure The system will go rich if pressure is too high. The PCM can compensate for some increase. However, if fuel pressure is too high, a DTC P0132 may be set. Refer to Fuel System Diagnosis. D Perform Injector Balance Test Refer to Fuel System Diagnosis.

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TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

cause the DTC to set during deceleration fuel mode. An HO2S which is faulty and not allowing a full voltage swing between the rich and lean thresholds can also cause this condition. Operate the vehicle by monitoring the HO2S voltage with a Tech 2. If the HO2S voltage is limited within a range between 300 mV to 600 mV, check the HO2S signal circuit wiring and associated terminal conditions. D If none of the above conditions are present, replace the affected HO2S.

D Check the EVAP canister for fuel saturation If full of fuel, check canister control and hoses. Refer to Evaporative (EVAP) Emission Control System. D MAF sensor The system can go rich if MAF sensor signal indicates an engine airflow measurement that is not correct. Disconnect the MAF sensor to see it the rich condition is corrected. If so, replace the MAF sensor. D Check for a leak in the fuel pressure regulator diaphragm by checking the vacuum line to the regulator for the presence of fuel. There should be no fuel in the vacuum line. D An intermittent TP sensor output will cause the system to go rich due to a false indication of the engine acceleration. D Shorted Heated Oxygen Sensor (HO2S) If the HO2S is internally shorted, the HO2S voltage displayed on the Tech 2 will be over 1 volt. Try disconnecting the affected HO2S with the key ON, engine OFF. If the displayed HO2S voltage changes from over 1000 mV to around 450 mV, replace the HO2S. Silicon contamination of the HO2S can also cause a high HO2S voltage to be indicated. This condition is indicated by a powdery deposit on the portion of the HO2S exposed to the exhaust stream. If contamination is noticed, replace the affected HO2S. D Open HO2S Signal Circuit or Faulty HO2SA poor connection or open in the HO2S signal circuit can

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 3. DTC P0132 failing during deceleration fuel cutoff mode operation may indicate a condition described in the Diagnostic Aids above. If the DTC P0132 test passes while the Failure Records conditions are being duplicated, an intermittent condition is indicated. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0132 HO2S Circuit High Voltage Bank 1 Sensor 1

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Install the Tech 2. 2. Run the engine at operating temperature. 3. Operate the vehicle within parameters specified under Conditions for Setting the DTC included in Diagnostic Support. 4. Using a Tech 2, monitor Bank 1 HO2S 1 voltage. Does the Bank 1 HO2S 1 voltage remain above the specified value?

Go to OBD System Check

952 mV (500 mV in deceleration fuel cutoff mode)

Go to Step 4

Go to Step 3

1. Ignition ON, review and record Tech 2 Failure Records data. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor DTC info for DTC P0132 until the DTC P0132 test runs. 4. Note the test result. Does the Tech 2 indicate DTC P0132 failed this ignition? Go to Step 4

Check the Procedure Refer to Diagnostic Aids

1. 2. 3. 4.

Ignition OFF. Disconnect Bank 1 HO2S 1. Ignition ON. At HO2S Bank 1 Sensor 1 connector (PCM side) use a DVM to measure voltages at the high and low signal terminals. 3-4 V Go to Step 5 Go to Step 6

Are the voltages in the specified range?

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E165

DTC P0132 HO2S Circuit High Voltage Bank 1 Sensor 1 (Cont'd)

Step Action Value(s) Yes No

5 6

Repair short to voltage in signal circuit. Is the action complete? 1. Ignition ON, engineOFF. 2. At Bank 1 HO2S 1 connector (PCM side) jumper both the HO2S high and low signal circuits (PCM side) to ground. 3. Using a Tech 2, monitor Bank 1 HO2S 1 voltage. Is Bank 1 HO2S 1 voltage below the specified value? 10 mV Go to Step 7 Check the Procedure Refer to Diagnostic Aids Go to Step 8 1. Disconnect the jumpers to ground from Bank 1 HO2S 1 PCM-side connector. 2. With the HO2S 1 connector disconnected, monitor Bank 1 HO2S 1 voltage. Is Bank 1 HO2S 1 voltage between the specified values? 425-475 mV Verify repair

Go to Step 8

Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

6E166

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0133 HO2S Slow Response Bank 1 Sensor 1

D06R200013

Circuit Description
The powertrain control module (PCM) continuously monitors the heated oxygen sensor (HO2S) activity for 90 seconds after closed loop has been enabled. During the monitoring period the PCM counts the number of times that a rich-to-lean and lean-to-rich response is indicated and adds the amount of time it took to complete all rich-to-lean transitions and lean-to-rich transitions. With this information, an average time for rich-to-lean and lean-to-rich transitions can be determined. If the average response time of either transition is too slow, a DTC P0133 will be set. A lean-to-rich transition is indicated when the HO2S voltage changes from less than 300 mV to greater than 600 mV. A rich-to-lean transition is indicated when the HO2S voltage changes from more than 600 mV to less than 300 mV. An HO2S that responds too slowly is likely to be faulty and should be replaced.

D Mass air flow is between 18 g/second and 42 g/second. D All above conditions are met for 3 seconds. D 90 seconds after closed loop has been enabled, Bank1 HO2S 1 average transition time between 300 mV and 600 mV is too slow. The lean-to-rich average transition response time was longer than 94 milliseconds or rich-to-lean average transition response time was longer than 105 milliseconds.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator Lamp (MIL) after the second consecutive trip in which the fault is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data. D Open loop fuel control will be in effect.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0133 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0133 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D No related DTCs. D Engine coolant temperature (ETC) is above 60C (140F). D Engine is operating in closed loop. D Engine has been running for at least 90 seconds. D Engine speed is between 1500 RPM and 3000 RPM. D Canister purge duty cycle is greater than 2%.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E167

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the Bank 1 HO2S 1 display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0133 cannot be duplicated, reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. Verifies that the fault is currently present. 3. HO2S transition time, ratio mean volts and switching DTCs set for multiple sensors indicate probable contamination. Before replacing the sensors, isolate and correct the source of the contamination to avoid damaging the replacement sensors.

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TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0133 HO2S Slow Response Bank 1 Sensor 1

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 NOTE: If any DTCs are set (expect P0153, P1133, P1134, P1153, and/or P1154), refer to those DTCs before proceeding with this diagnostic chart. 1. Install the Tech 2. 2. Idle the engine at normal operating temperature. 3. Operate the vehicle within parameters specified under Conditions for Setting the DTC included in Diagnostic Support. 4. Using a Tech 2, monitor DTC info for DTC P0133 until the DTC P0133 test runs. 5. Note the test result. Does the Tech 2 indicate DTC P0133 failed this ignition? Go to Step 3 Go to Step 17 Go to Step 5 Go to Step 2

Go to OBD System Check

Check the Procedure Refer to Diagnostic Aids Go to Step 4 Go to Step 6

3 4 5 6

Did the Tech 2 also indicate DTC P0153, P1133, P1134, P1153, and/or P1154 failed this ignition? Check for leaks at the pipe joints. Are the joints leaking? Tighten the Ubolt nuts at the leaking joints. Is the action complete? Check for gaskets that are damaged or improperly installed. Are there damaged or misaligned gaskets?

Go to Step 7

Go to Step 8

1. Replace damaged gaskets. 2. Align the connections. 3. Tighten the connections. Is the action complete? Go to Step 2 Go to Step 9 Go to Step 2 Go to Step 11 Go to Step 2 Go to Step 13 Go to Step 10 Go to Step 12 Go to Step 14 Check for loose exhaust flange connections. Are the flange connections loose? Tighten the stud nuts or bolts to specifications. Is the action complete? Check for burned or corroded exhaust pipes. Are the exhaust pipes burned or corroded? Replace the exhaust pipes, as required. Is the action complete? Check for leaks at the exhaust manifold. Are there leaks at the exhaust manifold? Tighten the bolts to specifications to replace the manifold if necessary. Is the action complete? Go to Step 2

8 9 10 11 12 13

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

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DTC P0133 HO2S Slow Response Bank 1 Sensor 1 (Cont'd)

Step Action Value(s) Yes No

14

Visually/physically inspect the following items: D Ensure that the Bank 1 HO2S 1 is securely installed. D Check for corrosion on terminals. D Check terminal tension (at Bank 1 HO2S 1 and at the PCM). D Check for damaged wiring. Was a problem found in any of the above areas? Go to Step 18 Go to Step 15 1. Disconnect Bank 1 HO2S 1. 2. Ignition ON. 3. Using a DVM at the PCM side of the HO2S 1 connector, measure the voltage between the high signal circuit and ground. Also measure the voltage between the low signal circuit and ground. Are both voltages in the specified range? 3-4 V Go to Step 16 Go to Step 19 1. With Bank 1 HO2S 1 disconnected, jumper the high and low (PCM side) signal circuits to ground. 2. Ignition ON. 3. Using a Tech 2, monitor the Bank 1 HO2S 1 voltage. Does the Tech 2 indicate less than 10 mV and immediately return to about 450 mV when the jumper is removed?

15

16

Go to Step 21

Go to Step 22

17

Replace the affected heated oxygen sensors. NOTE: Before replacing sensors, the cause of the contamination must be determined and corrected. D D D Fuel contamination. Use of improper RTV sealant. Engine oil/coolant consumption. Verify repair Verify repair Verify repair Verify repair Verify repair Go to Step 20

Is the action complete? 18 19 20 21 22 Repair condition as necessary. Is the action complete? Check for faulty PCM connections or terminal damage. Is the action complete? Repair open, short or grounded signal circuit. Is the action complete? Replace Bank 1 HO2S 1. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?

Verify repair

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TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1

D06R200013

Circuit Description
D The powertrain control module (PCM) supplies a bias voltage of about 450 mV between the heated oxygen sensor (HO2S) high and low circuits. When measured with a 10 megaohm digital voltmeter, this may display as low as 320 mV. The oxygen sensor varies the voltage within a range of about 1000 mV when the exhaust is rich, down through about 10 mV when exhaust is lean. The PCM constantly monitors the HO2S signal during closed loop operation and compensates for a rich or lean condition by decreasing or increasing injector pulse width as necessary. If the Bank 1 HO2S 1 voltage remains at or near the 450 mV bias for an extended period of time, DTC P0134 will be set, indicating an open sensor signal or sensor low circuit. D Heated oxygen sensors are used to minimize the amount of time required for closed loop fuel control operation and to allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of time required for fuel control sensors Bank 1 HO2S 1 and Bank 2 HO2S 1 to become active. D Oxygen sensor heaters are required by post-catalyst monitor sensors to maintain a sufficiently high temperature for accurate exhaust oxygen content readings further from the engine.

Conditions for Setting the DTC

D D D D No related DTCs. Battery voltage is above 10 volts. The engine has been running for over 5 seconds. Engine coolant temperature (ETC) is above 60C (140F). D Oxygen sensor heater has been determined to be functioning properly. D Bank 1 HO2S 1 signal voltage remains between 400 mV and 500 mV for a total of 77 seconds over a 90-second period of time.

Action Take When the DTC Sets

D The PCM will ON the MIL after second trip with detected fault. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data. D Open loop fuel control will be in effect.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0134 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0134 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

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Diagnostic Aids
Check for the following conditions: D Poor connection or damaged harness Inspect the harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness. D Faulty HO2S heater or heater circuit With the ignition ON, engine OFF, after a cool down period, the HO2S 1 voltage displayed on the Tech 2 is normally 455-460 mV. A reading over 1000 mV indicates a signal line shorted to voltage. A reading under 5 mV indicates a signal line shorted to ground or signal lines shorted together. Disconnect the HO2S and connect a test light between the HO2S ignition feed and heater ground circuits. If the test light does not light for 2 seconds when the ignition is turned on, repair the open ignition feed or sensor ground circuit as necessary. If the test light lights and the HO2S signal and low circuits are OK, replace the HO2S.

D Intermittent test With the Ignition ON, monitor the HO2S signal voltage while moving the wiring harness and related connectors. If the fault is induced, the HO2S signal voltage will change. This may help isolate the location of the malfunction.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 3. If the DTC P0134 test passes while the Failure Records conditions are being duplicated, an intermittent conditions is indicated. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Install the Tech 2. 2. Run the engine at operating temperature. 3. Operate the engine above 1200 RPM for two minutes. Does the Tech 2 indicate Bank 1 HO2S 1 voltage varying outside the specified values? 400-500 mV Go to Step 3

Go to OBD System Check

Go to Step 4

1. Ignition ON, engine OFF, review and record Tech 2 Failure Records data and note parameters. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor DTC info for DTC P0134 until the DTC P0134 test runs. 4. Note the test result. Does the Tech 2 indicate DTC P0134 failed this ignition? Go to Step 4 Verify repair

Check the Procedure Refer to Diagnostic Aids Go to Step 5

4 5

Check for a damaged harness. Was a problem found? Check for poor Bank 1 HO2S 1 high and low circuit terminal connections at the Bank 1 HO2S 1 harness connector and replace terminal(s) if necessary. Did any terminals require replacement? Verify repair Go to Step 6 Check for poor Bank 1 HO2S 1 high and low circuit terminal connections at the PCM and replace terminals if necessary. Did any terminals require replacement? Verify repair Go to Step 7

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DTC P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1 (Cont'd)

Step Action Value(s) Yes No

1. Ignition OFF. 2. With the PCM disconnected, check continuity of the Bank 1 HO2S 1 high circuit. 3. If the Bank 1 HO2S 1 high circuit measures over 5.0 ohms, repair open or poor connection as necessary. Was a Bank 1 HO2S 1 high circuit problem found and corrected? Verify repair Go to Step 8

1. Ignition OFF. 2. With the PCM disconnected, check continuity of the Bank 1 HO2S 1 low circuit. 3. If the Bank 1 HO2S 1 low circuit measures over 5 ohms, repair open or poor connection as necessary. Was a Bank 1 HO2S 1 low circuit problem found and corrected? Verify repair Go to Step 9

1. Ignition ON, engine OFF. 2. Disconnect Bank 1 HO2S 1 and jumper the HO2S high and low circuits (PCM side) to ground. 3. Using a Tech 2, monitor Bank 1 HO2S 1 voltage. Is Bank 1 HO2S 1 voltage in the specified range? 0-10 mV Go to Step 10 Verify repair Go to Step 11 Replace Bank 1 HO2S 1. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

10 11

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E173

Diagnostic Trouble Code (DTC) P0135 HO2S Heater Circuit Bank 1 Sensor 1

D06R200013

Circuit Description
Heated oxygen sensors are used to minimize the amount of time required for closed loop fuel control operation and to allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of time required for fuel control sensors Bank 1 HO2S 1 and Bank 2 HO2S 1 to become active. Oxygen sensor heaters are required by post-catalyst monitor sensors to maintain a sufficiently high temperature which allows accurate exhaust oxygen content readings further from the engine. The powertrain control module (PCM) will run the heater test only after a cold start (determined by engine coolant and intake air temperature at the time of start-up) and only once during an ignition cycle. When the engine is started the PCM will monitor the HO2S voltage. When the HO2S voltage indicates a sufficiently active sensor, the PCM looks at how much time has elapsed since start-up. If the PCM determines that too much time was required for the Bank 1 HO2S 1 to become active, a DTC P0135 will set. The time it should take the HO2S to reach operating temperature is based on the accumulated amount of air that has passed through the MAF sensor and into the engine (more accumulated air flow = shorter time to HO2S activity).

Conditions for Setting the DTC

D The engine has been running for over 120 seconds. D Heater signal is below 0.1A. D Bank 1 HO2S 1 voltage does not change more than 150 mV from the bias voltage (between 400 mV and 500 mV) for a longer amount of time than it should. The maximum amount of time to come up to operating range is 150 seconds. This warm-up time depends on the engine coolant temperature at start-up and accumulate air flow since start-up.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator lamp (MIL) after the second consecutive trip in which the fault is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0135 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0135 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

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2. The HO2S should be allowed to cool before performing this test. If the HO2S heater is functioning, the signal voltage will gradually increase or decrease as the sensor element warms. If the heater is not functioning, the HO2S signal will remain near the 450 mV bias voltage. 4. Ensures that the ignition feed circuit to the HO2S is not open or shorted. The test light should be connected to a good chassis ground, in case the HO2S low or HO2S heater ground circuit is faulty. 5. Checks the HO2S heater ground circuit. 6. Checks or an open or shorted HO2S heater element. 10.An open HO2S signal or low circuit can cause the HO2S heater to appear faulty. Check these circuits before replacing the sensor.

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the ECT display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart.

DTC P0135 HO2S Heater Circuit Bank 1 Sensor 1

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 NOTE: If the engine has just been operating ,allow the engine to cool for at least 15 minutes before proceeding. 1. Remove the fuel pump relay. 2. Connect a fused jumper at the fuel pump relay socket, between the battery positive at the relay and the relay wire that leads to the fuel pump and HO2S fuses. 3. Ignition OFF. 4. Install a Tech 2. 5. Ignition ON, engine OFF. 6. Monitor the Bank 1 HO2S 1 voltage for several minutes. Did the HO2S voltage go from bias voltage to above or below the specified values?

Go to OBD System Check

Above 650 mV or below 250 mV

Check the Procedure Refer to Diagnostic Aids Go to Step 15

Go to Step 3 Go to Step 4

3 4

Inspect the fuse for the Bank 1 HO2S 1 ignition feed. Is the fuse open? 1. 2. 3. 4. Ignition OFF. Raise the vehicle. Disconnect the Bank 1 HO2S 1 electrical connector. Using a test light connected to a good ground (do not use Bank 1 HO2S 1 heater ground or Bank 1 HO2S 1 low), probe the ignition feed circuit at the Bank 1 HO2S 1 electrical connector (PCM harness side). Go to Step 5 Go to Step 7

Does the test light illuminate? 5 Connect the test light between the Bank 1 HO2S 1 ignition feed and the Bank 1 HO2S 1 heater ground. Does the test light illuminate?

Go to Step 6

Go to Step 8

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DTC P0135 HO2S Heater Circuit Bank 1 Sensor 1 (Cont'd)

Step Action Value(s) Yes No

1. Allow the HO2S to cool for at least 15 minutes. 2. Using a DVM, measure the resistance between the Bank 1 HO2S 1 ignition feed and the Bank 1 HO2S 1 heater ground at the Bank 1 HO2S 1 pigtail. Is the HO2S heater resistance within the specified values? 3-6 ohms Go to Step 9 Go to Step 10

Repair the open Bank 1 HO2S 1 ignition feed circuit to Bank 1 HO2S 1. Is the action complete? Verify repair Repair the open Bank 1 HO2S 1 heater ground circuit to Bank 1 HO2S 1. Is the action complete? Verify repair 1. Check for a poor connection at the Bank 1 HO2S 1 harness terminals. 2. If a poor connection is found, replace terminals. Was a poor connection found? Verify repair Go to Step 10 Check for a poor Bank 1 HO2S 1 high or low circuit terminal connection at the Bank 1 HO2S 1 harness connector and replace terminal(s) if necessary. Did any terminals require replacement? Verify repair Go to Step 11 1. Ignition OFF. 2. Disconnect the PCM and check the continuity of the Bank 1 HO2S 1 signal circuit and the Bank 1 HO2S 1 low circuit. 3. If the Bank 1 HO2S 1 high circuit or HO2S low circuit measures over 5 ohms, repair open or poor connection as necessary. Was a problem found? Verify repair Go to Step 12 Check for a poor Bank 1 HO2S 1 low circuit terminal connection at the PCM and replace the terminal if necessary. Did the terminal require replacement? Verify repair Go to Step 13 Check for a poor Bank 1 HO2S 1 high circuit terminal connection at the PCM and replace the terminal if necessary. Did the terminal require replacement? Verify repair Verify repair Go to Step 14 Replace the Bank 1 HO2S 1. Is the action complete? Locate and repair the short to ground in Bank 1 HO2S 1 ignition feed circuit and replace the fault fuse. Is the action complete? Verify repair

10

11

12

13

14 15

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Diagnostic Trouble Code (DTC) P0137 HO2S Circuit Low Voltage Bank 1 Sensor 2

D06RY00173

Circuit Description
The powertrain control module (PCM) supplies bias voltage of about 450 mV between the heated oxygen sensor (HO2S) signal high and signal low circuits. When measured with a 10 megaohm impedance digital voltmeter, this may display as low as 350 mV. The oxygen sensor varies the voltage within a range of about 1000 mV when exhaust is rich, down through about 10 mV when the exhaust is lean. The PCM constantly monitors the HO2S signal during closed loop operation and compensates for a rich or lean condition by decreasing or increasing injector pulse width as necessary. If the Bank 1 HO2S 2 signal voltage remains excessively low for an extended period of time, DTC P0137 will be set.

D Bank 1 HO2S 2 signal voltage remains below 400 mV during power enrichment mode fuel control operation for up to 5 seconds.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected fault. D The PCM will store conditions which were present when the DTC set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0137 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0137 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D D D D No related DTCs. Engine is operating in closed loop. Engine coolant temperature is above 60C (140F). Closed loop commanded air/fuel ratio is between 14.5 and 14.8. D Throttle angle is between 3% and 19%. D Bank 1 HO2S 2 signal voltage remains below 22 mV during normal closed loop operation for a total of 106 seconds over a 125-second period of time. OR

Diagnostic Aids
Check for the following conditions: D Heated oxygen sensor wiring The sensor pigtail may be mispositioned and contacting the exhaust system. D Poor PCM to engine grounds. D Fuel pressure A condition which causes a lean exhaust can cause DTC P0137 to set. The system will go lean if pressure is too low. The PCM can

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

compensate for some decrease. However, if fuel pressure is too low, a DTC P0137 may be set. Refer to Fuel System Diagnosis. Lean injector(s) Perform Injector Balance Test. Vacuum leaks Check for disconnected or damaged vacuum hoses and for vacuum leaks at the intake manifold, throttle body, EGR system, and PCV system. Exhaust leaks An exhaust leak may cause outside air to be pulled into the exhaust gas stream past the HO2S, causing the DTC P0137 to set. Check for exhaust leaks near the Bank 1 HO2S 2 sensor. MAF sensor The system can go lean if the MAF sensor signal indicates an engine airflow measurement that is not correct. Disconnect the MAF sensor to see if the lean condition is corrected. If so, replace the MAF sensor. Fuel contamination Water, even in small amounts, can be delivered to the fuel injectors. The water can cause a lean exhaust to be indicated. Excessive

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D D D

alcohol in the fuel can also cause this condition. Refer to Fuel System Diagnosis for procedure to check for fuel contamination. D If none of the above conditions are present, replace the affected HO2S.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 3. DTC P0137 failing during operation may indicate a condition described in the Diagnostic Aids above. If the DTC0137 test passes while the Failure Records conditions are being duplicated, an intermittent condition is indicated. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0137 HO2S Circuit Low Voltage Bank 1 Sensor 2

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Install the Tech 2. 2. Run the engine at operating temperature. 3. Operate the vehicle within the parameters specified under Conditions for Setting the DTC criteria included in Diagnostic Support. 4. Using a Tech 2, monitor Bank 1 HO2S 2 voltage. Does the Bank 1 HO2S voltage remain below the specified value? 22 mV Go to Step 4

Go to OBD System Check

Go to Step 3

1. Ignition ON, engine OFF, review and record Tech 2 Failure Records data and note parameters. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor DTC info for DTC P0137 until the DTC P0137 test runs. 4. Note the test result. Does the Tech 2 indicate DTC P0137 failed this ignition? Go to Step 4

Check the Procedure Refer to Diagnostic Aids

1. Turn ignition OFF. 2. Disconnect the PCM. 3. Check the Bank 1 HO2S 2 high and low signal circuits for a short to ground or a short to the heater ground circuit. Were Bank 1 HO2S 2 signal circuits shorted? Go to Step 5 Verify repair Go to Step 6 Repair the Bank 1 HO2S 2 signal circuit. Is the action complete? 1. Ignition OFF. 2. Leave the PCM and HO2S 2 disconnected. 3. Check for continuity between the high and low signal circuits. Was there continuity between the high and low circuits? Go to Step 7 Go to Step 8

5 6

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DTC P0137 HO2S Circuit Low Voltage Bank 1 Sensor 2 (Cont'd)

Step Action Value(s) Yes No

7 8

Repair the short between the high and low circuits. Is the action complete? 1. Ignition OFF. 2. Reconnect the PCM, leave HO2S 2 disconnected. 3. Ignition ON. Does the Tech 2 indicate Bank 1 HO2S 2 voltage near the specified value? 425-475 mV Verify repair Check the Procedure Refer to Diagnostic Aids

Go to Step 9

Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

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Diagnostic Trouble Code (DTC) P0138 HO2S Circuit High Voltage Bank 1 Sensor 2

D06RY00173

Circuit Description
The powertrain control module (PCM) supplies bias voltage of about 450 mV between the heated oxygen sensor (HO2S) signal high and signal low circuits. When measured with a 10 megaohm digital voltmeter, this may display as low as 320 mV. The oxygen sensor varies the voltage within a range of about 1000 mV when exhaust is rich, down through about 10 mV when the exhaust is lean. The PCM constantly monitors the HO2S signal during closed loop operation and compensates for a rich or lean condition by decreasing or increasing injector pulse width as necessary. If the Bank 1 HO2S 2 voltage remains excessively high for an extended period of time, DTC P0138 will be set.

D Bank 1 HO2S 2 signal voltage remains above 500 mV during deceleration fuel cutoff mode operation for up to 3 seconds.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected fault. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0138 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0138 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D No related DTCs. D Engine is operating in closed loop. D Closed loop commanded air/fuel ratio is between 14.5 and 14.8. D Engine coolant temperature is above 60C (140F). D Throttle angle is between 3% and 19%. D Bank 1 HO2S 2 signal voltage remains above 952 mV during normal closed loop operation for a total of 106 seconds over a 125-second period of time. OR

Diagnostic Aids
Check for the following conditions: D Fuel pressure An excessively rich fuel mixture can cause a DTC P0138 to be set. Refer to Fuel System Diagnosis. D Rich injector(s) Perform Injector Balance Test. D Leaking injector Refer to Fuel System Diagnosis.

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D Open HO2S Signal Circuit of Faulty HO2S A poor connection or open in the HO2S signal circuit can cause the DTC to set during deceleration fuel mode. An HO2S which is faulty and not allowing a full voltage swing between the rich and lean thresholds can also cause this condition. Operate the vehicle while monitoring the HO2S voltage with a Tech 2. If the HO2S voltage is limited within a range between 300 mV to 600 mV, check the HO2S signal and wiring and associated terminal connections. D If none of the above conditions are present, replace the affected HO2S.

D Evaporative emissions (EVAP) canister purge Check for fuel saturation. If full of fuel, check the canister control and hoses. Refer to Evaporative Emission (EVAP) Control System. D MAF sensor The system can go rich if the MAF sensor signal indicates an engine airflow measurement that is not correct. Disconnect the MAF sensor to see if the rich condition is corrected. If so, replace the MAF sensor. D Check for a leak in fuel pressure regulator diaphragm by checking the vacuum line to the regulator for the presence of fuel. There should be no fuel in the vacuum line. D TP sensor An intermittent TP sensor output will cause the system to go rich, due to a false indication of the engine accelerating. D Shorted Heated Oxygen Sensor (HO2S) If the HO2S is internally shorted the HO2S voltage displayed on the Tech 2 will be over 1 volt. Try disconnecting the affected HO2S with the key ON, engine OFF. If the displayed HO2S voltage changes from over 1000 mV to around 450 mV, replace the HO2S. Silicon contamination of the HO2S can also cause a high HO2S voltage to be indicated. This condition is indicated by a powdery deposit on the portion of the HO2S exposed to the exhaust stream. If contamination is noticed, replace the affected HO2S.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 3. DTC P0138 being set during deceleration fuel mode operation may indicate a condition described in the Diagnostic Aids above. If the DTC P0138 test passes while the Failure Records conditions are being duplicated, an intermittent condition is indicated. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0138 HO2S Circuit High Voltage Bank 1 Sensor 2

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Install the Tech 2. 2. Run the engine at operating temperature. 3. Operate the vehicle within the parameters specified under Conditions for Setting the DTC criteria included in Diagnostic Support. 4. Using a Tech 2, monitor Bank 1 HO2S 2 voltage. Does the Bank 1 HO2S voltage remain above the specified value?

Go to OBD System Check

952 mV (500 mV in deceleration fuel cutoff mode)

Go to Step 4

Go to Step 3

1. Ignition ON, review and record Tech 2 Failure Records data. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor DTC info for DTC P0138 until the DTC P0138 test runs. 4. Note the test result. Does the Tech 2 indicate DTC P0138 failed this ignition? Go to Step 4

Check the Procedure Refer to Diagnostic Aids

1. 2. 3. 4.

Ignition OFF. Disconnect Bank 1 HO2S 1. Ignition ON. At the HO2S Bank 1 Sensor 2 connector (PCM side), use a DVM to measure voltages at the high and low signal terminals. 3-4 V Go to Step 5 Go to Step 6

Are the voltages above the specified range?

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E181

DTC P0138 HO2S Circuit High Voltage Bank 1 Sensor 2 (Cont'd)

Step Action Value(s) Yes No

5 6

Repair short to voltage in the signal circuit. Is the action complete? 1. Ignition ON, engineOFF. 2. At Bank 1 HO2S 2 connector (PCM side) jumper both the HO2S high and low signal circuits (PCM side) to ground. 3. Using a Tech 2, monitor Bank 1 HO2S 2 voltage. Is Bank 1 HO2S 2 voltage below the specified value? 10 mV Go to Step 7 Check the Procedure Refer to Diagnostic Aids Go to Step 8 1. Disconnect the jumpers to ground from Bank 1 HO2S 2 PCMside connector. 2. With the HO2S 2 connector disconnected, monitor BANK 1 HO2S 2 voltage. Is the Bank 1 HO2S 2 voltage between the specified values? 425-475 mV Verify repair

Go to Step 8

Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

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Diagnostic Trouble Code(DTC) P0140 HO2S Circuit Insufficient Activity Bank 1 Sensor 2

D06RY00173

Circuit Description
To control emissions of hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx), a three-way catalytic converter is used. The catalyst within the converter promotes a chemical reaction which oxidizes the HC and CO present in the exhaust gas, converting them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx, converting it to nitrogen. The powertrain control module (PCM) has the ability to monitor this process using the Bank 1 HO2S 1 and the Bank 1 HO2S 2 heated oxygen sensors. The Bank 1 HO2S 2 sensor produces an output signal which indicates the amount of oxygen present in the exhaust gas entering the three-way catalytic converter. The Bank 1 HO2S 2 sensor produces an output signal which indicates the oxygen storage capacity of the catalyst; this in turn indicates the catalysts ability to convert exhaust gases efficiently. If catalyst is operating efficiently, the Bank 1 HO2S 1 signal will be far more active than that produced by the Bank 1 HO2S 2 sensor. If the Bank 1 HO2S 2 signal voltage remains between 400 mV and 500 mV for an extended period of time, DTC P0140 will be set. Heated oxygen sensors are used to minimize the amount of time required for closed loop fuel control operation and to allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of time required for fuel control sensors Bank 1 HO2S 1 and Bank 2 HO2S 1 to become active. Oxygen sensor heaters are required by post-catalyst monitor sensors to

maintain a sufficiently high temperature for accurate exhaust oxygen content readings further from the engine.

Conditions for Setting the DTC

D D D D D D No related DTCs. Engine coolant temperature is above 60C (140F). The engine has been running for over 5 seconds. Oxygen sensor heater is functioning properly. Engine is operating in closed loop Bank 1 HO2S 2 signal voltage remains between 426 mV and 474 mV for a total of 106 seconds over a 125-second period of time.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected fault. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Cleaning the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0140 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0140 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

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Diagnostic Aids
Check for the following conditions: D Poor connection or damaged harness Inspect the harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness. D Faulty HO2S heater or heater circuitWith the ignitionON, engine OFF, the HO2S voltage displayed on a Tech 2 should gradually drop to below 250 mV. If not, disconnect the HO2S and connect a test light between the HO2S ignition feed and heater ground circuits. If the test light does not light, repair the open ignition feed or sensor ground circuit as necessary. If the test light lights and the HO2S signal and low circuits are OK, replace the HO2S.

D Intermittent testWith the ignition ON, monitor the HO2S signal voltage while moving the wiring harness and related connectors. If the fault is induced, the HO2S signal voltage will change. This may help isolate the location of the malfunction.

Test Description
Number (s) below refer to the step number (s) on the Diagnostic Chart. 3. If the DTC P0140 test passes while the Failure Records conditions are being duplicated, an intermittent condition is indicated. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0140 HO2S Circuit Insufficient Activity BANK 1 SENSOR 2

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Install the Tech 2. 2. Run the engine at operating temperature. 3. Operate the engine above 1200 RPM for two minutes. Does the Tech 2 indicate Bank 1 HO2S 2 voltage varying outside the specified values? 425-475 mV Go to Step 3

Go to OBD System Check

Go to Step 4

1. Ignition ON, engine OFF, review and record Tech 2 Failure Records data and note parameters. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor DTC info for DTC P0140 until the DTC P0140 test runs. 4. Note the test result. Does the Tech 2 indicate DTC P0140 failed this ignition? Go to Step 4 Verify repair

Check the Procedure Refer to Diagnostic Aids Go to Step 5

4 5

Check for a damaged harness. Was a problem found? Check for poor Bank 1 HO2S 2 high and low circuit terminal connections at the Bank 1 HO2S 2 harness connector and replace terminal(s) if necessary. Did any terminals require replacement? Verify repair Go to Step 6 Check for poor Bank 1 HO2S 2 high and low circuit terminal connections at the PCM and replace terminal(s) if necessary. Did any terminals require replacement? Verify repair Go to Step 7 1. Ignition OFF. 2. With the PCM disconnected, check continuity of the Bank 1 HO2S 2 high circuit. 3. If the Bank 1 HO2S 2 high circuit measures over 5.0 ohms, repair open or poor connection as necessary. Was a Bank 1 HO2S 2 high circuit problem found and corrected? Verify repair Go to Step 8

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DTC P0140 HO2S Circuit Insufficient Activity BANK 1 SENSOR 2 (Cont'd)

Step Action Value(s) Yes No

1. Ignition OFF. 2. With the PCM disconnected, check continuity of the Bank 1 HO2S 2 high circuit. 3. If the Bank 1 HO2S 2 low circuit measures over 5.0 ohms, repair open or poor connection as necessary. Was a Bank 1 HO2S 2 low circuit problem found and corrected? Verify repair Go to Step 9

1. Ignition ON, engineOFF. 2. Disconnect Bank 1 HO2S 2 and jumper the HO2S high and low circuits (PCM side) to ground. 3. Using a Tech 2, monitor Bank 1 HO2S 2 voltage. Is Bank 1 HO2S 2 voltage in the specified range? 0-10 mV Go to Step 10 Verify repair Go to Step 11 Replace Bank 1 HO2S 2. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

10 11

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E185

Diagnostic Trouble Code (DTC) P0141 HO2S Heater Circuit Bank 1 Sensor 2

D06RY00173

Circuit Description
Heated oxygen sensors are used to minimize the amount of time required for closed loop fuel control operation and to allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of time required for fuel control sensors Bank 1 HO2S 1 and Bank 2 HO2S 1 to become active. Oxygen sensor heaters are required by post-catalyst monitor sensors to maintain a sufficiently high temperature which allows accurate exhaust oxygen content readings further from the engine. The powertrain control module (PCM) will run the heater test only after a cold start (determined by engine coolant and intake air temperature at the time of start-up) and only once during an ignition cycle. When the engine is started the PCM will monitor the HO2S voltage. When the Bank HO2S voltage indicates a sufficiently active sensor, the PCM looks at how much time has elapsed since start-up. If the PCM determines that too much time was required for the Bank 1 HO2S 2 to become active, a DTC P0141 will set. The time it should take the HO2S to reach operating temperature is based on the total amount of air that has passed through the MAF sensor and into the engine (more total airflow = shorter time to HO2S activity).

D Ignition voltage is between 11 volts and 18 volts. D Bank 1 HO2S 2 voltage does not change more than 150 mV from the bias voltage (between 400 mV500 mV) for a longer amount of time than it should. The maximum amount of time to come up to operating range is 120 seconds. This warm-up time depends on the engine coolant temperature at start-up and accumulated air flow since start-up.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator lamp (MIL) after the second consecutive trip in which the fault is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0141 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0141 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D No related DTCs. D The engine has been running for over 120 seconds.

Diagnostic Aids
Check for the following conditions:

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2. The HO2S should be allowed to cool before performing this test. If the HO2S heater is functioning, the signal voltage will gradually increase or decrease as the sensor element warms. If the heater is not functioning, the HO2S signal will remain near the 450 mV bias voltage. 4. This ensures that the ignition feed circuit to the HO2S is not open or shorted. The test light should be connected to a good chassis ground, in case the HO2S low or HO2S heater ground circuit is faulty. 5. This checks the HO2S heater ground circuit. 6. This checks for an open or shorted HO2S heater element. 11.An open HO2S signal or low circuit can cause the HO2S heater to appear faulty. Check these circuits before replacing the sensor.

D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart.

DTC P0141 HO2S Heater Circuit Bank 1 Sensor 2

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 NOTE: If the engine has just been operating, allow the engine to cool for at least 15 minutes before proceeding. 1. Remove the fuel pump relay. 2. Connect a fused jumper at the fuel pump relay socket, between the battery positive at the relay and the relay wire that leads to the fuel pump and HO2S fuses. 3. Ignition OFF. 4. Install a Tech 2. 5. Ignition ON, engine OFF. 6. Monitor the Bank 1 HO2S 2 voltage for several minutes. Did the HO2S voltage go from bias voltage to above or below the specified values?

Go to OBD System Check

Above 650 mV or below 250 mV

Check the Procedure Refer to Diagnostic Aids Go to Step 15

Go to Step 3 Go to Step 4

3 4

Inspect the fuse for Bank 1 HO2S 2 ignition feed. Is the fuse open? 1. 2. 3. 4. Ignition OFF. Raise the vehicle. Disconnect the Bank 1 HO2S 2 electrical connector. Using a test light connected to a good ground (do not use Bank 1 HO2S 2 heater ground or Bank 1 HO2S 2 low), probe the ignition feed circuit at the Bank 1 HO2S 2 electrical connector (PCM harness side). Go to Step 5 Go to Step 7

Does the test light illuminate? 5 Connect the test light between the Bank 1 HO2S 2 ignition feed and the Bank 1 HO2S 2 heater ground. Does the test light illuminate?

Go to Step 6

Go to Step 8

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E187

DTC P0141 HO2S Heater Circuit Bank 1 Sensor 2 (Cont'd)

Step Action Value(s) Yes No

1. Allow the HO2S to cool for at least 15 minutes. 2. Using a DVM, measure the resistance between the Bank 1 HO2S 2 ignition feed and the Bank 1 HO2S 2 heater ground at the Bank 1 HO2S 2 pigtail. Is the HO2S resistance within the specified values? 3-6 ohms Go to Step 9 Go to Step 10 Repair the open Bank 1 HO2S 2 ignition feed circuit to Bank 1 HO2S 2. Is the action complete? Verify repair Verify repair Repair the open Bank 1 HO2S 2 heater ground circuit. Is the action complete? 1. Check for a poor connection at the Bank 1 HO2S 2 harness terminals. 2. If a poor connection is found, replace the terminals. Was a poor connection found? Verify repair Go to Step 10 1. Ignition OFF. 2. Disconnect the PCM and check the continuity of the Bank 1 HO2S 2 signal circuit and the Bank 1 HO2S 2 low circuit. 3. If the Bank 1 HO2S 2 signal circuit or the HO2S low circuit measures over 5 ohms, repair the open or poor connection as necessary. Was a problem found? Verify repair Go to Step 11 1. Ignition OFF. 2. Disconnect the PCM and check the continuity of the Bank 1 HO2S 1 signal circuit and the Bank 1 HO2S 1 low circuit. 3. If the Bank 1 HO2S 1 high circuit or the HO2S low circuit measures over 5 ohms, repair the open or poor connection as necessary. Was a problem found? Verify repair Go to Step 12 Check for a poor Bank 1 HO2S 2 low circuit terminal connection at the PCM and replace the terminal if necessary. Did the terminal require replacement? Verify repair Go to Step 13 Check for a poor Bank 1 HO2S 2 high circuit terminal connection at the PCM and replace the terminal if necessary. Did the terminal require replacement? Verify repair Verify repair Go to Step 14 Replace Bank 1 HO2S 2. Is the action complete? Locate and repair the short to ground in Bank 1 HO2S 2 ignition feed circuit and replace the faulty fuse. Is the action complete? Verify repair

8 9

10

11

12

13

14 15

6E188

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1

D06RY00175

Circuit Description
The powertrain control module (PCM) supplies a bias voltage of about 450 mV between the heated oxygen sensor (HO2S) signal high and signal low circuits. When measured with a 10 megaohm digital voltmeter, this may display as low as 320 mV. The oxygen sensor varies the voltage within a range of about 1000 mV when the exhaust is rich, down through about 10 mV when exhaust is lean. The PCM constantly monitors the HO2S signal during closed loop operation and compensates for a rich or lean condition by decreasing or increasing injector pulse width as necessary. If the Bank 2 HO2S 1 voltage remains excessively low for an extended period of time, DTC P0151 will be set.

D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data. D Open loop fuel control will be in effect.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0151 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0151 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D D D D No related DTCs. The engine is operating in closed loop. Engine coolant temperature is above 60C (140F). Closed loop commanded air/fuel ratio is between 14.5 and 14.8. D Bank 2 HO2S 1 signal voltage remains below 22 mV during normal closed loop operation for a total of 77 seconds over a 90-second period of time.

Diagnostic Aids
Check for the following conditions: D Heated oxygen sensor wiring The sensor pigtail may be mispositioned and contacting the exhaust system. D Poor PCM to engine block grounds. D Fuel pressure The system will go lean if pressure is too low. The PCM can compensate for some decrease. However, if fuel pressure is too low, a DTC P0151 may be set. Refer to Fuel System Diagnosis. D Lean injector(s) Perform Injector Balance Test. D Vacuum leaks Check for disconnected or damaged vacuum hoses and for vacuum leaks at the intake manifold, throttle body, EGR system, and PCV system.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected fault.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

D Exhaust leaks An exhaust leak may cause outside air to be pulled into the exhaust gas stream past the HO2S, causing the system to appear lean. Check for exhaust leaks that may cause a false lean condition to be indicated. D MAF sensor The system can go lean if the MAF sensor signal indicates an engine airflow measurement that is not correct. Disconnect the MAF sensor to see if the lean condition is corrected. If so, replace the MAF sensor. D Fuel contamination Water, even in small amounts, can be delivered to the fuel injectors. The water can cause a lean exhaust to be indicated. Excessive alcohol in the fuel can also cause this condition. Refer to Fuel System Diagnosis for the procedure to check for fuel contamination.

6E189

D If none of the above conditions are present, replace the affected HO2S.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 3. DTC P0151 failing during operation may indicate a condition described in the Diagnostic Aids above. If the DTC P0151 test passes while the Failure Records conditions are being duplicated, an intermittent condition is indicate. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Install the Tech 2. 2. Run the engine at operating temperature. 3. Operate the vehicle within the parameters specified under Conditions for Setting the DTC criteria included in Diagnostic Support. 4. Using a Tech 2, monitor Bank 2 HO2S 1 voltage. Does the Bank 2 HO2S 1 voltage remain below the specified value? 22 mV Go to Step 4

Go to OBD System Check

Go to Step 3

1. Ignition ON, engine OFF, review and record Tech 2 Failure Records data and note parameters. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor DTC info for DTC P0151 until the DTC P0151 test runs. 4. Note test result. Does the Tech 2 indicate DTC P0151 failed this ignition? Go to Step 4

Check the Procedure Refer to Diagnostic Aids

1. Turn ignition OFF. 2. Disconnect the PCM. 3. Check the Bank 2 HO2S 1 high and low signal circuits for a short to ground or a short to the heater ground circuit. Were Bank 2 HO2S 1 signal circuits shorted? Go to Step 5 Verify repair Go to Step 6 Repair the Bank 2 HO2S 1 signal circuit. Is the action complete? 1. Ignition OFF. 2. Leave the PCM and HO2S 1 disconnected. 3. Check for continuity between the high and low signal circuits. Was there continuity between the high and low circuits? Go to Step 7 Verify repair Go to Step 8 Repair the short between the high and low circuits. Is the action complete?

5 6

6E190

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1 (Cont'd)

Step Action Value(s) Yes No

1. Ignition OFF. 2. Reconnect the PCM, leave HO2S disconnected. 3. Ignition ON. Does the Tech 2 indicate Bank 2 HO2S 1 voltage near the specified value? 425-475 mV

Check the Procedure Refer to Diagnostic Aids

Go to Step 9

Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E191

Diagnostic Trouble Code (DTC) P0152 HO2S Circuit High Voltage Bank 2 Sensor 1

D06RY00175

Circuit Description
The powertrain control module (PCM) supplies a bias voltage of about 450 mV between the heated oxygen sensor (HO2S) signal high and signal low circuits. When measured with a 10 megaohm digital voltmeter, this may display as low as 320 mV. The oxygen sensor varies the voltage within a range of about 1000 mV when the exhaust is rich, down through about 10 mV when exhaust is lean. The PCM constantly monitors the HO2S signal during closed loop operation and compensates for a rich or lean condition by decreasing or increasing the injector pulse width as necessary. If the Bank 2 HO2S 1 voltage remains excessively high for an extended period of time, DTC P0152 will be set.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected fault D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data. D Open loop fuel control will be in effect.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0152 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0152 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D No related DTCs. D The engine is operating in closed loop. D The engine coolant temperature is above 60C (140F). D Bank 2 HO2S 1 signal voltage remains above 952 mV during normal closed loop operation for a total of 77 seconds over a 90-second period. OR D Bank 2 HO2S 1 signal voltage remains above 500 mV during deceleration fuel cutoff mode operation for up to 3 seconds.

Diagnostic Aids
Check for the following conditions: D Fuel pressure The system will go rich if pressure is too high. The PCM can compensate for some increase. However, if fuel pressure is too high, a DTC P0152 may be set. Refer to Fuel System Diagnosis. D Rich injector(s) Perform Injector Balance Test. D Leaking injector Refer to Fuel System Diagnosis. D Evaporative emissions (EVAP) system Check the canister for fuel saturation. If the canister is full of fuel,

6E192

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

cause the DTC to set during deceleration fuel mode. An HO2S which is faulty and not allowing a full voltage switch between the rich and lean thresholds can also cause the condition. Operate the vehicle while monitoring the HO2S voltage with a Tech 2. If the HO2S is limited within a range between 300 mV to 600 mV, check the HO2S signal circuit wiring and associated terminal connections. D If none of the above conditions are present, replace the affected HO2S.

D D D

check EVAP control system components and hoses. Refer to Evaporative Emission (EVAP) Control System. MAF sensor The system can go rich if the MAF sensor signal indicates an engine airflow measurement that is not correct. Disconnect the MAF sensor to see if rich condition is corrected. If so, replace MAF sensor. Check for leaking fuel pressure regulator diaphragm by checking vacuum line to regulator for the presence of fuel. There should be no fuel in the vacuum line. TP sensor An intermittent TP sensor output will cause the system to go rich, due to a false indication of the engine accelerating. Shorted Heated Oxygen Sensor (HO2S) If the HO2S is internally shorted, the HO2S voltage displayed on the Tech 2 will be over 1 volt. Try disconnecting the affected HO2S with the key ON, engine OFF. If the displayed HO2S voltage changes from over 1000 mV to around 450 mV, replace the HO2S. Silicon contamination of the HO2S can cause a high HO2S voltage to be indicated. This condition is indicated by powdery deposit on the portion of the HO2S exposed to the exhaust stream. If contamination is noticed, replace the affected HO2S. Open HO2S Signal Circuit of Faulty HO2S A poor connection or open in the HO2S signal circuit can

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 3. DTC P0152 failing during deceleration fuel cutoff mode operation may indicate a condition described in the Diagnostic Aids above. If the DTC P0152 test passes while the Failure Records conditions are being duplicated, an intermittent condition is indicated. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0152 HO2S Circuit High Voltage Bank 2 Sensor 1

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Install the Tech 2. 2. Engine is at operating temperature. 3. Operate the vehicle within the parameters specified under Conditions for Setting the DTC criteria included in Diagnostic Support. 4. Using a Tech 2, monitor Bank 2 HO2S 1 voltage. Does the Bank 2 HO2S 1 voltage remain above the specified value?

Go to OBD System Check

952 mV (500 mV in deceleration fuel cut-off mode)

Go to Step 4

Go to Step 3

1. Ignition ON. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Records conditions as noted. 4. Using a Tech 2, monitor DTC info for DTC P0152 until the DTC P0152 test runs. 5. Note the test result. Does the Tech 2 indicate DTC P0152 failed this ignition? Go to Step 4

Check the Procedure Refer to Diagnostic Aids

1. 2. 3. 4.

Ignition OFF. Disconnect Bank 2 HO2S 1. Ignition ON. At HO2S Bank 2 Sensor 1 connector (PCM side) use a DVM to measure voltages at the high and low signal terminals. 3-4 V Go to Step 5 Go to Step 6

Are the voltages in the specified range?

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E193

DTC P0152 HO2S Circuit High Voltage Bank 2 Sensor 1 (Cont'd)

Step Action Value(s) Yes No

5 6

Repair short to voltage in signal circuit. Is the action complete? 1. Ignition ON, engineOFF. 2. At Bank 2 HO2S 1 connector (PCM side) jumper both the HO2S high and low signal circuits (PCM side) to ground. 3. Using a Tech 2, monitor Bank 2 HO2S 1 voltage. Is Bank 2 HO2S 1 voltage below the specified value? 10 mV Go to Step 7 Check the Procedure Refer to Diagnostic Aids Go to Step 8 1. Disconnect the jumpers to ground from Bank 2 HO2S 1 PCM-side connector. 2. With the HO2S 1 connector disconnected, monitor Bank 2 HO2S 1 voltage. Is the Bank 2 HO2S 1 voltage between the specified values? 425-475 mV Verify repair

Go to Step 8

Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

6E194

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0153 HO2S Slow Response Bank 2 Sensor 1

D06RY00175

Circuit Description
The powertrain control module (PCM) continuously monitors the heated oxygen sensor (HO2S) activity for 90 seconds after closed loop has been enabled. During the monitoring period the PCM counts the number of times that a rich-to-lean and lean-to-rich response is indicated and adds the amount of time it took to complete all rich-to-lean transitions and lean-to-rich transitions. With this information, an average time for rich-to-lean and lean-to-rich transitions can be determined. If the average response time of either transition is too slow, a DTC P0153 will be set. A lean-to-rich transition is indicated when the HO2S voltage changes from less than 300 mV to greater than 600 mV. A rich-to-lean transition is indicated when the HO2S voltage changes from more than 600 mV to less than 300 mV. An HO2S that responds too slowly is likely to be faulty and should be replaced.

D Mass air flow is between 18 g/second and 42 g/second. D All above conditions are met for 3 seconds. D 90 seconds after closed loop has been enabled, Bank 2 HO2S 1 average transition time between 300 mV and 600 mV is too slow. The lean-to-rich average transition response time was longer than 94 milliseconds or the rich-to-lean average transition response time was longer than 105 milliseconds.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator lamp (MIL) after the second consecutive trip in which the fault is detected. D The PCM will store conditions which were present when the DTC set as Freeze Frame and in the Failure Records data. D Open loop fuel control will be in effect.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0153 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0153 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D No related DTCs. D Engine coolant temperature (ECT) is above 60C (140F). D The engine is operating in closed loop. D Engine has been running for over 60 seconds. D Canister purge duty cycle is above 2%. D Engine speed is between 1500 RPM and 3000 RPM.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E195

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the Bank 2 HO2S 1 display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often

the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. Verifies that the fault is currently present. 3. HO2S transition time, ratio mean volts and switching DTCs set for multiple sensors indicate probable contamination. Before replacing the sensors, isolate and correct the source of the contamination to avoid damaging the replacement sensors.

DTC P0153 HO2S Slow Response Bank 2 Sensor 1

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 NOTE: If any DTCs are set, (except P0133, P1133, P1134, P1153, and/or P1154), refer to those DTCs before proceeding with this diagnostic chart. 1. Install the Tech 2. 2. Idle the engine at operating temperature. 3. Operate the vehicle within parameters specified under Conditions for Setting the DTC criteria included in Diagnostic Support. 4. Using a Tech 2, monitor DTC info for DTC P0153 until the DTC P0153 test runs. 5. Note the test result. Does the Tech 2 indicate DTC P0153 failed this ignition? Go to Step 3 Go to Step 17 Go to Step 5 Go to Step 2

Go to OBD System Check

Check the Procedure Refer to Diagnostic Aids Go to Step 4 Go to Step 6

3 4 5 6

Did the Tech 2 also indicate DTC P0153, P1133, P1134, P1153, and/or P1154 test failed this ignition? Check for leaks at the pipe joints. Are the joints leaking? Tighten the U-bolt nuts at the leaking joint. Is your action complete? Check for gaskets that are damage or improperly installed. Are there damaged or misaligned gaskets?

Go to Step 7

Go to Step 8

1. Replace the damaged gaskets. 2. Align the connections. 3. Tighten the connections. Is your action complete? Go to Step 2 Go to Step 9 Go to Step 2 Go to Step 11 Go to Step 10 Go to Step 12 Check for loose exhaust flange connections. Are the flange connections loose? Tighten the stud nuts or bolts to specifications. Is your action complete? Check for burned or corroded exhaust pipes. Are the exhaust pipes burned or corroded?

8 9 10

6E196

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0153 HO2S Slow Response Bank 2 Sensor 1 (Cont'd)

Step Action Value(s) Yes No

11 12 13

Replace the exhaust pipes, as required. Is your action complete? Check for leaks at the exhaust manifold. Are there leaks at the exhaust manifold? Tighten the bolts to specifications or replace the manifold if necessary. Is your action complete? Go to Step 2 1. Visually/physically inspect the following items: D Ensure that the Bank 2 HO2S 1 is securely installed. D Check for corrosion on terminals. D Check terminal tension (at Bank 2 HO2S 1 and at the PCM). D Check for damaged wiring. Was a problem found in any of the above areas? Go to Step 18 Go to Step 15 1. Disconnect Bank 2 HO2S 1. 2. Ignition ON. 3. Using a DVM at the PCM side of the HO2S 1 connector, measure the voltage between the high signal circuit and ground. Are both voltages in the specified range? 3-4 V Go to Step 16 Go to Step 19 1. With Bank 2 HO2S 1 disconnected, jumper the high and low (PCM side) signal circuits to ground. 2. Ignition ON. 3. Using a Tech 2, monitor the Bank 2 HO2S 1 voltage. Does the Tech 2 indicate less than 10 mV and immediately return to about 450 mV when the jumper is removed? Go to Step 13 Go to Step 14 Go to Step 2

14

15

16

Go to Step 21

Go to Step 22

17

Replace the affected heated oxygen sensors. NOTE: Before replacing the sensors, the cause of the contamination must be determined and corrected. D D D Fuel contamination. Use of improper RV sealant. Engine oil/coolant consumption. Verify repair Verify repair Verify repair Verify repair Go to Step 20

Is the action complete? 18 19 20 Repair condition as necessary. Is the action complete? Check for faulty PCM connections or terminal damage. Is the action complete? Repair open, short or grounded signal circuit. Is the action complete?

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E197

DTC P0153 HO2S Slow Response Bank 2 Sensor 1 (Cont'd)

Step Action Value(s) Yes No

21 22

Replace Bank 2 HO2S 1. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair Verify repair

6E198

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1

D06RY00175

Circuit Description
The powertrain control module (PCM) supplies a bias voltage of about 450 mV between the heated oxygen sensor (HO2S) high and low circuits. When measured with a 10 megaohm digital voltmeter, this may display as low as 320 mV. The oxygen sensor varies the voltage within a range of about 1000 mV when the exhaust is rich, down through about 10 mV when exhaust is lean. The PCM constantly monitors the HO2S signal during closed loop operation and compensates for a rich or lean condition by decreasing or increasing injector pulse width as necessary. If the Bank 2 HO2S 1 voltage remains at or near the 450 mV bias for an extended period of time, DTC P0154 will be set, indicating an open sensor signal or sensor low circuit. Heated oxygen sensors are used to minimize the amount of time required for closed loop fuel control operation and to allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of time required for fuel control sensors Bank 1 HO2S 1 and Bank 2 HO2S 1 to become active. Oxygen sensor heaters are required by post-catalyst monitor sensors to maintain a sufficiently high temperature for accurate exhaust oxygen content readings further from the engine.

D The engine has been running for over 5 seconds. D Oxygen sensor heater is functioning properly. D Bank 2 HO2S 1 signal voltage remains between 400 mV and 500 mV for a total of 77 seconds over a 90-second period of time.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected fault. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data. D Open loop fuel control will be in effect.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0154 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0154 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Diagnostic Aids
Check for the following conditions: D Poor connection or damaged harness Inspect the harness connectors for backed-out terminals,

Conditions for Setting the DTC

D No related DTCs. D Engine coolant temperature is above 60C (140F).

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire-connection, and damaged harness. D Faulty HO2S heater or heater circuit With the ignition ON, engine OFF, the HO2S 1 voltage displayed on the Tech 2 is normally 455-460 mV. A reading over 1000 mV indicates a signal line shorted to voltage. A reading under 5 mV indicates a signal line shorted to ground or signal lines shorted together. If not, disconnect the HO2S and connect a test light between the HO2S ignition feed and heater ground circuits. If the test light does not light for 2 seconds when the ignition is turned on, repair the open ignition feed or sensor ground circuit as necessary. If the test light lights and the HO2S signal and low circuits are OK, replace the HO2S. D Intermittent test With the ignition ON, monitor the HO2S signal voltage while moving the wiring harness

6E199

and related connectors. If the fault is induced, the HO2S signal voltage will change. This may help isolate the location of the malfunction.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 3. If the DTC P0154 test passes while the Failure Records conditions are being duplicated, an intermittent condition is indicated. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Install the Tech 2. 2. Run the engine at operating temperature. 3. Operate the engine above 1200 RPM for two minutes. Does the Tech 2 indicate Bank 2 HO2S 1 voltage varying outside the specified values? 400-500 mV Go to Step 3

Go to OBD System Check

Go to Step 4

1. Ignition ON, engine OFF. 2. Review and record Tech 2 Failure Records data and note parameters. 3. Operate the vehicle within Failure Records conditions as noted. 4. Using a Tech 2, monitor DTC info for DTC P0154 until the DTC P0154 test runs. 5. Note the test result. Does the Tech 2 indicate DTC P0154 failed this ignition? Go to Step 4 Verify repair

Check the Procedure Refer to Diagnostic Aids Go to Step 5

4 5

Check for a damaged harness. Was a problem found? Check for a poor Bank 2 HO2S 1 high and low circuit terminal connections at the Bank 2 HO2S 1 harness connector and replace terminal(s) if necessary. Did any terminals require replacement? Verify repair Go to Step 6 Check for a poor Bank 2 HO2S 1 high and low circuit terminal connections at the PCM and replace terminal(s) if necessary. Did the terminal require replacement? Verify repair Go to Step 7

6E200

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1 (Cont'd)

Step Action Value(s) Yes No

1. Ignition OFF. 2. With the PCM disconnected, check continuity of the Bank 2 HO2S 1 high circuit. 3. If the Bank 2 HO2S 1 high circuit measures over 5.0 ohms, repair open or poor connection as necessary. Was a Bank 2 HO2S 1 high circuit problem found and corrected? Verify repair Go to Step 8

1. Ignition OFF. 2. With the PCM disconnected, check continuity of the Bank 2 HO2S 1 low circuit. 3. If the Bank 2 HO2S 1 low circuit measures over 5.0 ohms, repair open or poor connection as necessary. Was a Bank 2 HO2S 1 low circuit problem found and corrected? Verify repair Go to Step 9

1. Ignition ON, engine OFF. 2. Disconnect Bank 2 HO2S 1 and jumper the HO2S high and low circuits (PCM side) to ground. 3. Using a Tech 2, monitor Bank 2 HO2S 1 voltage. Is the Bank 2 HO2S 1 voltage in the specified range? 0-10 mV Go to Step 10 Verify repair Go to Step 11 Replace Bank 2 HO2S 1. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

10 11

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E201

Diagnostic Trouble Code (DTC) P0155 HO2S Heater Circuit Open Bank 2 Sensor 1

D06RY00175

Circuit Description
Heated oxygen sensors are used to minimize the amount of time required for closed loop fuel control operation and to allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of time required for fuel control sensors Bank 1 HO2S 1 and Bank 2 HO2S 1 to become active. Oxygen sensor heaters are required by post-catalyst monitor sensors to maintain a sufficiently high temperature which allows accurate exhaust oxygen content readings further from the engine. The powertrain control module (PCM) will run the heater test only after a cold start (determined by engine coolant and intake air temperature at the time of start-up) and only once during an ignition cycle. When the engine is started the PCM will monitor the HO2S voltage. When the Bank HO2S voltage indicates a sufficiently active sensor, the PCM looks at how much time has elapsed since start-up. If the PCM determines that too much time was required for the Bank 2 HO2S 1 to become active, a DTC P0155 will set. The time it should take the HO2S to reach operating temperature is based on the total amount of air that has passed through the mass air flow (MAF) sensor and into the engine (more total air flow = shorter time to HO2S activity).

D Ignition voltage is between 11 volts and 18 volts. D Heater signal is below 0.1A. D Bank 1 HO2S 2 voltage does not change more than 150 mV from the bias voltage (between 400 mV-500 mV) for a longer amount of time than it should. The maximum amount of time to come up to operating range is 120 seconds. This warm-up time depends on the engine coolant temperature at start-up and accumulated air flow since start-up.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator lamp (MIL) after the second consecutive trip in which the fault is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0155 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0155 can be cleared by using the Tech 2 Clear info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D No related DTCs. D The engine has been running for over 120 seconds.

6E202

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

2. The HO2S should be allowed to cool before performing this test. If the HO2S heater is functioning, the signal voltage will gradually increase or decrease as the sensor element warms. If the heater is not functioning, the HO2S signal will remain near the 450 mV bias voltage. 4. Ensures that the ignition feed circuit to the HO2S is not open or shorted. The test light should be connected to a good chassis ground, in case the HO2S low or HO2S heater ground circuit is faulty. 5. Checks the HO2S heater ground circuit. 6. Checks for an open or shorted HO2S heater element. 10.An open HO2S signal or low circuit can cause the HO2S heater to appear faulty. Check these circuits before replacing the sensor.

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart.

DTC P0155 HO2S Heater Circuit Open Bank 2 Sensor 1

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 NOTE: If the engine has just been operating, allow the engine to cool for at least 15 minutes before proceeding. 1. Remove the fuel pump relay. 2. Connect a fused jumper at the fuel pump relay socket, between the battery positive at the relay and the relay wire that leads to the fuel pump and HO2S fuses. 3. Ignition OFF. 4. Install a Tech 2. 5. Ignition ON, engine OFF. 6. Monitor the Bank 1 HO2S 1 voltage for several minutes. Did the HO2S voltage go from bias voltage to above or below the specified value?

Go to OBD System Check

Above 650 mV or below 250 mV

Check the Procedure Refer to Diagnostic Aids Go to Step 15

Go to Step 3 Go to Step 4

3 4

Inspect the fuse for the Bank 2 HO2S 1 ignition feed. Is the fuse open? 1. 2. 3. 4. Ignition OFF. Raise the vehicle. Disconnect the Bank 2 HO2S 1 electrical connector. Using a test light connected to a known good ground (do not use Bank 2 HO2S 1 heater ground or Bank 2 HO2S 1 low), probe the ignition feed circuit at the Bank 2 HO2S 1 electrical connector (PCM harness side). Go to Step 5 Go to Step 7

Does the test light illuminate? 5 Connect the test light between Bank 2 HO2S 1 ignition feed and Bank 2 HO2S 1 heater ground. Does the test light illuminate?

Go to Step 6

Go to Step 8

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E203

DTC P0155 HO2S Heater Circuit Open Bank 2 Sensor 1 (Cont'd)

Step Action Value(s) Yes No

1. Allow the HO2S to cool for at least 15 minutes. 2. Using a DVM, measure resistance between the Bank 2 HO2S 1 ignition feed and the Bank 2 HO2S 1 heater ground at the Bank 2 HO2S 1 pigtail. Is the HO2S resistance within the specified values? 3-6 ohms Go to Step 9 Go to Step 10 Repair the open Bank 2 HO2S 1 ignition feed circuit to Bank 2 HO2S 1. Is the action complete? Verify repair Verify repair Repair the open Bank 2 HO2S 1 heater ground circuit. Is the action complete? 1. Check for a poor connection at the Bank 2 HO2S 1 harness terminals. 2. If a poor connection is found, replace terminals. Was a poor connection found? Verify repair Go to Step 10 Check for a poor Bank 2 HO2S 1 signal or low circuit terminal connection at the Bank 2 HO2S 1 harness connector and replace terminal(s) if necessary. Did any terminals require replacement? Verify repair Go to Step 11 1. Ignition OFF. 2. Disconnect the PCM and check the continuity of the Bank 2 HO2S 1 signal circuit and the Bank 2 HO2S 1 low circuit. 3. If the Bank 2 HO2S 1 signal circuit or HO2S low circuit measures over 5 ohms, repair open or poor connection as necessary. Was a problem found? Verify repair Go to Step 12 Check for a poor Bank 2 HO2S 1 low circuit terminal connection at the PCM and replace the terminal if necessary. Did the terminal require replacement? Verify repair Go to Step 13 Check for a poor Bank 2 HO2S 1 signal circuit terminal connection at the PCM and replace the terminal if necessary. Did the terminal require replacement? Verify repair Verify repair Go to Step 14 Replace Bank 2 HO2S 1. Is the action complete? Locate and repair short to ground in Bank 2 HO2S 1 ignition feed circuit and replace the faulty fuse. Is the action complete? Verify repair

8 9

10

11

12

13

14 15

6E204

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0157 HO2S Circuit Low Voltage Bank 2 Sensor 2

D06RY00177

Circuit Description
To control emissions of hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx), a three-way catalytic converter is used. The catalyst within the converter promotes a chemical reaction which oxidizes the HC and CO present in the exhaust gas, converting them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx, converting it to nitrogen. The powertrain control module (PCM) has the ability to monitor this process using the Bank 2 HO2S 1 and the Bank 2 HO2S 2 heated oxygen sensors. The Bank 2 HO2S 1 sensor produces an output signal which indicates the amount of oxygen present in the exhaust gas entering the three-way catalytic converter. The Bank 2 HO2S 2 sensor produces an output signal which indicates the oxygen storage capacity of the catalyst; this in turn indicates the catalysts ability to convert exhaust gases efficiently. If the catalyst is operating efficiently, the Bank 2 HO2S 1 signal will be far more active than that produced by the Bank 2 HO2S 2 sensor. If the Bank 2 HO2S 2 signal voltage remains excessively low for an extended period of time, DTC P0157 will be set.

D Closed loop commanded air/fuel ratio is between 14.5 and 14.8 D Bank 2 HO2S 2 signal voltage remains below 22 mV during normal closed loop operation for a total of 106 seconds over a 125-second period of time. OR D Bank 2 HO2S 2 signal voltage remains below 400 mV during power enrichment mode fuel control operation for up to 5 seconds.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected fault. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0157 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0157 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D No related DTCs. D The engine is operating in closed loop. D Engine coolant temperature is above 60C (140F).

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E205

Diagnostic Aids
Check for the following conditions: D Heated oxygen sensor wiring The sensor pigtail may be mispositioned and contacting the exhaust system. D Poor PCM to engine grounds. D Fuel pressure A condition which causes a lean exhaust can cause DTC P0157 to set. The system will go lean if pressure is too low. The PCM can compensate for some decrease. However, if fuel pressure is too low, a DTC P0157 may be set. Refer to Fuel System Diagnosis. D Lean injector(s) Perform Injector Balance Test. D Vacuum leaks Check for disconnected or damaged vacuum hoses and for vacuum leaks at the intake manifold, throttle body, EGR system, and PCV system. D Exhaust leaks An exhaust leak may cause outside air to be pulled into the exhaust gas stream past the HO2S, causing the DTC P0157 to set. Check for exhaust leaks near the Bank 1 HO2S 2 sensor. D MAF sensor The system can go lean if the MAF sensor signal indicates an engine airflow

measurement that is not correct. Disconnect the MAF sensor to see if the condition is corrected. If so, replace the MAF sensor. D Fuel contamination Water, even in small amounts, can be delivered to the fuel injectors. The water can cause a lean exhaust to be indicated. Excessive alcohol in the fuel can also cause this condition. Refer to Fuel System Diagnosis for the procedure to check for fuel contamination. D If none of above conditions are present, replace the affected HO2S 2.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 3. DTC P0157 failing during operation may indicate a condition described in the Diagnostic Aids above. If the DTC P0157 test passes while the Failure Records conditions are being duplicated, an intermittent condition is indicated.

DTC P0157 HO2S Circuit Low Voltage Bank 2 Sensor 2

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Install the Tech 2. 2. Run the engine at operating temperature. 3. Operate the vehicle within the parameters specified under Conditions for Setting the DTC criteria included in Diagnostic Support. 4. Using a Tech 2, monitor Bank 2 HO2S 2 voltage. Does the Bank 2 HO2S 2 voltage remain below the specified value? 22 mV Go to Step 4

Go to OBD System Check

Go to Step 3

1. Ignition ON, engine OFF. 2. Review and record Tech 2 Failure Records data and note parameters. 3. Operate the vehicle within Failure Records conditions as noted. 4. Using a Tech 2, monitor DTC info for DTC P0157 until the DTC P0157 test runs. 5. Note the test result. Does the Tech 2 indicate DTC P0157 failed this ignition? Go to Step 4

Check the Procedure Refer to Diagnostic Aids

1. Turn the ignition OFF. 2. Disconnect the PCM. 3. Check the Bank 2 HO2S 2 high and low signal circuits for a short to ground or a short to the heater ground circuit. Were Bank 2 HO2S 2 signal circuits shorted? Go to Step 5 Verify repair Go to Step 6 Repair the Bank 1 HO2S 2 signal circuit. Is the action complete?

6E206

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0157 HO2S Circuit Low Voltage Bank 2 Sensor 2 (Cont'd)

Step Action Value(s) Yes No

1. Ignition OFF. 2. Leave the PCM and HO2S 2 disconnected. 3. Check for continuity between the high and low signal circuits. Was there continuity between the high and low circuits? Go to Step 7 Verify repair Check the Procedure Refer to Diagnostic Aids Go to Step 8 Repair the short between the high and low circuits. Is the action complete? 1. Ignition OFF. 2. Reconnect the PCM, leave HO2S 2 disconnected. 3. Ignition ON. Does the Tech 2 indicate Bank 2 HO2S 2 voltage near the specified value? 425-475 mV

7 8

Go to Step 9

Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to the latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E207

Diagnostic Trouble Code (DTC) P0158 HO2S Circuit High Voltage Bank 2 Sensor 2

D06RY00177

Circuit Description
To control emissions of hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx), a three-way catalytic converter is used. The catalyst within the converter promotes a chemical reaction which oxidizes the HC and CO present in the exhaust gas, converting them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx, converting it to nitrogen. The powertrain control module (PCM) has the ability to monitor this process using the Bank 2 HO2S 1 and the Bank 2 HO2S 2 heated oxygen sensors. The Bank 2 HO2S 1 sensor produces an output signal which indicates the amount of oxygen present in the exhaust gas entering the three-way catalytic converter. The Bank 2 HO2S 2 sensor produces an output signal which indicates the oxygen storage capacity of the catalyst; this in turn indicates the catalysts ability to convert exhaust gases efficiently. If the catalyst is operating efficiently, the Bank 2 HO2S 1 signal will be far more active than that produced by the Bank 2 HO2S 2 sensor. If the Bank 2 HO2S 2 signal voltage remains excessively high for an extended period of time, DTC P0158 will be set.

D Engine coolant temperature is above 60C (140F). D Bank 2 HO2S 2 signal voltage remains above 952 mV during normal closed loop operation for a total of 106 seconds over a 125-second period. OR D Bank 2 HO2S 2 signal voltage remains above 500 mV during deceleration fuel cutoff mode operation for up to 3 seconds.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected fault. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0158 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0158 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D No related DTCs. D Engine is operating in closed loop. D Closed loop commanded air/fuel ratio is between 14.5 and 14.8.

6E208

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

indicated by a powdery deposit on the portion of the HO2S exposed to the exhaust stream. If contamination is noticed, replace the affected HO2S. D Open HO2S signal or low circuit, or faulty HO2S A poor connection or open in the HO2S signal or low circuit can cause the DTC to set during deceleration fuel cutoff mode operation. An HO2S which is faulty and does not allow full voltage swing between the rich and lean thresholds can also cause this condition. Operate the vehicle while monitoring the HO2S voltage with a Tech 2. If the HO2S voltage is limited within a range between 300 mV to 600 mV, check the HO2S signal and low circuit wiring and associated terminal connections. If the wiring and connections are OK, replace the HO2S. D If none of above conditions are present, replace the affected HO2S.

Diagnostic Aids
Check for the following conditions: D Fuel pressure An excessively rich fuel mixture can cause a DTC P0158 to be set. Refer to Fuel System Diagnosis. D Rich injector(s) Perform Injector Balance Test. D Leaking injector Refer to Fuel System Diagnosis. D Evaporative emissions (EVAP) canister purge Check for fuel saturation. If full of fuel, check canister control and hoses. Refer to Evaporative Emission (EVAP) Control System. D MAF sensor The system can go rich if the MAF sensor signal indicates an engine airflow measurement that is not correct. Disconnect the MAF sensor to see if a rich condition is corrected. If so, replace the MAF sensor. D Check for a leaking fuel pressure regulator diaphragm by checking the vacuum line to the regulator for the presence of fuel. There should be no fuel in the vacuum line. D TP sensor An intermittent TP sensor output will cause the system to go rich, due to a false indication of the engine accelerating. D Shorted Heated Oxygen Sensor (HO2S) If the HO2S is internally shorted, the HO2S voltage displayed on the Tech 2 will be over 1 volt. Try disconnecting the affected HO2S with the key ON, engine OFF. If the displayed HO2S voltage changes from over 1000 mV to around 450 mV, replace the HO2S. Silicon contamination of the HO2S can also cause a high HO2S voltage to be indicated. This condition is

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 3. DTC P0158 being set during deceleration fuel cutoff mode operation may indicate a condition described in the Diagnostic Aids above. If the DTC P0158 test passes while the Failure Records conditions are being duplicated, an intermittent condition is indicated. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0158 HO2S Circuit High Voltage Bank 2 Sensor 2

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Install the Tech 2. 2. Run the engine at operating temperature. 3. Operate the vehicle within parameters specified under Conditions for Setting the DTC criteria included in Diagnostic Support. 4. Using a Tech 2, monitor Bank 2 HO2S 2 voltage. Does the Bank 2 HO2S 2 voltage remain above the specified value?

Go to OBD System Check

952 mV (500 mV in deceleration fuel cut-out mode)

Go to Step 4

Go to Step 3

1. Ignition ON. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Records conditions as noted. 4. Using a Tech 2, monitor DTC info for DTC P0158 until the DTC P0158 test runs. 5. Note the test result. Does the Tech 2 indicate DTC P0158 failed this ignition? Go to Step 4

Check the Procedure Refer to Diagnostic Aids

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E209

DTC P0158 HO2S Circuit High Voltage Bank 2 Sensor 2 (Cont'd)

Step Action Value(s) Yes No

1. 2. 3. 4.

Ignition OFF. Disconnect Bank 2 HO2S 2. Ignition ON. At the HO2S Bank 2 Sensor 2 connector (PCM side), use a DVM to measure voltages at the high and low signal terminals. 3-4 V Go to Step 5 Verify repair Go to Step 6

Are the voltages in the specified range? 5 6 Repair short to voltage in signal circuit. Is the action complete? 1. Ignition ON, engine OFF. 2. At Bank 2 HO2S 2 connector (PCM side) jumper both the HO2S high and low signal circuits (PCM side) to ground. 3. Using a Tech 2, monitor Bank 2 HO2S 2 voltage. Is Bank 2 HO2S 2 voltage below the specified value? 7 1. Disconnect the jumpers to ground from Bank 2 HO2S 2 PCM-side connector. 2. With the HO2S 2 connector disconnected, monitor Bank 2 HO2S 2 voltage. Is Bank 2 HO2S 2 voltage between the specified values? 8 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to the latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?

10 mV

Go to Step 7 Check the Procedure Refer to Diagnostic Aids

Go to Step 8

425-475 mV

Go to Step 8

Verify repair

6E210

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0160 HO2S Circuit Insufficient Activity Bank 2 Sensor 2

D06RY00177

Circuit Description
To control emissions of hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx), a three-way catalytic converter is used. The catalyst within the converter promotes a chemical reaction which oxidizes the HC and CO present in the exhaust gas, converting them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx, converting it to nitrogen. The powertrain control module (PCM) has the ability to monitor this process using the Bank 2 HO2S 1 and the Bank 2 HO2S 2 heated oxygen sensors. The Bank 2 HO2S 1 sensor produces an output signal which indicates the amount of oxygen present in the exhaust gas entering the three-way catalytic converter. The Bank 2 HO2S 2 sensor produces an output signal which indicates the oxygen storage capacity of the catalyst; this in turn indicates the catalysts ability to convert exhaust gases efficiently. If the catalyst is operating efficiently, the Bank 2 HO2S 1 signal will be far more active than that produced by the Bank 2 HO2S 2 sensor. If the Bank 2 HO2S 2 signal voltage remains between 400 mV and 500 mV for an extended period of time, DTC P0160 will be set. Heated Oxygen sensors are used to minimize the amount of time required for closed loop fuel control operation and allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of time required for fuel control sensors Bank 1 HO2S 1 and Bank

2 HO2S 1 to become active. Oxygen sensor heaters are required by post-catalyst monitor sensors to maintain a sufficiently high temperature for accurate exhaust oxygen content readings further from the engine.

Conditions for Setting the DTC

D D D D D D No related DTCs. Battery voltage is above 10 volts. The engine has been running for over 5 seconds. Oxygen sensor heater is functioning properly. Engine is in closed loop operation. Bank 2 HO2S 2 signal voltage remains between 426 mV and 474 mV for a total of 106 seconds over a 125-second period of time.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected fault. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0160 will clear after 40 consecutive warm-up cycles have occurred without a fault.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

D DTC P0160 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

6E211

Diagnostic Aids
Check for the following conditions: D Poor connection or damaged harness Inspect the harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness. D Faulty HO2S heater or heater circuit With the ignition ON, engine OFF, the HO2S voltage displayed on a Tech 2 should gradually drop to below 250 mV. If not, disconnect the HO2S and connect a test light between the HO2S ignition feed and heater ground circuits. If the test light does not light, repair the open ignition feed or sensor ground circuit as necessary. If the test light lights and the HO2S signal and low circuits are OK, replace the HO2S.

D Intermittent test With the ignition ON, monitor the HO2S signal voltage while moving the wiring harness and related connectors. If the fault is induced, the HO2S signal voltage will change. This may help isolate the location of the malfunction.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 3. If the DTC P0160 test passes while the Failure Records conditions are being duplicated, an intermittent condition is indicated. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0160 HO2S Circuit Insufficient Activity Bank 2 Sensor 2

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Install the Tech 2. 2. Run the engine at operating temperature. 3. Operate the engine above 1200 RPM for two minutes. Does the Tech 2 indicate Bank 2 HO2S 2 voltage varying outside the specified values? 425-475 mV Go to Step 3

Go to OBD System Check

Go to Step 4

1. Ignition ON, engine OFF, review and record Tech 2 Failure Records data and note parameters. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor DTC info for DTC P0160 until the DTC P0160 test runs. 4. Note the test result. Does the Tech 2 indicate DTC P0160 failed this ignition? Go to Step 4 Verify repair

Check the Procedure Refer to Diagnostic Aids Go to Step 5

4 5

Check for a damaged harness. Was problem found? Check for poor Bank 2 HO2S 2 high and low circuit terminal connections at the Bank 2 HO2S 2 harness connector and replace terminal(s) if necessary. Did either terminal require replacement? Verify repair Go to Step 6 Check for poor Bank 2 HO2S 2 high and low circuit terminal connections at the PCM and replace terminals if necessary. Did any terminals require replacement? Verify repair Go to Step 7

6E212

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0160 HO2S Circuit Insufficient Activity Bank 2 Sensor 2 (Cont'd)

Step Action Value(s) Yes No

1. Ignition OFF. 2. With the PCM disconnected, check continuity of the Bank 2 HO2S 2 high circuit. 3. If the Bank 2 HO2S 2 high circuit measures over 5.0 ohms, repair open or poor connections as necessary. Was a Bank 2 HO2S 2 high circuit problem found and corrected? Verify repair Go to Step 8

1. Ignition OFF. 2. With the PCM disconnected, check continuity of the Bank 2 HO2S 2 low circuit. 3. If the Bank 2 HO2S 2 low circuit measures over 5 ohms, repair open or poor connections as necessary. Was a Bank 2 HO2S 2 low circuit problem found and corrected? Verify repair Go to Step 9

1. Ignition ON, engine OFF. 2. Disconnect Bank 2 HO2S 2 and jumper the HO2S high and low circuits (PCM side) to ground. 3. Using a Tech 2, monitor Bank 2 HO2S 2 voltage. Is Bank 2 HO2S 2 voltage in the specified range? 0-10 mV Go to Step 10 Verify repair Go to Step 11 Replace Bank 2 HO2S 2. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to the latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

10 11

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E213

Diagnostic Trouble Code (DTC) P0161 HO2S Heater Circuit Bank 2 Sensor 2

D06RY00177

Circuit Description
Heated oxygen sensors are used to minimize the amount of time required for closed loop fuel control operation and to allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of time required for fuel control sensors Bank 1 HO2S 1 and Bank 2 HO2S 1 to become active. Oxygen sensor heaters are required by post-catalyst monitor sensors to maintain a sufficiently high temperature which allows accurate exhaust oxygen content readings further from the engine. The powertrain control module (PCM) will run the heater test only after a cold start (determined by engine coolant and intake air temperature at the time of start-up) and only once during an ignition cycle. When the engine is started, the PCM will monitor the HO2S voltage. When the Bank 2 HO2S 2 voltage indicates a sufficiently active sensor, the PCM looks at how much time has elapsed since start-up. If the PCM determines that too much time was required for the Bank 2 HO2S 2 to become active, a DTC P0161 will set. The time it should take the HO2S to reach operating temperature is based on the total amount of air that has passed through the MAF sensor and into the engine (more total air flow = shorter time to HO2S activity).

D Ignition voltage is between 11 volts and 18 volts. D Average mass air flow for the sample period is less than 23 g/second. D Bank 2 HO2S 2 voltage does not change more than 150 mV from the bias voltage (between 400 mV-500 mV) for a longer amount of time than it should. The maximum amount of time to come up to operating range is 120 seconds. This warm-up time depends on the engine coolant temperature at start-up and accumulated air flow since start-up.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator lamp (MIL) after the second consecutive trip in which the fault is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0161 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0161 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D No related DTCs. D The engine has been running for over 120 seconds.

6E214

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

2. The HO2S should be allowed to cool before performing this test. If the HO2S heater is functioning, the signal voltage will gradually increase or decrease as the sensor element warms. If the heater is not functioning, the HO2S signal will remain near the 450 mV bias voltage. 4. This ensures that the ignition feed circuit to the HO2S is not open or shorted. The test light should be connected to a good chassis ground, in case the HO2S low or HO2S heater ground circuit is faulty. 5. This checks the HO2S heater ground circuit. 6. This checks for an open or shorted HO2S heater element. 11.An open HO2S signal or low circuit can cause the HO2S heater to appear faulty. Check these circuits before replacing the sensor.

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart.

DTC P0161 HO2S Heater Circuit Bank 2 Sensor 2

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 NOTE: If the engine has just been operating, allow the engine to cool for at least 15 minutes before proceeding. 1. Remove the fuel pump relay. 2. Connect a fused jumper at the fuel pump relay socket, between the battery positive at the relay and the relay wire that leads to the fuel pump and HO2S fuses. 3. Ignition OFF. 4. Install a Tech 2. 5. Ignition ON, engine OFF. 6. Monitor the Bank 2 HO2S 2 voltage for several minutes. Did the HO2S voltage go from bias voltage to above or below the specified values?

Go to OBD System Check

Above 650 mV or Below 250 mV

Check the Procedure Refer to Diagnostic Aids Go to Step 15

Go to Step 3 Go to Step 4

3 4

Inspect the fuse for the Bank 2 HO2S 2 ignition feed. Is the fuse open? 1. 2. 3. 4. Ignition OFF. Raise the vehicle. Disconnect the Bank 2 HO2S 2 electrical connector. Using a test light connected to a known good ground (do not use Bank 2 HO2S 2 heater ground or Bank 2 HO2S 2 low), probe the ignition feed circuit at the Bank 2 HO2S 2 electrical connector (PCM harness side). Go to Step 5 Go to Step 7

Does the test light illuminate? 5 Connect the test light between the Bank 2 HO2S 2 ignition feed and the Bank 2 HO2S 2 heater ground. Does the test light illuminate?

Go to Step 6

Go to Step 8

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E215

DTC P0161 HO2S Heater Circuit Bank 2 Sensor 2 (Cont'd)

Step Action Value(s) Yes No

1. Allow the HO2S to cool for at least 15 minutes. 2. Using a DVM, measure resistance between the Bank 2 HO2S 2 ignition feed and the Bank 2 HO2S 2 heater ground at the Bank 2 HO2S 2 pigtail. Is the HO2S resistance within the specified values? 3-6 ohms Go to Step 9 Go to Step 10 Repair the open Bank 2 HO2S 2 ignition feed circuit to Bank 2 HO2S 2. Is the action complete? Verify repair Verify repair Repair the open Bank 2 HO2S 2 heater ground circuit. Is the action complete? 1. Check for a poor connection at the Bank 2 HO2S 2 harness terminals. 2. If a poor connection is found, replace the terminals. Was a poor connection found? Verify repair Go to Step 10 1. Ignition OFF. 2. Disconnect the PCM and check the continuity of the Bank 2 HO2S 2 signal circuit and the Bank 2 HO2S 2 low circuit. 3. If the Bank 2 HO2S 2 signal circuit or HO2S low circuit measures over 5 ohms, repair the open or poor connection as necessary. Was a problem found? Verify repair Go to Step 11 1. Ignition OFF. 2. Disconnect the PCM and check the continuity of the Bank 2 HO2S 2 signal circuit and the Bank 2 HO2S 2 low circuit. 3. If the Bank 2 HO2S 2 signal circuit or HO2S low circuit measures over 5 ohms, repair the open or poor connection as necessary. Was a problem found? Verify repair Go to Step 12 Check for a poor Bank 2 HO2S 2 low circuit terminal connection at the PCM and replace the terminal if necessary. Did the terminal require replacement? Verify repair Go to Step 13 Check for a poor Bank 2 HO2S 2 high circuit terminal connection at the PCM and replace the terminal if necessary. Did the terminal require replacement? Verify repair Verify repair Go to Step 14 Replace Bank 2 HO2S 2. Is the action complete? Locate and repair the short to ground in the Bank 2 HO2S 2 ignition feed circuit and replace the faulty fuse. Is the action complete? Verify repair

8 9

10

11

12

13

14 15

6E216

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0171 Fuel Trim System Lean Bank 1

D06R200010

Circuit Description
To provide the best possible combination of driveability, fuel economy, and emission control, a closed loop air/fuel metering system is used. While in closed loop, the powertrain control module (PCM) monitors the Bank 1 HO2S 1 and Bank 2 HO2S 1 signals and adjusts fuel delivery based upon the HO2S signal voltages. A change made to fuel delivery will be indicated by the long and short term fuel trim values which can be monitored with a Tech 2. Ideal fuel trim values are around 0%; if the HO2S signals are indicating a lean condition the PCM will add fuel, resulting in fuel trim values above 0%. If a rich condition is detected, the fuel trim values will be below 0%, indicating that the PCM is reducing the amount of fuel delivered. If an excessively lean condition is detected on Bank 1, the PCM will set DTC P0171. The PCMs maximum authority to control long term fuel trim allows a range between 15% (automatic transmission) or 12% (manual transmission) and +20%. The PCM monitors fuel trim under various engine speed/load fuel trim cells before determining the status of the fuel trim diagnostic.

D Engine coolant temperature is between 6C (42.8F) and 105C (221F). D Intake air temperature is between 40C (40F) and 120C (248F). D Manifold absolute pressure is between 24 kPa and 99 kPa. D Throttle angle is steady below 95%. D Vehicle speed is below 136 km/h (85 mph). D Engine speed is between 400 and 6,000 RPM. D Barometric pressure is greater than 72.5 kPa. D Mass air flow is between 2 g/second and 200 g/second. D Ignition voltage is above 9.5 volts. D Fuel system is in closed loop. D Canister purge duty cycle is greater than 0% if on.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator lamp (MIL) after the second consecutive trip in which the fault is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Setting the DTC

D None of the following: EGR DTCs, HO2S DTCs, (response, transition, open, low volts, no activity), MAF DTCs, TP sensor DTCs, MAP DTCs, IAT DTCs, canister purge DTCs, EVAP DTCs, injector circuit DTCs, or misfire DTCs.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0171 will clear after 40 consecutive warm-up cycles have occurred without a fault.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

D DTC P0171 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

6E217

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the Bank 1 HO2S 1 display on the Tech 2 while moving connectors and wiring harnesses related to the engine harness. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. DTCs other than P0171 and P0174 may indicate a condition present which may cause a lean condition. If this is the case, repairing the condition which caused the other DTC will most likely correct the DTC P0171/P0174. 4. If the DTC P0171 test passes while the Failure Records conditions are being duplicated, the lean condition is intermittent. Refer to Diagnostic Aids or Symptoms for additional information on diagnosing intermittent problems.

6E218

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0171 Fuel Trim System Lean Bank 1

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Go to the applicable DTC charts and repair the other DTCs before proceeding with this chart Are any DTCs set other than P0171 and P0174?

Go to OBD System Check

3 1. Start the engine and operate the vehicle in closed loop. 2. Observe the BANK 1 L.T. FUEL TRIM display on the Tech 2. Is the displayed value greater than the specified value? 4 1. Review and record the Tech 2 Failure Records data. 2. Clear the DTC P0171/P0174 and operate the vehicle to duplicate the Failure Records conditions. 3. Monitor the Tech 2 DTC info for DTC P0171 while operating the vehicle to duplicate the Failure Records conditions. 4. Continue operating the vehicle until the DTC P0171 test runs and note the test result. Does the Tech 2 indicate DTC P0171 failed this ignition? 5 6 Was DTC P0174 also set? Visually and physically inspect the vacuum hoses for disconnections, splits, kinks, improper routing and improper connections and repair any problem found. Did your inspection reveal a problem requiring repair? 7 Visually and physically inspect the crankcase ventilation valve for proper installation and repair any problem found (refer to Crankcase Ventilation System). Did your inspection reveal a problem requiring repair? 8 1. Inspect the MAF sensor inlet screen for damage or for the presence of foreign objects which may partially block the air flow sample through the MAF sensor. 2. Correct any problem that is found as necessary. Did your inspection of the MAF sensor reveal a condition requiring repair? 9 10 Start the engine and note the idle quality. Is a high or unsteady idle being experienced? 1. Visually and physically inspect the throttle body, intake manifold, EGR valve and the EGR feed pipe for vacuum leaks. 2. Repair any vacuum leaks as necessary. Did your inspection reveal a vacuum leak?

Go to Step 3

L.T. Fuel Trim: +20%

Go to Step 5

Go to Step 4

Go to Step 5 Go to Step 6

The lean condition is not present. If a driveability symptom still exists, refer to Symptoms section. Go to Step 15

Verify repair

Go to Step 7

Verify repair

Go to Step 8

Verify repair Go to Step 10

Go to Step 9 Go to Step11

Verify repair

Go to Step 11

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E219

DTC P0171 Fuel Trim System Lean Bank 1 (Cont'd)

Step Action Value(s) Yes No

11

Check the fuel for excessive water, alcohol, or other contaminants (see Diagnosis in Engine Fuel for the procedure) and correct the contaminated fuel condition if present (see Engine Fuel). Was the fuel contaminated? Verify repair Go to Step 12 1. Visually and physically inspect the PCM injector grounds, power grounds and sensor grounds to ensure that they are clean, tight, and in their proper locations. 2. If a faulty ground condition is present, correct it as necessary. Did your inspection reveal a condition requiring repair? Verify repair Go to Step 13 1. Disconnect the MAF sensor electrical connector. 2. Operate the vehicle in closed loop while monitoring the BANK 1 S.T. FUEL TRIM displayed on the Tech 2. Does BANK 1 S.T. FUEL TRIM value decrease to near the specified value? 0% Go to Step 19 Go to Step 14

12

13

14

Perform the procedure in the Fuel System Pressure Test and repair fuel system problem if necessary. Did Fuel System Pressure Test isolate a condition requiring repair? Verify repair Go to Step 15

15

1. Visually and physically inspect the intake manifold, injector O-rings, EGR adapter, EGR valve and the EGR feed pipes for vacuum leaks. 2. Repair any problem that is found. Did your inspection reveal a problem? Verify repair Go to Step 16 Visually and physically inspect the Bank 1 exhaust manifold for leaks and loose or missing hardware and correct any problem found. Did your inspection reveal a problem? Verify repair Go to Step 17 Perform the Injector Balance Test, and correct any problem found (refer to Fuel Metering System). Did Injector Balance Test isolate a problem? Verify repair Go to Step 18 Check the Procedure Refer to Diagnostic Aids 1. Visually and physically inspect the Bank 1 HO2S 1 to ensure that it is installed securely and that the Bank 1 HO2S 1 pigtail and wiring harness are not contacting the exhaust or otherwise damaged. 2. If a problem is found, correct it as necessary. Did your inspection reveal a problem? Verify repair Verify repair Replace the MAF sensor. Is the action complete?

16

17

18

19

6E220

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0172 Fuel Trim System Rich Bank 1

D06R200010

Circuit Description
To provide the best possible combination of driveability, fuel economy, and emission control, a closed loop air/fuel metering system is used. While in closed loop, the powertrain control module (PCM) monitors the Bank 1 heated oxygen sensors (HO2S) 1 and Bank 2 HO2S 1 signals and adjusts fuel delivery based upon the HO2S signal voltages. A change made to fuel delivery will be indicated by the long and short term fuel trim values which can be monitored with a Tech 2. Ideal fuel trim values are around 0%; if the HO2S signals are indicating a lean condition the PCM will add fuel, resulting in fuel trim values above 0%. If a rich condition is detected, the fuel trim values will be below 0%, indicating that the PCM is reducing the amount of fuel delivered. If an excessively rich condition is detected on Bank 1, the PCM will set DTC P0172. The PCMs maximum authority to control long term fuel trim allows a range between 15% (automatic transmission) or 12 (manual transmission) and +20%. The PCMs maximum authority to control short term fuel trim allows a range between 11% and +20%. The PCM monitors fuel trim under various engine speed/load fuel trim cells before determining the status of the fuel trim diagnostic. D D D D D D D D D D D

DTCs, canister purge DTCs, EVAP DTCs, injector circuit DTCs, or misfire DTCs. Engine coolant temperature is between 6C (42.8F) and 105C (221F). Intake air temperature is between 40C (40F) and 120C (248F). Manifold absolute pressure is between 24 kPa and 99 kPa. Throttle angle is steady below 95%. Vehicle speed is below 136 km/h (85 mph). Engine speed is between 400 and 6,000 RPM. Barometric pressure is greater than 72.5 kPa. Mass air flow is between 2 g/second and 200 g/second. Ignition voltage is above 9.5 volts. Fuel system is in closed loop. Canister purge duty cycle is greater than 0%, if ON.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator lamp (MIL) after the second consecutive trip in which the fault is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Setting the DTC

D None of the following was set: EGR DTCs, HO2S DTCs, (response, transition, open, low volts, no activity), MAF DTCs, TPS DTCs, MAP DTCs, IAT

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

D A history DTC P0172 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0172 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

6E221

the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. DTCs other than P0172 and P0175 may indicate a condition present which may cause a lean condition. If this is the case, repairing the condition which caused the other DTC will most likely correct the DTC P0172/P0175. 4. If the DTC P0172 test passes while the Failure Records conditions are being duplicated, the rich condition is intermittent. Refer to Diagnostic Aids or Symptoms for additional information on diagnosing intermittent problems.

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the Bank 1 HO2S 1 display on the Tech 2 while moving connectors and wiring harnesses related to the engine harness. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often

DTC P0172 Fuel Trim System Rich Bank 1

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Go to the applicable DTC charts and repair the other DTCs before proceeding with this chart Are any DTCs set other than P0172 and P0175?

Go to OBD System Check

3 1. Start the engine and operate the vehicle in closed loop. 2. Observe B1 Long Term Fuel Trim display on the Tech 2. Is the displayed value more negative than the specified value? 4 1. Review and record the Tech 2 Failure Records data. 2. Clear the DTC P0172/P0175 and operate the vehicle to duplicate the Failure Records conditions. 3. Monitor the Tech 2 DTC info for DTC P0172 while operating the vehicle to duplicate the Failure Records conditions. 4. Continue operating the vehicle until the DTC P0172 test runs and note test result. Does the Tech 2 indicate DTC P0172 failed this ignition? 5 6 Is DTC P0175 also set? Visually and physically inspect the air filter element and replace it if necessary. Did the air filter require replacement? 7 Visually and physically inspect the air intake duct for collapse or restriction and repair if necessary. Did your inspection reveal a condition requiring repair? L.T. Fuel Trim: 15% (auto. trans.) OR 12% (man. trans.)

Go to Step 3

Go to Step 5

Go to Step 4

Go to Step 5 Go to Step 6

The rich condition is not present. If a driveability symptom still exists, refer to Symptoms. Go to Step 15

Verify repair

Go to Step 7

Verify repair

Go to Step 8

6E222

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0172 Fuel Trim System Rich Bank 1 (Cont'd)

Step Action Value(s) Yes No

Inspect the MAF sensor inlet screen for damage or for the presence of foreign objects which may partially block air flow through the screen and correct any problem found. Did your inspection of the MAF sensor reveal a condition requiring repair or replacement? Verify repair Go to Step 10 Go to Step 9 Go to Step 11

9 10

Start the engine and note the idle quality. Is a low or unsteady idle being experienced? 1. Ignition OFF. 2. Physically inspect the throttle body bore and throttle plate for coking and foreign objects. 3. If a problem was found, repair as necessary. Did your inspection reveal a condition requiring repair? Verify repair Go to Step 11 1. Disconnect the vacuum hose from the fuel pressure regulator and inspect the hose for the presence of fuel. 2. If fuel is present in the vacuum hose, replace the fuel pressure regulator (refer to Fuel Metering System). Did the fuel pressure regulator require replacement? Verify repair Go to Step 12 Ignition ON, engine OFF, monitor the TP1 Angle display on the Tech 2 while slowly depressing the accelerator pedal. Does the TP Angle display increase steadily and evenly from minimum value at closed throttle to maximum value at wide-open throttle? Minimum 8% Maximum 92%

11

12

Go to Step 13

Go to Step 21

13

1. Disconnect the MAF sensor electrical connector. 2. Operate the vehicle in closed loop while monitoring the BANK 1 L.T. FUEL TRIM and BANK 1 S. T. FUEL TRIM display on the Tech 2. Did both values change to near the specified value? 0% Go to Step 22 Go to Step 14 1. Perform Fuel System Pressure Test. 2. If Fuel System Pressure Test isolates a problem, repair as necessary (refer to Engine Fuel or Fuel Metering System). Did the Fuel System Pressure Test isolate a problem requiring repair? Verify repair Go to Step 15

14

15

1. Ignition ON, engine OFF. 2. Connect a test light between the harness connector terminals of canister purge solenoid. Is the test light on? Go to Step 16 Go to Step 19 Check for short to ground in the wire (YEL/RED) between the canister purge solenoid and PCM terminal S-48. Was there a short to ground? Go to Step 17 Verify repair Go to Step 18 Repair the short to ground. Is the action complete?

16

17

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E223

DTC P0172 Fuel Trim System Rich Bank 1 (Cont'd)

Step Action Value(s) Yes No

18

Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to the latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

19

1. Perform the Injector Balance Test. 2. If Injector Balance Test isolates a problem, repair as necessary (refer to Fuel Metering System). Did the Injector Balance Test isolate a problem requiring repair? Verify repair Go to Step 20

20

1. Remove and visually/physically inspect the Bank 1 HO2S 1 for silicon contamination. This will be indicated by a powdery deposit on the portion of the HO2S that is exposed to the exhaust stream. 2. If contamination is evident on the Bank 1 HO2S 1, replace the contaminated sensors. Did the sensor require replacement? Verify repair 1. Check the TP sensor mounting screws and tighten or replace them as necessary if they are loose or missing. 2. If the screws are OK, replace the TP sensor. Is the action complete? Verify repair Verify repair

Check the Procedure Refer to Diagnostic Aids

21

22

Replace the MAF sensor. Is the action complete?

6E224

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0174 Fuel Trim System Lean Bank 2

D06R200010

Circuit Description
To provide the best possible combination of driveability, fuel economy, and emission control, a closed loop air/fuel metering system is used. While in closed loop, the powertrain control module (PCM) monitors the Bank 1 HO2S 1 and Bank 2 HO2S 1 signals and adjusts fuel delivery based upon the HO2S signal voltages. A change made to fuel delivery will be indicated by the long and short term fuel trim values which can be monitored with a Tech 2. Ideal fuel trim values are around 0%; if the HO2S signals are indicating a lean condition the PCM will add fuel, resulting in fuel trim values above 0%. If a rich condition is detected, the fuel trim values will be below 0%, indicating that the PCM is reducing the amount of fuel delivered. If an excessively lean condition is detected on Bank 2, the PCM will set DTC P0174. The PCMs maximum authority to control long term fuel trim allows a range between 15%(automatic transmission) or 12%(manual transmission) and +20%. The PCM monitors fuel trim under various engine speed/load fuel trim cells before determining the status of the fuel trim diagnostic.

D Intake air temperature is between 40C (40F) and 120C (248F). D Manifold absolute pressure is between 24 kPa and 99 kPa. D Throttle angle is steady between 3 and 95%. D Vehicle speed is below 136 km/h (85 mph). D Engine speed is between 400 and 6,000 RPM. D Barometric pressure is greater than 72.5 kPa. D Mass air flow is between 2 g/second and 200 g/second. D Ignition voltage is above 9.5 volts. D Fuel system is in closed loop. D Canister purge duty cycle is greater than 0%, if ON.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator lamp (MIL) after the second consecutive trip in which the failure is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0174 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0174 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D None of the following DTCs are set: idle system, EGR, HO2S, (response, transition, open, low volts, no activity), MAF, TP sensor, MAP, IAT, canister purge, EVAP, injector circuit, or misfire. D Engine coolant temperature is between 6C (42.8F) and 105C (221F).

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E225

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the Bank 2 HO2S 1 display on the Tech 2 while moving connectors and wiring harnesses related to the engine harness. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. DTCs other than P0171 and P0174 may indicate a condition present which may cause a lean condition. If this is the case, repairing the condition which caused the other DTC will most likely correct the DTC P0171/P0174. 4. If the DTC P0174 test passes while the Failure Records conditions are being duplicated, the lean condition is intermittent. Refer to Diagnostic Aids or Symptoms for additional information on diagnosing intermittent problems.

6E226

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0174 Fuel Trim System Lean Bank 2

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Go to the applicable DTC charts and repair the other DTCs before proceeding with this chart. Are any DTCs set other than P0174 and P0171?

Go to OBD System Check

3 1. Start the engine and operate the vehicle in closed loop. 2. Observe the BANK 2 L.T. FUEL TRIM display on the Tech 2. Is the displayed values greater than the specified values? 4 1. Review and record Tech 2 Failure Records data. 2. Clear the DTC P0171/P0174 and operate the vehicle to duplicate the Failure Records conditions. 3. Monitor the Tech 2 DTC info for DTC P0174 while operating the vehicle to duplicate the Failure Records conditions. 4. Continue operating the vehicle until the DTC P0174 test runs. 5. Note the test result. Does the Tech 2 indicate DTC P0174 failed this ignition? 5 6 Was DTC P0171 also set? Visually and physically inspect the vacuum hoses for disconnections, splits, kinks, improper routing and improper connections and repair any problem found. Did your inspection reveal a problem requiring repair? 7 Visually and physically inspect the crankcase ventilation valve for proper installation and repair any problem found (refer to Crankcase Ventilation System). Did your inspection reveal a problem requiring repair? 8 1. Inspect the MAF sensor inlet screen for damage or for the presence of foreign objects which may partially block the air flow sample through the MAF sensor. 2. Correct any problem that is found as necessary. Did your inspection of the MAF sensor reveal a condition requiring repair? 9 Start the engine and note the idle quality. Is a high or unsteady idle being experienced? L.T. Fuel Trim: +20%

Go to Step 3

Go to Step 5

Go to Step 4

Go to Step 5 Go to Step 6

The lean condition is not present. If a driveability symptom still exists, refer to Symptoms section. Go to Step 15

Verify repair

Go to Step 7

Verify repair

Go to Step 8

Verify repair Go to Step 10

Go to Step 9 Go to Step 11

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E227

DTC P0174 Fuel Trim System Lean Bank 2 (Cont'd)

Step Action Value(s) Yes No

10

1. Visually and physically inspect the throttle body, intake manifold, EGR valve and the EGR feed pipe for vacuum leaks. 2. Repair any vacuum leaks as necessary. Did your inspection reveal a vacuum leak? Verify repair Go to Step 11 Check the fuel for excessive water, alcohol, or other contaminants (see Diagnosis in Engine Fuel for procedure) and correct the contaminated fuel condition is present (see Engine Fuel). Was the fuel contaminated? Verify repair Go to Step 12 1. Visually and physically inspect the PCM injector grounds, power grounds and sensor grounds to ensure that they are clean, tight, and in their proper locations. 2. If a faulty ground condition is present, correct it as necessary. Did your inspection reveal a condition requiring repair? Verify repair Go to Step 13 1. Disconnect the MAF sensor electrical connector. 2. Operate the vehicle in closed loop while monitoring the BANK 2 S.T. FUEL TRIM displayed on the Tech 2. Does the BANK 2 S.T. FUEL TRIM value decrease to near the specified value? 0% Go to Step 19 Go to Step 14

11

12

13

14

Perform the procedure in the Fuel System Pressure Test and repair fuel system problem if necessary. Did the Fuel System Pressure Test isolate a condition requiring repair? Verify repair Go to Step 15

15

1. Visually and physically inspect the intake manifold, injector O-rings, EGR adapter, EGR valve and the EGR feed pipes for vacuum leaks. 2. Repair any problem that is found. Did your inspection reveal a problem? Verify repair Go to Step 16 Visually and physically inspect the Bank 2 exhaust manifold for leaks and loose or missing hardware and correct any problem found. Did your inspection reveal a problem? Verify repair Go to Step 17 Perform the Injector Balance Test and correct any problem found (refer to Fuel Metering System). Did the Injector Balance Test isolate a problem? Verify repair Go to Step 18 Check the Procedure Refer to Diagnostic Aids 1. Visually and physically inspect the Bank 2 HO2S 1 to ensure that it is installed securely and that the Bank 2 HO2S 1 pigtail and wiring harness are not contacting the exhaust or otherwise damaged. 2. If a problem is found, correct it as necessary. Did your inspection reveal a problem? Verify repair Verify repair Replace the MAF sensor. Is the action complete?

16

17

18

19

6E228

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0175 Fuel Trim System Rich Bank 2

D06R200010

Circuit Description
To provide the best possible combination of driveability, fuel economy, and emission control, a closed loop air/fuel metering system is used. While in closed loop, the powertrain control module (PCM) monitors the Bank 1 HO2S 1 and Bank 2 HO2S 1 signals and adjusts fuel delivery based upon the HO2S signal voltages. A change made to fuel delivery will be indicated by the long and short term fuel trim values which can be monitored with a Tech 2. Ideal fuel trim values are around 0%; if the HO2S signals are indicating a lean condition the PCM will add fuel, resulting in fuel trim values above 0%. If a rich condition is detected, the fuel trim values will be below 0%, indicating that the PCM is reducing the amount of fuel delivered. If an excessively rich condition is detected on Bank 2, the PCM will set DTC P0175. The PCMs maximum authority to control long term fuel trim allows a range between 15%(automatic transmission) or 12%(manual transmission) and +20%. The PCMs maximum authority to control short term fuel trim allows a range between 11% and +20%. The PCM monitors fuel trim under various engine speed/load fuel trim cells before determining the status of the fuel trim diagnostic. D D D D D D D D D D

activity), MAF, TPS, MAP, IAT, canister purge, EVAP, injector circuit, or misfire. Engine coolant temperature is between 6C (42.8F) and 105C (221F). Intake air temperature is between 40C (40F) and 120C (248F). Manifold absolute pressure is between 24 kPa and 99 kPa. Throttle angle is steady between 3 and 95%. Vehicle speed is below 136 km/h (85 mph). Engine speed is between 400 and 6,000 RPM. Barometric pressure is greater than 72.5 kPa. Mass air flow is between 2 g/second and 200 g/second. Ignition voltage is above 9.5 volts. Fuel system is in closed loop.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator lamp (MIL) after the second consecutive trip in which the failure is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Setting the DTC

D None of the following DTCs are set: idle system, EGR, HO2S, (response, transition, open, low volts, no

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

D A history DTC P0175 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0175 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

6E229

the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. DTCs other than P0172 and P0175 may indicate a condition present which may cause a lean condition. If this is the case, repairing the condition which caused the other DTC will most likely correct the DTC P0172/P0175. 4. If the DTC P0175 test passes while the Failure Records conditions are being duplicated, the rich condition is intermittent. Refer to Diagnostic Aids or Symptoms for additional information on diagnosing intermittent problems.

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed -out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the Bank 2 HO2S 1 display on the Tech 2 while moving connectors and wiring harnesses related to the engine harness. A change in the display will indicate the location of the fault. Reviewing the Failure Records Vehicle mileage since the diagnostic test last failed may help determine how often

DTC P0175 Fuel Trim System Rich Bank 2

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Go to the applicable DTC charts and repair the other DTCs before proceeding with this chart. Are any DTCs set other than P0172 and P0175?

Go to OBD System Check

3 1. Start the engine and operate the vehicle in closed loop. 2. Observe the BANK 2 L.T. FUEL TRIM display on the Tech 2. Is the displayed value more negative than the specified value? 4 1. Review and record the Tech 2 Failure Records data. 2. Clear the DTC P0172/P0175 and operate the vehicle to duplicate the Failure Records conditions. 3. Monitor the Tech 2 DTC info for DTC P0175 while operating the vehicle to duplicate the Failure Records conditions. 4. Continue operating the vehicle until the DTC P0175 test runs. 5. Note the test result. Does the Tech 2 indicate DTC P0175 failed this ignition? 5 6 Was DTC P0172 also set? Visually and physically inspect the air filter element and replace it if necessary. Did the air filter require replacement? L.T. Fuel Trim: 15% (auto. trans.) OR 12% (man. trans.)

Go to Step 3

Go to Step 5

Go to Step 4

Go to Step 5 Go to Step 6

The rich condition is not present. If a driveability symptom still exists, refer to Symptoms. Go to Step 15

Verify repair

Go to Step 7

6E230

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0175 Fuel Trim System Rich Bank 2 (Cont'd)

Step Action Value(s) Yes No

Visually and physically inspect the air intake duct for collapse or restriction and repair if necessary. Did your inspection reveal a problem requiring repair? Verify repair Go to Step 8 Inspect the MAF sensor inlet screen for damage or for the presence of foreign objects which may partially block air flow through the screen and correct any problem found. Did your inspection of the MAF sensor reveal a condition requiring repair or replacement? Verify repair Go to Step 10 Go to Step 9 Go to Step 11

9 10

Start the engine and note the idle quality. Is a low or unsteady idle being experienced? 1. Turn the ignition off and physically inspect the throttle body bore, throttle plate, and IAC passages for coking and foreign objects. 2. If a problem was found, repair as necessary. Did your inspection reveal a condition requiring repair? Verify repair Go to Step 11 1. Disconnect the vacuum hose from the fuel pressure regulator and inspect the hose for the presence of fuel. 2. If fuel is present in the vacuum hose, replace the fuel pressure regulator (refer to Fuel Metering System). Did the fuel pressure regulator require replacement? Verify repair Go to Step 12 1. Ignition ON, engine OFF. 2. Monitor the TP Angle display on the Tech 2 while slowly depressing the accelerator pedal. Does the TP Angle display increase steadily and evenly from minimum value at closed throttle to maximum value at wide-open throttle? Minimum 8% Maximum 92%

11

12

Go to Step 13

Go to Step 21

13

1. Disconnect the MAF sensor electrical connector. 2. Operate the vehicle in closed loop while monitoring the BANK 2 L.T. FUEL TRIM and BANK 2 S.T. FUEL TRIM display on the Tech 2. Did both values change to near the specified value? 0% Go to Step 22 Go to Step 14 1. Perform the Fuel System Pressure Test. 2. If Fuel System Pressure Test isolates a problem, repair as necessary (refer to Engine Fuel or Fuel Metering System). Did the Fuel System Pressure Test isolate a condition requiring repair? Verify repair Go to Step 15

14

15

1. Ignition ON, engine OFF. 2. Connect a test light between the harness connector terminals of canister purge solenoid. Is the test light on? Go to Step 16 Go to Step 19 Check for short to ground in the wire (YEL/RED) between the canister purge solenoid and PCM terminal S-48. Was there a short to ground? Go to Step 17 Go to Step 18

16

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E231

DTC P0175 Fuel Trim System Rich Bank 2 (Cont'd)

Step Action Value(s) Yes No

17 18

Repair the short to ground. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to the latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair Verify repair

19

1. Perform the Injector Balance Test. 2. If the Injector Balance Test isolates a problem, repair as necessary (refer to Fuel Metering System). Did the Injector Balance Test isolate a problem requiring repair? Verify repair Go to Step 20

20

1. Remove and visually/physically inspect the Bank 2 HO2S 1 for silicon contamination. This will be indicated by a powdery deposit on the portion of the HO2S that is exposed to the exhaust stream. 2. If contamination is evident on the Bank 2 HO2S 1, replace the contaminated sensor. Did the sensor require replacement? Verify repair 1. Check the TP sensor mounting screws and tighten or replace them as necessary if they are loose or missing. 2. If the screws are OK, replace the TP sensor. Is the action complete? Verify repair Verify repair

Check the Procedure Refer to Diagnostic Aids

21

22

Replace the MAF sensor. Is the action complete?

6E232

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit

D06R200014

Circuit Description
The powertrain control module (PCM) has six individual injector driver circuits. Each controls an injector. When a driver circuit is grounded by the PCM, the injector is activated. The PCM monitors the current in each driver circuit. The voltage on each driver is monitored to detect a fault. If the voltage is not what the PCM expects to monitor on the circuit, a DTC is set. This DTC is also set if an injector driver is shorted to voltage or if there is an open circuit.

Conditions for Clearing the MIL/DTC

D The PCM will turn OFF the MIL on the third consecutive trip cycle in which the diagnostic has been run and the fault is no longer present. D A history DTC P0201 will clear after 40 consecutive warm-up cycles occur without a fault. D DTC P0201 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Diagnostic Aids
An injector driver circuit that is open or shorted to voltage will cause a DTC P0201 to set. It will also cause a misfire due to an inoperative injector. A misfire DTC will also be set indicating which cylinder is inoperative. Long term and short term fuel trims that are excessively high or low are a good indication that an injector is faulty. Use Fuel Injector Coil Test Procedure to check for faulty injectors.

Conditions for Setting the DTC

D The battery voltage is more than 9 volts. D Engine speed is more than 700 rpm. D The engine is turning, determined by 58X crankshaft position input signal. D The injector voltage does not equal the ignition voltage when the injector is commanded OFF or the injector voltage does not equal 0 volts when the injector is commanded ON. D The above conditions are met for 5 seconds.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator lamp (MIL) the first time the fault is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E233

Test Description
The number(s) below refer to the step number(s) on the Diagnostic Chart. 3. This step determines if DTC P0201 is the result of a hard failure or an intermittent condition. 5. A special injector test connector is provided so that the injectors can be electrically tested without removal of the manifold. The test connector can be identified by the blue connector lock which is tethered to the wiring harness. If the light for cylinder 1 is ON steady before cranking the engine as well as while cranking the engine, then the injector driver circuit is shorted to ground. If the test light blinks while cranking, the PCM and the wiring to the injectors are OK. The Fuel Injector Coil Test Procedure will check if the injectors are faulty.

R321054

7. Because the test light was ON steady, voltage to the injector is OK, but the driver circuit is grounded at all times. This step determines if the circuit is shorted to ground or the PCM is faulty. 9. The reading should be about 12-14m. 10.Locating the open in the harness or in the injector will require removal of the manifold to provide access.

DTC P0201 Injector 1 Control Circuit

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Will the engine start? Go to Step 3

Go to OBD System Check Go to Engine Cranks But Will Not Run chart

1. Install the Tech 2. Clear the DTC. 2. Idle the engine for one minute. Does DTC P0201 reset? Go to Step 5 Go to Step 4 1. Review the Freeze Frame data with the ignition ON and the engine OFF and note the parameters. 2. Operate the vehicle within the Freeze Frame conditions as noted. Does P0201 reset? Go to Step 5 1. Engine OFF. 2. Disconnect the injector connector. 3. Install an injector test light J-39021-65 on the injector test connector. 4. Crank the engine and note the light. Does the injector test light blink?

Check the Procedure Go to Diagnostic Aids

Go to Fuel Injector Coil Test Procedure

Go to Step 6

6E234

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0201 Injector 1 Control Circuit (Cont'd)

Step Action Value(s) Yes No

Note whether the injector test light for cylinder 1 was OFF or ON steady in step 5. Was the test light ON steady while cranking the engine? Go to Step 7 Go to Step 9

1. Disconnect the PCM connector for the affected injectors. 2. With a test light connected to B+, probe the affected injector driver circuit. Does the test light illuminate? Go to Step 8 Go to OBD System Check Go to Step 15 Repair short to ground in the injector driver circuit. Is the action complete?

1. Disconnect the injector test connector. 2. At the injector side of the harness, connect an ohmmeter between the positive wire (red with blue tracer) and the wire for cylinder 1 (green with white tracer). Does the ohmmeter indicate continuity? Go to Step 11 Verify repair Go to Step 10 Repair the open injector harness wire or open injector. Is the action complete? At the PCM side of the injector test connector, check the green/white wire for a short to voltage. Was there a short to voltage? Go to Step 12 Verify repair Go to Step 13 Repair the short to voltage. Is the action complete? Check for an open circuit between the injector test connector and the PCM. Was there an open circuit? Go to Step 14 Verify repair Go to Step 15 Repair the open circuit. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to the latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

10 11

12 13

14 15

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E235

Diagnostic Trouble Code (DTC) P0202 Injector 2 Control Circuit

D06R200014

Circuit Description
The powertrain control module (PCM) has six individual injector driver circuits. Each controls an injector. When a driver circuit is grounded by the PCM, the injector is activated. The PCM monitors the current in each driver circuit. The voltage on each driver is monitored to detect a fault. If the voltage is not what the PCM expects to monitor on the circuit, a DTC is set. This DTC is also set if an injector driver is shorted to voltage or if there is an open circuit.

Conditions for Clearing the MIL/DTC

D The PCM will turn OFF the MIL on the third consecutive trip cycle in which the diagnostic has been run and the fault is no longer present. D A history DTC P0202 will clear after 40 consecutive warm-up cycles occur without a fault. D DTC P0202 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Diagnostic Aids
An injector driver circuit that is open or shorted to voltage will cause a DTC P0202 to set. It will also cause a misfire due to an inoperative injector. A misfire DTC will also be set indicating which cylinder is inoperative. Long term and short term fuel trims that are excessively high or low are a good indication that an injector is faulty. Use Fuel Injector Coil Test Procedure to check for faulty injectors.

Conditions for Setting the DTC

D The battery voltage is more than 9 volts. D Engine speed is more than 700 rpm. D The engine is turning, determined by 58X crankshaft position input signal. D The injector voltage does not equal the ignition voltage when the injector is commanded OFF or the injector voltage does not equal 0 volts when the injector is commanded ON. D The above conditions are met for 5 seconds.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator lamp (MIL) the first time the fault is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

6E236

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Test Description
The number(s) below refer to the step number(s) on the Diagnostic Chart. 3. This step determines if DTC P0202 is the result of a hard failure or an intermittent condition. 5. A special injector test connector is provided so that the injectors can be electrically tested without removal of the manifold. The test connector can be identified by the blue connector lock which is tethered to the wiring harness. If the light for cylinder 2 is ON steady before cranking the engine as well as while cranking the engine, then the injector driver circuit is shorted to ground. If the test light blinks while cranking, the PCM and the wiring to the injectors are OK. The Fuel Injector Coil Test Procedure will check if the injectors are faulty.

R321055

7. Because the test light was ON steady, voltage to the injector is OK, but the driver circuit is grounded at all times. This step determines if the circuit is shorted to ground or the PCM is faulty. 9.The reading should be about 12-14m. 10.Locating the open in the harness or in the injector will require removal of the manifold to provide access.

DTC P0202 Injector 2 Control Circuit

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Will the engine start? Go to Step 3

Go to OBD System Check Go to Engine Cranks But Will Not Run chart

1. Install the Tech 2. Clear the DTC. 2. Idle the engine for one minute. Does DTC P0202 reset? Go to Step 5 Go to Step 4 1. Review the Freeze Frame data with the ignition ON and the engine OFF and note the parameters. 2. Operate the vehicle within the Freeze Frame conditions as noted. Does P0202 reset? Go to Step 5 1. Engine OFF. 2. Disconnect the injector test connector. 3. Install an injector test light J-39021-65 on injector connector. 4. Crank the engine and note the light. Does the cylinder 2 test light blink?

Check the Procedure Go to Diagnostic Aids

Go to Fuel Injector Coil Test Procedure

Go to Step 6

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E237

DTC P0202 Injector 2 Control Circuit (Cont'd)

Step Action Value(s) Yes No

Note whether the injector test light for cylinder 2 was OFF or ON steady in step 5. Was the test light ON steady while cranking the engine? Go to Step 7 Go to Step 9

1. Disconnect the PCM connector for the affected injectors. 2. With a test light connected to B+, probe the affected injector driver circuit. Does the test light illuminate? Go to Step 8 Go to OBD System Check Go to Step 15 Repair short to ground in the injector driver circuit. Is the action complete?

1. Disconnect the injector test connector. 2. At the injector side of the harness, connect an ohmmeter between the positive wire (red with blue tracer) and the wire for cylinder 2 (green with orange tracer). Does the ohmmeter indicate continuity? Go to Step 11 Verify repair Go to Step 10 Repair the open injector harness wire or open injector. Is the action complete? At the PCM side of the injector test connector, check the green/orange wire for a short to voltage. Was there a short to voltage? Go to Step 12 Verify repair Go to Step 13 Repair the short to voltage. Is the action complete? Check for an open circuit between the injector test connector and the PCM. Was there an open circuit? Go to Step 14 Verify repair Go to Step 15 Repair the open circuit. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to the latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

10 11

12 13

14 15

6E238

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0203 Injector 3 Control Circuit

D06R200014

Circuit Description
The powertrain control module (PCM) has six individual injector driver circuits. Each controls an injector. When the driver circuit is grounded by the PCM, the injector is activated. The PCM monitors the current in each driver circuit. The voltage on each driver is monitored to detect a fault. If the voltage is not what the PCM expects to monitor on the circuit, a DTC is set. This DTC is also set if an injector driver is shorted to voltage or if there is an open circuit.

D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn OFF the MIL on the third consecutive trip cycle in which the diagnostic has been run and the fault is no longer present. D A history DTC P0203 will clear after 40 consecutive warm-up cycles occur without a fault. D DTC P0203 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D The battery voltage is more than 9 volts. D Engine speed is more than 700 rpm. D The engine is turning, determined by the 58X crankshaft position input signal. D The injector voltage does not equal the ignition voltage when the injector is commanded OFF or the injector voltage does not equal 0 volts when the injector is commanded ON. D The above conditions are met for 5 seconds.

Diagnostic Aids
An injector driver circuit that is open or shorted to voltage will cause a DTC P0203 to set. It will also cause a misfire due to an inoperative injector. A misfire DTC will also be set indicating which cylinder is inoperative. Long term and short term fuel trims that are excessively high or low are a good indication that an injector is faulty. Use Fuel Injector Coil Test Procedure to check for faulty injectors.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator lamp (MIL) the first time the fault is detected.

Test Description
The number(s) below refer to the step number(s) on the Diagnostic Chart.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

3. This step determines if DTC P0203 is the result of a hard failure or an intermittent condition. 5. A special injector test connector is provided so that the injectors can be electrically tested without removal of the manifold. The test connector can be identified by the blue connector lock which is tethered to the wiring harness. If the light for cylinder 3 is ON steady before cranking the engine as well as while cranking the engine, then the injector driver circuit is shorted to ground. If the test light blinks while cranking, the PCM and the wiring to the injectors are OK. The Fuel Injector Coil Test Procedure will check if the injectors are faulty.

6E239

7. Because the test light was ON steady, voltage to the injector is OK, but the driver circuit is grounded at all times. This step determines if the circuit is shorted to ground or the PCM is faulty. 9. The reading should be about 12-14m. 10.Locating the open in the harness or in the injector will require removal of the manifold to provide access.

R321056

DTC P0203 Injector 3 Control Circuit

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Will the engine start? Go to Step 3

Go to OBD System Check Go to Engine Cranks But Will Not Run chart

1. Install the Tech 2. Clear the DTC. 2. Idle the engine for one minute. Does DTC P0203 reset? Go to Step 5 Go to Step 4 1. Review the Freeze Frame data with the ignition ON and the engine OFF and note the parameters. 2. Operate the vehicle within the Freeze Frame conditions as noted. Does P0203 reset? Go to Step 5

Check the Procedure Go to Diagnostic Aids

6E240

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0203 Injector 3 Control Circuit (Cont'd)

Step Action Value(s) Yes No

1. Engine OFF. 2. Disconnect the injector test connector . 3. Install an injector test light J-39021-65 on injector connector. 4. Crank the engine and note the light. Does the cylinder 3 test light blink? Note whether the injector test light for cylinder 3 was OFF or ON steady in step 5. Was the test light ON steady while cranking the engine?

Go to Fuel Injector Coil Test Procedure

Go to Step 6

Go to Step 7

Go to Step 9

1. Disconnect the PCM connector for the affected injectors. 2. With a test light connected to B+, probe the affected injector driver circuit. Does the test light illuminate? Go to Step 8 Go to OBD System Check Go to Step 15 Repair short to ground in the injector driver circuit. Is the action complete?

1. Disconnect the injector test connector. 2. At the injector side of the harness, connect an ohmmeter between the positive wire (red with blue tracer) and the wire for cylinder 3 (green). Does the ohmmeter indicate continuity? Go to Step 11 Verify repair Go to Step 10 Repair the open injector harness wire or open injector. Is the action complete? At the PCM side of the injector test connector, check the green wire for a short to voltage. Was there a short to voltage? Go to Step 12 Verify repair Go to Step 13 Repair the short to voltage. Is the action complete? Check for an open circuit between the injector test connector and the PCM. Was there an open circuit? Go to Step 14 Verify repair Go to Step 15 Repair the open circuit. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to the latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

10 11

12 13

14 15

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E241

Diagnostic Trouble Code (DTC) P0204 Injector 4 Control Circuit

D06R200014

Circuit Description
The powertrain control module (PCM) has six individual injector driver circuits. Each controls an injector. When the driver circuit is grounded by the PCM, the injector is activated. The PCM monitors the current in each driver circuit. The voltage on each driver is monitored to detect a fault. If the voltage is not what the PCM expects to monitor on the circuit, a DTC is set. This DTC is also set if an injector driver is shorted to voltage or if there is an open circuit.

Conditions for Clearing the MIL/DTC

D The PCM will turn OFF the MIL on the third consecutive trip cycle in which the diagnostic has been run and the fault is no longer present. D A history DTC P0204 will clear after 40 consecutive warm-up cycles occur without a fault. D DTC P0204 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Diagnostic Aids
An injector driver circuit that is open or shorted to voltage will cause a DTC P0204 to set. It will also cause a misfire due to an inoperative injector. A misfire DTC will also be set indicating which cylinder is inoperative. Long term and short term fuel trims that are excessively high or low are a good indication that an injector is faulty. Use Fuel Injector Coil Test Procedure to check for faulty injectors.

Conditions for Setting the DTC

D The battery voltage is more than 9 volts. D Engine speed is more than 700 rpm. D The engine is turning, determined by the 58X crankshaft position input signal. D The injector voltage does not equal the ignition voltage when the injector is commanded OFF or the injector voltage does not equal 0 volts when the injector is commanded ON. D The above conditions are met for 5 seconds.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator lamp (MIL) the first time the fault is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

6E242

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Test Description
The number(s) below refer to the step number(s) on the Diagnostic Chart. 3. This step determines if DTC P0204 is the result of a hard failure or an intermittent condition. 5. A special injector test connector is provided so that the injectors can be electrically tested without removal of the manifold. The test connector can be identified by the blue connector lock which is tethered to the wiring harness. If the light for cylinder 4 is ON steady before cranking the engine as well as while cranking the engine, then the injector driver circuit is shorted to ground. If the test light blinks while cranking, the PCM and the wiring to the injectors are OK. The Fuel Injector Coil Test Procedure will check if the injectors are faulty.

R321057

7. Because the test light was ON steady, voltage to the injector is OK, but the driver circuit is grounded at all times. This step determines if the circuit is shorted to ground or the PCM is faulty. 9. The reading should be about 12-14m. 10.Locating the open in the harness or in the injector will require removal of the manifold to provide access.

DTC P0204 Injector 4 Control Circuit

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Will the engine start? Go to Step 3

Go to OBD System Check Go to Engine Cranks But Will Not Run chart

1. Install the Tech 2. Clear the DTC. 2. Idle the engine for one minute. Does DTC P0204 reset? Go to Step 5 Go to Step 4 1. Review the Freeze Frame data with the ignition ON and the engine OFF and note the parameters. 2. Operate the vehicle within the Freeze Frame conditions as noted. Does P0204 reset? Go to Step 5 1. Engine OFF. 2. Disconnect the injector test connector. 3. Install an injector test light J-39021-65 on injector connector. 4. Crank the engine and note the light. Does the cylinder 4 test light blink?

Check the Procedure Go to Diagnostic Aids

Go to Fuel Injector Coil Test Procedure

Go to Step 6

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E243

DTC P0204 Injector 4 Control Circuit (Cont'd)

Step Action Value(s) Yes No

Note whether the injector test light for cylinder 4 was OFF or ON steady in step 5. Was the test light ON steady while cranking the engine? Go to Step 7 Go to Step 9

1. Disconnect the PCM connector for the affected injectors. 2. With a test light connected to B+, probe the affected injector driver circuit. Does the test light illuminate? Go to Step 8 Go to OBD System Check Go to Step 15 Repair short to ground in the injector driver circuit. Is the action complete?

1. Disconnect the injector test connector. 2. At the injector side of the harness, connect an ohmmeter between the positive wire (red with blue tracer) and the wire for cylinder 4 (green/red). Does the ohmmeter indicate continuity? Go to Step 11 Verify repair Go to Step 10 Repair the open injector harness wire or open injector. Is the action complete? At the PCM side of the injector test connector, check the green/red wire for a short to voltage. Was there a short to voltage? Go to Step 12 Verify repair Go to Step 13 Repair the short to voltage. Is the action complete? Check for an open circuit between the injector test connector and the PCM. Was there an open circuit? Go to Step 14 Verify repair Go to Step 15 Repair the open circuit. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to the latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

10 11

12 13

14 15

6E244

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0205 Injector 5 Control Circuit

D06R200014

Circuit Description
The powertrain control module (PCM) has six individual injector driver circuits. Each controls an injector. When the driver circuit is grounded by the PCM, the injector is activated. The PCM monitors the current in each driver circuit. If the voltage is not what the PCM expects to monitor on the circuit, a DTC is set. This DTC is also set if an injector driver is shorted to voltage or if there is an open circuit.

Conditions for Clearing the MIL/DTC

D The PCM will turn OFF the MIL on the third consecutive trip cycle in which the diagnostic has been run and the fault is no longer present. D A history DTC P0205 will clear after 40 consecutive warm-up cycles occur without a fault. D DTC P0205 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D The battery voltage is more than 9 volts. D Engine speed is more than 700 rpm. D The engine is turning, determined by the 58X crankshaft position input signal. D The injector voltage does not equal the ignition voltage when the injector is commanded OFF or the injector voltage does not equal 0 volts when the injector is commanded ON. D The above conditions are met for 5 seconds.

Diagnostic Aids
An injector driver circuit that is open or shorted to voltage will cause a DTC P0205 to set. It will also cause a misfire due to an inoperative injector. A misfire DTC will also be set indicating which cylinder is inoperative. Long term and short term fuel trims that are excessively high or low are a good indication that an injector is faulty. Use Fuel Injector Coil Test Procedure to check for faulty injectors.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator lamp (MIL) the first time the fault is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E245

Test Description
The number(s) below refer to the step number(s) on the Diagnostic Chart. 3. This step determines if DTC P0205 is the result of a hard failure or an intermittent condition. 5. A special injector test connector is provided so that the injectors can be electrically tested without removal of the manifold.The test connector can be identified by the blue connector lock which is tethered to the wiring harness. If the light for cylinder 5 is ON steady before cranking the engine as well as while cranking the engine, then the injector driver circuit is shorted to ground. If the test light blinks while cranking, the PCM and the wiring to the injectors are OK. The Fuel Injector Coil Test Procedure will check if the injectors are faulty.

R321058

7. Because the test light was ON steady, voltage to the injector is OK, but the driver circuit is grounded at all times. This step determines if the circuit is shorted to ground or the PCM is faulty. 9. The reading should be about 12-14m. 10.Locating the open in the harness or in the injector will require removal of the manifold to provide access.

DTC P0205 Injector 5 Control Circuit

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Will the engine start? Go to Step 3

Go to OBD System Check Go to Engine Cranks But Will Not Run chart

1. Install the Tech 2. Clear the DTC. 2. Idle the engine for one minute. Does DTC P0205 reset? Go to Step 5 Go to Step 4 1. Review the Freeze Frame data with the ignition ON and the engine OFF and note the parameters. 2. Operate the vehicle within the Freeze Frame conditions as noted. Does P0205 reset? Go to Step 5 1. Engine OFF. 2. Disconnect the injector test connector. 3. Install an injector test light J-39021-65 on injector connector. 4. Crank the engine and note the light. Does the cylinder 5 test light blink?

Check the Procedure Go to Diagnostic Aids

Go to Fuel Injector Coil Test Procedure

Go to Step 6

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DTC P0205 Injector 5 Control Circuit (Cont'd)

Step Action Value(s) Yes No

Note whether the injector test light for cylinder 5 was OFF or ON steady in step 5. Was the test light ON steady while cranking the engine? Go to Step 7 Go to Step 9

1. Disconnect the PCM connector for the affected injectors. 2. With a test light connected to B+, probe the affected injector driver circuit. Does the test light illuminate? Go to Step 8 Go to OBD System Check Go to Step 15 Repair short to ground in the injector driver circuit. Is the action complete?

1. Disconnect the injector test connector. 2. At the injector side of the harness, connect an ohmmeter between the positive wire (red with blue tracer) and the wire for cylinder 5 (green with black tracer). Does the ohmmeter indicate continuity? Go to Step 11 Verify repair Go to Step 10 Repair the open injector harness wire or open injector. Is the action complete? At the PCM side of the injector test connector, check the green/black wire for a short to voltage. Was there a short to voltage? Go to Step 12 Verify repair Go to Step 13 Repair the short to voltage. Is the action complete? Check for an open circuit between the injector test connector and the PCM. Was there an open circuit? Go to Step 14 Verify repair Go to Step 15 Repair the open circuit. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to the latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

10 11

12 13

14 15

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E247

Diagnostic Trouble Code (DTC) P0206 Injector 6 Control Circuit

D06R200014

Circuit Description
The powertrain control module (PCM) has six individual injector driver circuits. Each controls an injector. When the driver circuit is grounded by the PCM, the injector is activated. The PCM monitors the current in each driver circuit. The voltage on each driver is monitored to detect a fault. If the voltage is not what the PCM expects to monitor on the circuit, a DTC is set. This DTC is also set if an injector driver is shorted to voltage or if there is an open circuit.

Conditions for Clearing the MIL/DTC

D The PCM will turn OFF the MIL on the third consecutive trip cycle in which the diagnostic has been run and the fault is no longer present. D A history DTC P0206 will clear after 40 consecutive warm-up cycles occur without a fault. D DTC P0206 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Diagnostic Aids
An injector driver circuit that is open or shorted to voltage will cause a DTC P0206 to set. It will also cause a misfire due to an inoperative injector. A misfire DTC will also be set indicating which cylinder is inoperative. Long term and short term fuel trims that are excessively high or low are a good indication that an injector is faulty. Use Fuel Injector Coil Test Procedure to check for faulty injectors.

Conditions for Setting the DTC

D The battery voltage is more than 9 volts. D Engine speed is more than 700 rpm. D The engine is turning, determined by 58X crankshaft position input signal. D The injector voltage does not equal the ignition voltage when the injector is commanded OFF or the injector voltage does not equal 0 volts when the injector is commanded ON. D The above conditions are met for 5 seconds.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator lamp (MIL) the first time the fault is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

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Test Description
The number(s) below refer to the step number(s) on the Diagnostic Chart. 3. This step determines if DTC P0206 is the result of a hard failure or an intermittent condition. 5. A special injector test connector is provided so that the injectors can be electrically tested without removal of the manifold.The test connector can be identified by the blue connector lock which is tethered to the wiring harness. If the light for cylinder 6 is ON steady before cranking the engine as well as while cranking the engine, then the injector driver circuit is shorted to ground. If the test light blinks while cranking, the PCM and the wiring to the injectors are OK. The Fuel Injector Coil Test Procedure will check if the injectors are faulty.

R321059

7. Because the test light was ON steady, voltage to the injector is OK, but the driver circuit is grounded at all times. This step determines if the circuit is shorted to ground or the PCM is faulty. 9. The reading should be about 12-14m. 10.Locating the open in the harness or in the injector will require removal of the manifold to provide access.

DTC P0206 Injector 6 Control Circuit

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Will the engine start? Go to Step 3

Go to OBD System Check Go to Engine Cranks But Will Not Run chart

1. Install the Tech 2. Clear the DTC. 2. Idle the engine for one minute. Does DTC P0206 reset? Go to Step 5 Go to Step 4 1. Review the Freeze Frame data with the ignition ON and the engine OFF and note the parameters. 2. Operate the vehicle within the Freeze Frame conditions as noted. Does P0206 reset? Go to Step 5 1. Engine OFF. 2. Disconnect the injector test connector. 3. Install an injector test light J-39021-65 on injector connector. 4. Crank the engine and note the light. Does the cylinder 6 test light blink?

Check the Procedure Go to Diagnostic Aids

Go to Fuel Injector Coil Test Procedure

Go to Step 6

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E249

DTC P0206 Injector 6 Control Circuit (Cont'd)

Step Action Value(s) Yes No

Note whether the injector test light for cylinder 6 was OFF or ON steady in step 5. Was the test light ON steady while cranking the engine? Go to Step 7 Go to Step 9

1. Disconnect the PCM connector for the affected injectors. 2. With a test light connected to B+, probe the affected injector driver circuit. Does the test light illuminate? Go to Step 8 Go to OBD System Check Go to Step 15 Repair short to ground in the injector driver circuit. Is the action complete?

1. Disconnect the injector test connector. 2. At the injector side of the harness, connect an ohmmeter between the positive wire (red with blue tracer) and the wire for cylinder 6 (green with yellow tracer). Does the ohmmeter indicate continuity? Go to Step 11 Verify repair Go to Step 10 Repair the open injector harness wire or open injector Is the action complete? At the PCM side of the injector test connector, check the green/yellow wire for a short to voltage. Was there a short to voltage? Go to Step 12 Verify repair Go to Step 13 Repair the short to voltage. Is the action complete? Check for an open circuit between the injector test connector and the PCM. Was there an open circuit? Go to Step 14 Verify repair Go to Step 15 Repair the open circuit. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to the latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

10 11

12 13

14 15

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Diagnostic Trouble Code (DTC) P0300 Engine Misfire Detected

Circuit Description
Misfire is monitored as a function of the combustion quality (CQ) signals generated from the ION Sensing Module. Combustion signals represent the degree of combustion in each cylinder. Misfire is detected when the combustion signal is below a predetermined value. This DTC P0300 will determine if a multiple cylinder misfire is occurring by monitoring the Combustion Quality. D Damaged or faulty ignition coil Check for cracks or other damage. D Substitute a known good coil Swap the ignition coils and retest. If the misfire follows the coil, replace the ignition coil. If the misfire is random, check for the following conditions: D System grounds Ensure all connections are clean and properly tightened. D MAF A mass air flow (MAF) sensor output that causes the PCM to sense a lower than normal air flow will cause a lean condition. D Air induction system Air leaks into the induction system which bypass the MAF sensor will cause a lean condition. Check for disconnected or damaged vacuum hoses, incorrectly installed or faulty PCV valve, or for vacuum leaks at the throttle body, EGR valve, and intake manifold mounting surfaces. D Fuel pressure Perform a fuel system pressure test. A faulty fuel pump, plugged filter, or faulty fuel system pressure regulator will contribute to a lean condition. D Injector(s) Perform an injector coil/balance test to locate faulty injector(s) contributing to a lean or flooding condition. In addition to the above test, check the condition of the injector O-rings. D EGR Check for a leaking valve, adapter, or feed pipes which will contribute to a lean condition or excessive EGR flow. D Fuel quality Using fuel with the wrong octane rating for the vehicle may cause driveability problems. Although alcohol-enhanced fuels may raise the octane rating, the fuels ability to turn into vapor in cold temperatures deteriorates. This may affect the cold driveability of the engine. The Reid Vapor Pressure of the fuel can also create problems in the fuel system, especially during the spring and fall when changes by the refineries may not coincide with changes in the weather. D Vehicle marshalling The transportation of new vehicles from the assembly plant to the dealership can involve as many as 60 key cycles within 2 to 3 miles of driving. This type of operation contributes to the fuel fouling of the spark plugs and will turn on the MIL with a P0300 Misfire DTC. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Conditions for Setting the DTC

D None of the following DTCs occur: TP sensor, MAF sensor, VSS, ECT sensor. D The engine speed is between 600 and 6250 RPM. D The system voltage is between 11 and 16 volts. D The engine temperature sensor (ECT) indicates an engine temperature between 7C (20F) and 110C (230F). D Throttle angle is steady and throttle changes less than 2% per 125 milliseconds.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected the fault. D If the misfire is severe enough to cause possible catalyst damage, the PCM will flash the MIL for as long as the misfire remains at catalyst damaging levels. D The PCM will disable the TCC operation. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle in which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0300 will clear after 40 consecutive warm-up cycles occur without a fault. D DTC P0300 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Diagnostic Aids
The Tech 2 display Misfire Cur. #1 through #6 can be useful to determine whether the misfire is isolated to a single cylinder.

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6E251

DTC P0300 Engine Misfire Detected

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Start the engine. Run the engine at idle. 2. Review and record the Tech 2 Freeze Frame data. 3. Operate the vehicle to duplicate the conditions present when the DTC was set (as defined by the Freeze Frame data). 4. Monitor the Tech 2 Misfire Cur. # display for each cylinder. Is Misfire Cur. # display increasing for any cylinder (indicating a misfire currently occurring)? Go to Step 3

Go to OBD System Check

Check the Procedure Refer to Diagnostic Aids

1. Visually and physically inspect the vacuum hoses for splits, kinks, and improper connections. 2. If a problem is found, repair or replace the vacuum hoses as necessary. Did your inspection reveal a problem? Verify repair Go to Step 4 1. Visually and physically inspect the following areas for vacuum leaks: D The intake manifold D The injector O-rings D The EGR adapter D The EGR feed pipes D ION Sensing Module 2. If a problem is found, repair the vacuum leak as necessary. Did your inspection reveal a vacuum leak? Verify repair Go to Step 5 1. Visually and physically inspect the crankcase ventilation valve for improper installation or damaged grommet. 2. If a problem is found, repair as necessary (refer to Crankcase Ventilation System). Did your inspection reveal a problem? Verify repair Go to Step 6 1. Inspect the MAF sensor inlet screen for damage or for the presence of foreign objects that may partially block the air flow sample through the MAF sensor. 2. If a problem is found, repair or replace the MAF sensor as necessary. Did your inspection of the MAF sensor reveal a condition requiring repair or replacement? Verify repair Go to Step 7

1. Remove the EGR valve and visually/physically inspect the valve to ensure that the pintle is not sticking partially open. Also, inspect the EGR valve pintle and seat for carbon deposits or burrs that may interfere with the pintle closing completely. 2. If a problem is found, clean the EGR valve pintle and seat or replace the EGR valve as necessary. Did your inspection reveal a problem? Verify repair Go to Step 8

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DTC P0300 Engine Misfire Detected (Cont'd)

Step Action Value(s) Yes No

1. Install a spark tester at the spark plug end of the ignition coil for a cylinder that indicated a misfire. 2. Crank the engine while observing the spark tester. A crisp, blue spark should be observed. Is adequate spark present? Go to Step 14 Go to Step 9 1. Remove and visually/physically inspect the ignition coil(s) associated with the cylinders that were indicated as misfiring. Ensure that the coil(s) are free of cracks. 2. If a problem is found, replace the damaged ignition coil(s) as necessary. Did any ignition coils require replacement? Verify repair Go to Step 10 1. Remove the spark plugs from the cylinders that were indicated as misfiring. 2. Visually inspect the spark plug electrodes. Does your inspection reveal any spark plugs exhibiting excessive fouling?

10

Go to Engine Mechanical Diagnosis

Go to Step 11

11

1. Visually inspect the spark plug insulators for cracks, carbon tracking, or other damage. 2. If a problem is found, replace the faulty spark plug(s) as necessary. Did your inspection reveal a problem? Verify repair Go to Step 12 1. Disconnect the MAF sensor electrical connector. BANK 1 L.T. 2. Operate the vehicle in closed loop while FUEL TRIM monitoring the BANK 1 L.T. FUEL TRIM and below +20%; BANK 1 S.T. FUEL TRIM display on the Tech 2. BANK 1 S.T. Do both values decrease below the specified values? FUEL TRIM below +50% Replace the ignition coil control module. Is the action complete? Verify repair 1. Visually and physically inspect the PCM injector grounds, power grounds and sensor grounds to ensure that they are clean, tight and in their proper locations. 2. If a problem is found, correct the faulty ground condition as necessary. Did your inspection reveal a poor ground? Verify repair Go to Step 15 1. Perform the Fuel System Pressure Test procedure. 2. If a problem is found, repair as necessary (refer to Engine Fuel or Fuel Metering System). Was a fuel system problem found? Verify repair Go to Step 16 1. Check the fuel for excessive water, alcohol, or other contaminants (refer to Diagnosis in Engine Fuel for procedure). 2. If a problem is found, correct the contaminated fuel condition as necessary. Was the fuel contaminated? Verify repair Go to Step 17

12

Go to Step 13

Replace the ignition coil of the affected cylinder

13 14

15

16

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6E253

DTC P0300 Engine Misfire Detected (Cont'd)

Step Action Value(s) Yes No

17

1. Perform the Injector Coil/Balance Test. 2. If a problem is found, replace faulty injector(s) as necessary. Did any of the injectors require replacement? Verify repair Go to Step 18 1. Check for an engine mechanical problem. Refer to Engine Mechanical Diagnosis to diagnose the following conditions: D A faulty or incorrect camshaft D Leaking or sticky valves or rings D Excessive valve deposits D Weak valve springs D Incorrect valve timing D A leaking head gasket D A loose or broken motor mount 2. If a problem is found, repair as necessary. Was a basic engine mechanical problem found and repaired? Verify repair Go to Step 19

18

19

1. Check for a transmission TCC problem. Refer to 4L30-E Automatic Transmission Diagnosis. 2. If a problem is found, repair the transmission as necessary. Refer to 4L30-E Automatic Transmission Unit Repair. Was a transmission problem found and repaired? Verify repair Verify repair Go to Step 20 Replace the MAF sensor. Is the action complete?

20

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Diagnostic Trouble Code (DTC) P0325 ION Sensing Module/ION Sensing Knock Intensity Circuit Fault

D06R200098

Circuit Description
The Power Control Module (PCM) checks the validity of the signals used in the ION Sensing module at the following engine operating conditions. D The test is performed to evacuate the Knock Intensity (KI) signal pulse width if it is within a predetermined range. If the KI signal pulse width is out of the predetermined range, the fail counter will be incremented. If the failure counter exceeds the calibration, then test is complete and a failure will be reported. If the sample counter threshold is reached before the failure threshold, then the test is complete and a pass will be reported. This test will detect an open/short in the KI line circuit, ION module faults and analog input faults in the PCM.

D The PCM will store condition which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0325 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault. D DTC P0325 can be cleared using the Tech2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for setting the DTC

D D D D Ignition voltage is between 10volt and 16 volts. No Crank DTCs set. No EST DTCs set. No Misfire DTCs set.

Diagnostic Aids
An intermittent may be caused by the following: D Poor connections. D Misrouted harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D Poor connection at PCM- Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harness-Inspect the wiring harness for damage.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected the fault. D The PCM calculates an air flow value based on idle air control valve position, throttle position, RPM and barometric pressure.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

If the harness appears to be OK, observe the Knock Present, Knock Sensor Noise Channel display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault.

6E255

If DTC P0325 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P0325 Diagnostic Chart may isolate the cause of the fault.

DTC P0325 - ION Sensing Module Knock Intensity Circuit Fault

Step Action Value(s) Yes No

Was the On-Board (OBD) System Check performed? Go to Step 2

Go to OBD System Check

1. Ignition ON, engine OFF. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Records conditions as noted. 4. Using a Tech 2, monitor DTC info for DTC P0325. Does the Tech 2 indicate DTC P0325 failed this ignition? Go to Step 3

Check the Procedure Refer to Diagnostic Aids

1. Ignition OFF. 2. Disconnect the ION sensing module. 3. Disconnect the PCM. Is the action complete? Go to Step 4 Check the ION sensing harness between the PCM (F68) and ION sensing module circuit (RED Wire) at the KI line harness connector. Was a problem found? Verify repair Go to Step 6 Go to Step 5 1. Disconnect the ignition coil. Is the action complete? Check the ION sensing harness for open or short circuit between the ignition coil and ION sensing module circuit at the harness connector. Was a problem found? Verify repair Go to Step 7 Check the following items; 1. Ignition coil and ignition coil circuit. 2. Ignition coil ground circuit for a poor connection. 3. If a problem is found, repair wiring harness as necessary. Was a problem found? Verify repair Verify repair Go to Step 8 Go to Step 9

5 6

8 9

Replace the Ignition coil. Is the action complete? Check the following items; 1. ION sensing module ground circuit for a poor connection. 2. If a problem is found, repair wiring harness as necessary. Was a problem found? Go to Step 10 Verify repair Go to Step 11 Go to Step 11

10

Repair wiring harness. Is the action complete?

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DTC P0325 - ION Sensing Module Knock Intensity Circuit Fault (Cont'd)
Step Action Value(s) Yes No

11 12

Replace the ION Sensing module. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not .And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair Verify repair Go to Step 12

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6E257

Diagnostic Trouble Code (DTC) P0336 58X Reference Signal Circuit

D06R200044

Circuit Description
The 58X reference signal is produced by the crankshaft position (CKP) sensor. During one crankshaft revolution, 58 crankshaft pulses will be produced. The powertrain control module (PCM) uses the 58X reference signal to calculate engine RPM and crankshaft position. The PCM constantly monitors the number of pulses on the 58X reference circuit. If the PCM receives an incorrect number of pulses on the 58X reference circuit, DTC P0336 will set.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator lamp (MIL) after the second consecutive trip in which the fault is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0336 will clear after 40 consecutive warmup cycles have occurred without a fault. D DTC P0336 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D Engine is running. D Extra or missing pulse is detected between consecutive 58X reference pulses. D Above condition is detected in 10 of 100 crankshaft rotations.

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Diagnostic Aids
An intermittent may be caused by a poor connection, rubbed-through wire insulation or a wire broken inside the insulation. Check for: D Poor connection - Inspect the PCM harness and connectors for improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, disconnect the PCM, turn the ignition on and observe a voltmeter connected to the 58X reference circuit at the PCM harness connector while moving connectors and wiring harnesses related to the PCM. A change in voltage will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E259

DTC P0336 58X Reference Signal Circuit

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Attempt to start the engine. Does the engine start? Go to Step 3

Go to OBD System Check Go to Engine Cranks But Will Not Run chart Check the Procedure Refer to Diagnostic Aids

1. 2. 3. 4.

Review and record Failure Records information. Clear DTC P0336. Start the engine and idle for 1 minute. Observe DTCs. Go to Step 4

Is DTC P0336 set? 4 1. Disconnect the PCM and CKP sensor. 2. Check for an open or a short to ground in the 58X reference circuit between the CKP sensor connector and the PCM harness connector. 3. If a problem is found, repair as necessary. Was a problem found? 5 1. Reconnect the PCM and CKP sensor. 2. Connect a DVM to measure voltage on the 58X reference circuit at the PCM connector. 3. Observe the voltage while cranking the engine. Is the voltage near the specified value? 6 Check the connections at the CKP sensor and replace the terminals if necessary. Did any terminals require replacement? 7 Replace the CKP sensor. Use caution to avoid any hot oil that may drip out. Is the action complete? 8 Check connections at the PCM and replace the terminals if necessary. Did any terminals require replacement? 9 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?

Verify repair

Go to Step 5

2.5 V

Go to Step 8

Go to Step 6

Verify repair

Go to Step 7

Verify repair

Verify repair

Go to Step 9

Verify repair

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Diagnostic Trouble Code (DTC) P0337 CKP Sensor Circuit Low Frequency

D06R200044

Circuit Description
The 58X reference signal is produced by the crankshaft position (CKP) sensor. During one crankshaft revolution, 58 crankshaft reference pulses will be produced. The powertrain control module (PCM) uses the 58X reference signal to calculate engine RPM and crankshaft position. The PCM constantly monitors the number of pulses on the 58X reference circuit. If the PCM does not receive pulses on the 58X reference circuit, DTC P0337 will set.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator lamp (MIL) after the second consecutive trip in which the fault is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0337 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0337 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D Engine cranking. D Crankshaft position (CKP) sensor signal is not present between two cam pulses. D CKP reference pulse is not detected within 8 CMP pulses.

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Diagnostic Aids
An intermittent may be caused by a poor connection, rubbed-through wire insulation or a wire broken inside the insulation. Check for: D Poor connection Inspect the PCM harness and connectors for improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, disconnect

the PCM, turn the ignition on and observe a voltmeter connected to the 58X reference circuit at the PCM harness connector while moving connectors and wiring harnesses related to the PCM. A change in voltage will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0337 CKP Sensor Circuit Low Frequency

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Go to Step 3 Attempt to start the engine. Does the engine start?

Go to OBD System Check Go to Chart 3 Check the Procedure Refer to Diagnostic Aid

2 3

1. 2. 3. 4.

Review and record Failure Records information. Clear DTC P0337. Start the engine and idle for 1 minute. Observe DTCs. Go to Step 4

Is DTC P0337 set? 4 1. Disconnect the CKP sensor. 2. Ignition ON. 3. Using a DVM, verify that 5 V reference and ground are being supplied at the sensor connector (PCM side). Are 4-6 volts and ground available at the sensor? 5 1. Ignition ON. 2. With a DVM, backprobe the PCM connector 5 V reference and ground connections. Are 5 V reference and ground available at the PCM? 6 Check 5 V reference or ground between the CKP sensor and PCM and repair the open circuit, short to ground or short to voltage. Is the action complete? 7 1. Ignition OFF. 2. Disconnect the PCM and CKP sensor. 3. Check for an open or a short to ground in the 58X reference circuit between the CKP sensor connector and the PCM harness connector. 4. If a problem is found, repair as necessary. Was a problem found? 8 1. Reconnect the PCM and CKP sensor. 2. Connect a DVM to measure voltage on the 58X reference circuit at the PCM connector. 3. Observe the voltage while cranking the engine. Is the voltage near the specified value? 9 Check the connections at the CKP sensor and replace the terminals if necessary. Did any terminals require replacement?

Go to Step 7

Go to Step 5

Go to Step 6

Go to Step 11

Verify repair

Verify repair

Go to Step 8

2.5 V

Go to Step 11

Go to Step 9

Verify repair

Go to Step 10

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DTC P0337 CKP Sensor Circuit Low Frequency (Cont'd)

Step Action Value(s) Yes No

10

Replace the CKP sensor. Use caution and avoid hot oil that may drip out. Is the action complete? Verify repair Check the connections at the PCM and replace the terminals if necessary. Did any terminals require replacement? Verify repair Go to Step 12 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

11

12

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E263

Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit

D06R200098

Circuit Description
ION Sensing Module has the function to energize and de-energize the primary ignition coil in response to signals from the PCM. The PCM controls ignition timing and dwell time. This diagnosis detects open circuit or short-circuiting in the Ignition Electronic Spark Timing (EST) line by monitoring EST signals. A failure determination is made when the signal voltage remains higher or lower than the threshold for corresponding fault code beyond a predetermined time period. When the PCM detects a problem on EST control circuit 1, it will set a DTC P0351.

D The output voltage is not equal to 0 volts when output is OFF. D Ten test failures occur within 10 samples of continuous spark events.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator lamp (MIL) the first time the fault is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle in which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0351 will clear after 40 consecutive warm-up cycles occur without a fault. D DTC P0351 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D The ignition is ON. D The engine is running, determined by the 58X crankshaft position input signal. D The output voltage is not equal to 5 volts when output is ON.

6E264

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Tech 2 display related to DTC P0351 while moving the connector and wiring related to the ignition system. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect the harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connections. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the

DTC P0351 Ignition 1 Control Circuit

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition ON, engine OFF. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Record conditions as noted. 4. Use a Tech 2 to monitor the DTC information for DTC P0351 until the DTC P0351 test runs. 5. Note the test result. Does the Tech 2 indicate DTC P0351 failed this ignition cycle? Go to Step 3 Verify repair Verify repair

Go to OBD System Check

Check the Procedure Go to Diagnostic Aids Go to Step 4 Go to Step 5

3 4 5

Check for faulty connection at ignition coil. Was a problem found? Check for faulty connection at PCM connector. Was a problem found? 1. Ignition ON, engine OFF. 2. Back probe the ignition control circuit 1 at the ION Sensing Module with a DVM. Is the voltage near the specified value? 25-55 mV Go to Step 6 Go to Step 9 1. Ignition ON, engine running. 2. Back probe the ignition control circuit at the ION Sensing Module for the cylinder being tested. Is the voltage in the specified range, rapidly toggling back and forth to a reading 20-50 mV higher? 100-180 mV Go to Step 7 Go to Step 13

1. Ignition OFF. 2. Disconnect the 3-pin and connector at the ignition coil. 3. Check ignition control circuit 1 voltage at the ignition coil connector while cranking the engine. Does the voltage measure between the specified values? 200-1200 mV Go to Step 8 Verify repair Go to Step 11

8 9

Replace the ignition coil. Is the action complete? 1. Ignition OFF. 2. Disconnect the PCM and the ignition coil. 3. Check ignition control circuit 1 for short to ground. Was a problem found? Verify repair Verify repair Go to Step 10 Go to Step 13 Check ignition control circuit 1 for short to voltage. Was a problem found?

10

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E265

DTC P0351 Ignition 1 Control Circuit (Cont'd)

Step Action Value(s) Yes No

11 12 13

Check for an open ignition control circuit 1. Was the ignition control circuit open? Repair the open ignition control circuit. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair Verify repair Go to Step 12 Go to Step 13

6E266

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0352 Ignition 2 Control Circuit

D06R200098

Circuit Description
ION Sensing Module has the function to energize and de-energize the primary ignition coil in response to signals from the PCM. The PCM controls ignition timing and dwell time. This diagnosis detects open circuit or short-circuiting in the Ignition Electronic Spark Timing (EST) line by monitoring EST signals. A failure determination is made when the signal voltage remains higher or lower than the threshold for corresponding fault code beyond a predetermined time period. When the PCM detects a problem on EST control circuit 2, it will set a DTC P0352.

D The output voltage is not equal to 0 volts when output is OFF. D Ten test failures occur within 10 samples of continuous spark events.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator lamp (MIL) the first time the fault is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle in which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0352 will clear after 40 consecutive warm-up cycles occur without a fault. D DTC P0352 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D The ignition is ON. D The engine is running, determined by the 58 X crankshaft position input signal. D The output voltage is not equal to 5 volts when output is ON.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E267

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect the harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connections. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the

Tech 2 display related to DTC P0352 while moving the connector and wiring related to the ignition system. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0352 Ignition 2 Control Circuit

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition ON, engine OFF. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Record conditions as noted. 4. Use a Tech 2 to monitor the DTC information for DTC P0352 until the DTC P0352 test runs. 5. Note the test result. Does the Tech 2 indicate DTC P0352 failed this ignition cycle? Go to Step 3 Verify repair Verify repair

Go to OBD System Check

Check the Procedure Refer to Diagnostic Aids Go to Step 4 Go to Step 5

3 4 5

Check for faulty connection at ignition coil. Was a problem found? Check for faulty connection at PCM connector. Was a problem found? 1. Ignition ON, engine OFF. 2. Back probe the ignition control circuit 2 at the ION Sensing Module with a DVM . Is the voltage near the specified value? 25-55 mV Go to Step 6 Go to Step 9 1. Ignition ON, engine running. 2. Back probe the ignition control circuit at the ION Sensing Module for the cylinder being tested. Is the voltage in the specified range, rapidly toggling back and forth to a reading 20-50 mV higher? 100-180 mV Go to Step 7 Go to Step 13

1. Ignition OFF. 2. Disconnect the 3-pin connector at the ignition coil. 3. Check ignition control circuit 2 voltage at the ignition coil connector while cranking the engine connector. Does the voltage measure between the specified 200-1200 mV values? Go to Step 8 Verify repair Go to Step 11

8 9

Replace the ignition coil. Is the action complete? 1. Ignition OFF. 2. Disconnect the PCM and the ignition coil. 3. Check ignition control circuit 2 for short to ground. Was a problem found? Verify repair Verify repair Go to Step 10 Go to Step 13 Check ignition control circuit 2 for short to voltage. Was a problem found?

10

6E268

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0352 Ignition 2 Control Circuit (Cont'd)

Step Action Value(s) Yes No

11 12 13

Check for an open ignition control circuit 2. Was the ignition control circuit open? Repair the open ignition control circuit. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair Verify repair Go to Step 12 Go to Step 13

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E269

Diagnostic Trouble Code (DTC) P0353 Ignition 3 Control Circuit

D06R200098

Circuit Description
ION Sensing Module has the function to energize and de-energize the primary ignition coil in response to signals from the PCM. The PCM controls ignition timing and dwell time. This diagnosis detects open circuit or short-circuiting in the Ignition Electronic Spark Timing (EST) line by monitoring EST signals. A failure determination is made when the signal voltage remains higher or lower than the threshold for corresponding fault code beyond a predetermined time period. When the PCM detects a problem on EST control circuit 3, it will set a DTC P0353.

D The output voltage is not equal to 0 volts when output is OFF. D Ten test failures occur within 10 samples of continuous spark events.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator lamp (MIL) the first time the fault is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle in which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0353 will clear after 40 consecutive warm-up cycles occur without a fault. D DTC P0353 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D The ignition is ON. D The engine is running, determined by the 58X crankshaft position input signal. D The output voltage is not equal to 5 volts when output is ON.

6E270

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Tech 2 display related to DTC P0353 while moving the connector and wiring related to the ignition system. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect the harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connections. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the

DTC P0353 Ignition 3 Control Circuit

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition ON, engine OFF. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Record conditions as noted. 4. Use a Tech 2 to monitor the DTC information for DTC P0353 until the DTC P0353 test runs. 5. Note the test result. Does the Tech 2 indicate DTC P0353 failed this ignition cycle? Go to Step 3 Verify repair Verify repair

Go to OBD System Check

Check the Procedure Refer to Diagnostic Aids Go to Step 4 Go to Step 5

3 4 5

Check for faulty connection at ignition coil. Was a problem found? Check for faulty connection at PCM connector. Was a problem found? 1. Ignition ON, engine OFF. 2. Back probe the ignition control circuit 3 at the ION Sensing Module with a DVM positive lead with the negative lead to ground. Is the voltage near the specified value? 25-55 mV Go to Step 6 Go to Step 9 1. Ignition ON, engine running. 2. Back probe the ignition control circuit at the ION Sensing Module for the cylinder being tested. Is the voltage in the specified range, rapidly toggling back and forth to a reading 20-50 mV higher? 100-180 mV Go to Step 7 Go to Step 13

1. Ignition OFF. 2. Disconnect the 3-pin connector at the ignition coil. 3. Check ignition control circuit 3 voltage at the ignition coil connector while cranking the engine. Does the voltage measure between the specified 200-1200 mV values? Go to Step 8 Verify repair Go to Step 11

8 9

Replace the ignition coil. Is the action complete? 1. Ignition OFF. 2. Disconnect the PCM and the ignition coil. 3. Check ignition control circuit 3 for short to ground. Was a problem found? Verify repair Verify repair Go to Step 10 Go to Step 13 Check ignition control circuit 3 for short to voltage. Was a problem found?

10

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E271

DTC P0353 Ignition 3 Control Circuit (Cont'd)

Step Action Value(s) Yes No

11 12 13

Check for an open ignition control circuit 3. Was the ignition control circuit open? Repair the open ignition control circuit. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair Verify repair Go to Step 12 Go to Step 13

6E272

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0354 Ignition 4 Control Circuit

D06R200098

Circuit Description
ION Sensing Module has the function to energize and de-energize the primary ignition coil in response to signals from the PCM. The PCM controls ignition timing and dwell time. This diagnosis detects open circuit or short-circuiting in the Ignition Electronic Spark Timing (EST) line by monitoring EST signals. A failure determination is made when the signal voltage remains higher or lower than the threshold for corresponding fault code beyond a predetermined time period. When the PCM detects a problem on EST control circuit 4, it will set a DTC P0354.

D The output voltage is not equal to 0 volts when output is OFF. D Ten test failures occur within 10 samples of continuous spark events.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator lamp (MIL) the first time the fault is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle in which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0354 will clear after 40 consecutive warm-up cycles occur without a fault. D DTC P0354 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D The ignition is ON. D The engine is running, determined by the 58X crankshaft position input signal. D The output voltage is not equal to 5 volts when output is ON.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E273

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect the harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connections. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the

Tech 2 display related to DTC P0354 while moving the connector and wiring related to the ignition system. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0354 Ignition 4 Control Circuit

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition ON, engine OFF. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Record conditions as noted. 4. Use a Tech 2 to monitor the DTC information for DTC P0354 until the DTC P0354 test runs. 5. Note the test result. Does the Tech 2 indicate DTC P0354 failed this ignition cycle? Go to Step 3 Verify repair Verify repair

Go to OBD System Check

Check the Procedure Refer to Diagnostic Aids Go to Step 4 Go to Step 5

3 4 5

Check for faulty connection at ignition coil. Was a problem found? Check for faulty connection at PCM connector. Was a problem found? 1. Ignition ON, engine OFF. 2. Back probe the ignition control circuit 4 at the ION Sensing with a DVM positive lead with the negative lead to ground. Is the voltage near the specified value? 25-55 mV Go to Step 6 Go to Step 9 1. Ignition ON, engine running. 2. Back probe the ignition control circuit at the ION Sensing Module for the cylinder being tested. Is the voltage in the specified range, rapidly toggling back and forth to a reading 20-50 mV higher? 100-180 mV Go to Step 7 Go to Step 13

1. Ignition OFF. 2. Disconnect the 3-pin connector at the ignition coil. 3. Check ignition control circuit 4 voltage at the ignition coil connector while cranking the engine. Does the voltage measure between the specified 200-1200 mV values? Go to Step 8 Verify repair Go to Step 11

8 9

Replace the ignition coil. Is the action complete? 1. Ignition OFF. 2. Disconnect the PCM and the ignition coil. 3. Check ignition control circuit 4 for short to ground. Was a problem found? Verify repair Verify repair Go to Step 10 Go to Step 13 Check ignition control circuit 4 for short to voltage. Was a problem found?

10

6E274

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0354 Ignition 4 Control Circuit (Cont'd)

Step Action Value(s) Yes No

11 12 13

Check for an open ignition control circuit 4. Was the ignition control circuit open? Repair the open in ignition control circuit. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair Verify repair Go to Step 12 Go to Step 13

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E275

Diagnostic Trouble Code (DTC) P0355 Ignition 5 Control Circuit

D06R200098

Circuit Description
ION Sensing Module has the function to energize and de-energize the primary ignition coil in response to signals from the PCM. The PCM controls ignition timing and dwell time. This diagnosis detects open circuit or short-circuiting in the Ignition Electronic Spark Timing (EST) line by monitoring EST signals. A failure determination is made when the signal voltage remains higher or lower than the threshold for corresponding fault code beyond a predetermined time period. When the PCM detects a problem on EST in control circuit 5, it will set a DTC P0355.

D The output voltage is not equal to 0 volts when output is OFF. D Ten test failures occur within 10 samples of continuous spark events.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator lamp (MIL) the first time the fault is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle in which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0355 will clear after 40 consecutive warm-up cycles occur without a fault. D DTC P0355 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D The ignition is ON. D The engine is running, determined by the 58X crankshaft position input signal. D The output voltage is not equal to 5 volts when output is ON.

6E276

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Tech 2 display related to DTC P0355 while moving the connector and wiring related to the ignition system. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect the harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connections. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the

DTC P0355 Ignition 5 Control Circuit

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition ON, engine OFF. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Record conditions as noted. 4. Use a Tech 2 to monitor the DTC information for DTC P0355 until the DTC P0355 test runs. 5. Note the test result. Does the Tech 2 indicate DTC P0355 failed this ignition cycle? Go to Step 3 Verify repair Verify repair

Go to OBD System Check

Check the Procedure Refer to Diagnostic Aids Go to Step 4 Go to Step 5

3 4 5

Check for faulty connection at ignition coil. Was a problem found? Check for faulty connection at PCM connector. Was a problem found? 1. Ignition ON, engine OFF. 2. Back probe the ignition control circuit 5 at the ION Sensing Module with a DVM positive lead with the negative lead to ground. Is the voltage near the specified value? 25-55 mV Go to Step 6 Go to Step 9 1. Ignition ON, engine running. 2. Back probe the ignition control circuit at the ION Sensing Module for the cylinder being tested. Is the voltage in the specified range, rapidly toggling back and forth to a reading 20-50 mV higher? 100-180 mV Go to Step 7 Go to Step 13

1. Ignition OFF. 2. Disconnect the 3-pin connector at the ignition coil. 3. Check ignition control circuit 5 voltage at the ignition coil connector while cranking the engine. Does the voltage measure between the specified 200-1200 mV values? Go to Step 8 Verify repair Go to Step 11

8 9

Replace the ignition coil. Is the action complete? 1. Ignition OFF. 2. Disconnect the PCM and the ignition coil. 3. Check ignition control circuit 5 for short to ground. Was a problem found? Verify repair Verify repair Go to Step 10 Go to Step 13 Check ignition control circuit 5 for short to voltage. Was a problem found?

10

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E277

DTC P0355 Ignition 5 Control Circuit (Cont'd)

Step Action Value(s) Yes No

11 12 13

Check for an open ignition control circuit 5. Was the ignition control circuit open? Repair the open ignition control circuit. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair Verify repair Go to Step 12 Go to Step 13

6E278

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0356 Ignition 6 Control Circuit

D06R200098

Circuit Description
ION Sensing Module has the function to energize and de-energize the primary ignition coil in response to signals from the PCM. The PCM controls ignition timing and dwell time. This diagnosis detects open circuit or short-circuiting in the Ignition Electronic Spark Timing (EST) line by monitoring EST signals. A failure determination is made when the signal voltage remains higher or lower than the threshold for corresponding fault code beyond a predetermined time period. When the PCM detects a problem on EST control circuit 6, it will set a DTC P0356.

D The output voltage is not equal to 0 volts when output is OFF. D Ten test failures occur within 10 samples of continuous circuit monitoring.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator lamp (MIL) the first time the fault is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle in which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0356 will clear after 40 consecutive warm-up cycles occur without a fault. D DTC P0356 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D The ignition is ON. D The engine is running, determined by the 58X crankshaft position input signal. D The output voltage is not equal to 5 volts when output is ON.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E279

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect the harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connections. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the

Tech 2 display related to DTC P0356 while moving the connector and wiring related to the ignition system. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0356 Ignition 6 Control Circuit

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition ON, engine OFF. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Record conditions as noted. 4. Use a Tech 2 to monitor the DTC information for DTC P0356 until the DTC P0356 test runs. 5. Note the test result. Does the Tech 2 indicate DTC P0356 failed this ignition cycle? Go to Step 3 Verify repair Verify repair

Go to OBD System Check

Check the Procedure Refer to Diagnostic Aids Go to Step 4 Go to Step 5

3 4 5

Check for faulty connection at ignition coil. Was a problem found? Check for faulty connection at PCM connector. Was a problem found? 1. Ignition ON, engine OFF. 2. Back probe the ignition control circuit 6 at the ION Sensing Module with a DVM positive lead with the negative lead to ground. Is the voltage near the specified value? 25-55 mV Go to Step 6 Go to Step 9 1. Ignition ON, engine running. 2. Back probe the ignition control circuit at the ION Sensing Module for the cylinder being tested. Is the voltage in the specified range, rapidly toggling back and forth to a reading 20-50 mV higher? 100-180 mV Go to Step 7 Go to Step 13

1. Ignition OFF. 2. Disconnect the 3-pin connector at the ignition coil. 3. Check ignition control circuit 6 voltage at the ignition coil connector while cranking the engine. Does the voltage measure between the specified 200-1200 mV values? Go to Step 8 Verify repair Go to Step 11

8 9

Replace the ignition coil. Is the action complete? 1. Ignition OFF. 2. Disconnect the PCM and the ignition coil. 3. Check ignition control circuit 6 for short to ground. Was a problem found? Verify repair Verify repair Go to Step 10 Go to Step 13 Check ignition control circuit 6 for short to voltage. Was a problem found?

10

6E280

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0356 Ignition 6 Control Circuit (Cont'd)

Step Action Value(s) Yes No

11 12 13

Check for an open ignition control circuit 6. Was the ignition control circuit open? Repair the open ignition control circuit. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair Verify repair Go to Step 12 Go to Step 13

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E281

Diagnostic Trouble Code (DTC) P0401 EGR Flow Insufficient

D06R200087

Circuit Description
The powertrain control module (PCM) tests the exhaust gas recirculation (EGR) system during deceleration by momentarily commanding the EGR valve to open while monitoring the manifold absolute pressure (MAP) sensor signal. When the EGR valve is opened, the PCM monitors the change in MAP input signal. The PCM compares the MAP change to a RPM vs. BARO table. When the PCM interprets the change in MAP to be out of limits, the PCM will set DTC P0401. The number of test samples required to accomplish this may vary according to the severity of the detected flow error. Normally, the PCM will only allow one EGR flow test sample to be taken during an ignition cycle. To aid in verifying a repair, the PCM allows twelve test samples during the first ignition cycle following a Tech 2 Clear Info or a battery disconnect. Between nine and twelve samples should be sufficient for the PCM to determine adequate EGR flow and pass the EGR test.

D A/C clutch status is unchanged. D TCC status is unchanged.

Start Test
D D D D D D TP angle is less than 0.8%. EGR duty cycle is less than 1%. MAP is steady, changing less than 2 kPa. Engine speed is between 1100 RPM and 2000 RPM (M/T). MAP between 10 kPa and 40 kPa. Engine speed is between 900 RPM and 1500 rpm (A/T). The test will be aborted if the vehicle speed changes by more than 16 km/h (10 mph), engine speed changes by more than 100 RPM or the EGR is opened less than 95% of commanded position. The PCM will only run the EGR test during a closed throttle condition. The PCM will only run the EGR test at vehicle speeds above 24 km/h (15 mph). Several deceleration cycles will be necessary to run a sufficient number of EGR flow tests.

D D D

Conditions for Setting the DTC

D No TP sensor, vehicle speed sensor (VSS), MAP sensor, IAT sensor, IAC, EGR Pintle Position sensor, ECT sensor, misfire, or automatic transmission DTCs set. D Engine coolant temperature is greater than 60C (140F). D Ignition voltage between 11.5 and 16 volts. D Vehicle speed is greater than 24 km/h (15 mph).

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected fault.

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TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Diagnostic Aids
Check for the following conditions: D Poor connection or damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the Actual EGR Position display on the Tech 2 while moving connectors and wiring harnesses related to the EGR valve. A change in the display will indicate the location of the fault. D Ensure EGR valve is correctly mounted. See On-Vehicle Service. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition. NOTE: If the EGR valve shows signs of excessive heat, check the exhaust system for blockage (possibly a plugged catalytic converter) using the Restricted Exhaust System Check.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart 3. A malfunctioning MAP sensor can set an EGR DTC. The MAP sensor could send a constant signal which is not low enough to set a low MAP DTC. The constant signal from the MAP sensor also may not be high enough to set a high MAP DTC. This step verifies that the MAP sensor is responding.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E283

DTC P0401 EGR Flow Insufficient

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Go to DTC 1404 Is DTC P1404 also set? 1. Start the engine. 2. Monitor the MAP signal with a Tech 2 while idling. 3. While idling, jab the accelerator pedal about halfway down and immediately let the engine return to idle. Did the MAP value on the Tech 2 show an immediate large change? Go to Step 5 Verify repair

Go to OBD System Check Go to Step 3

2 3

Go to Step 4

4 5

Replace the MAP sensor. Is the action complete? 1. Inspect the exhaust system for modification of original installed parts or leaks. 2. If a problem was found, repair exhaust system as necessary. Was a condition present that required repair? Go to Step 8 Go to Step 6 1. Remove the EGR valve. 2. Visually and physically inspect the pintle, valve passages and the adapter for excessive deposits or any kind of a restriction. 3. If a problem is found, clean or replace EGR system components as necessary. Was a condition present that required repair? Go to Step 8 Go to Step 7 1. Remove the EGR inlet and outlet pipes from the exhaust manifold and the intake manifold. 2. Inspect the manifold EGR ports and the EGR inlet and outlet pipes for a blockage caused by excessive deposits or other damage. 3. If a problem is found, correct the condition as necessary. Was a condition present that required repair? Go to Step 8 1. Review and record the Tech 2 Failure Records data. 2. Clear DTC and monitor the Tech 2 System Info Screen while operating the vehicle as specified in Diagnostic Aids. 3. Using a Tech 2, monitor DTC info for DTC P0401 until the DTC P0401 test runs. 4. Note the test result. Does the Tech 2 indicate DTC P0401 failed this ignition? Repair complete

Check the Procedure Refer to Diagnostic Aids

6E284

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0402 EGR Pintle Crank Error

D06R200087

Circuit Description
The powertrain control module (PCM) monitors the EGR valve pintle position input to ensure that the valve responds properly to commands from the PCM, and to detect a fault if pintle position is stuck open. If the PCM detects a pintle position signal indicates more than 21.5% and more than for 625 msec during cranking, the PCM will set DTC P0402.

D A history DTC P0402 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0402 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Diagnostic Aids
Check for the following conditions: D Foreign material on EGR valve between pintle and seat may cause EGR stuck open. Inspect foreign material in EGR valve. D Excessive carbon deposit may cause unsmooth operation of EGR valve shaft. Inspect for carbon deposit and clean up inside of carbon deposit. D Poor connection or damaged harnessinspect the wiring harness for damage If the harness appears to be OK, observe the EGR actual position display on the Tech 2 while moving connectors and wiring harnesses related to EGR valve. A change in the display will indicate the location of the fault. NOTE: If the EGR valve shows signs of excessive heat, check the exhaust system for blockage (possibly a plugged catalytic converter) using the Restricted Exhaust System Check.

Conditions for Setting the DTC

D Ignition voltage is between 11 and 16 volts. D At Engine revolution less than 600 RPM, EGR pintle position indicates more than 21.0% and more than for 625 msecs.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator lamp (MIL) after the second consecutive trip in which the fault is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E285

DTC P0402 EGR Pintle Crank Open Error

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition ON, engine OFF, review and record Tech 2 Failure Records data. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor DTC info for DTC P0402 until the DTC P0402 test runs. Note the result. Does the Tech 2 indicates DTC P0402 failed this ignition? Go to Step 3

Go to OBD System Check

Check the Procedure Refer to Diagnostic Aids

1. Disconnect the EGR valve harness connector. 2. Inspect the EGR valve and connectors for damaged pin or terminals. Were there any damaged pins or terminals? Go to Step 4 Verify repair Go to Step 5 Repair the damaged pin or terminal. Is the action complete? 1. Remove EGR valve from Engine. 2. Inspect EGR valve whether there is any foreign material between seat and pintle. Was any foreign material in EGR valve? Go to Step 6 Go to Step 7 1. Remove EGR valve foreign material from EGR valve and clean up inside. 2. Visually inspect for damage of pintle and seat, which leakage may occur. Was there any severe damage which affects function? Go to Step 7 1. 2. 3. 4. 5. 6. Reconnect. Ignition OFF. Install the Tech 2. Run the engine at idle. On Tech-II, select special function for EGR. Use the UP arrow to increase the EGR from 0% to 40%. Go to Step 9 Verify repair Go to Step 8 Verify repair

4 5

Verify repair Go to Step 8

Did EGR work properly? 8 9 Replace the EGR valve. Does DTC P0402 still fail DTC test on the Tech 2? Replace the PCM. Is the action complete?

6E286

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0404 EGR Open Stuck

D06R200087

Circuit Description
The powertrain control module (PCM) monitors the EGR valve pintle position input to ensure that the valve responds properly to commands from the PCM, and to detect a fault if pintle position is different from commanded position. If the PCM detects a pintle position signal indicates more than 15 points different between current and commanded and more than 15 seconds, the PCM will set DTC P0404.

D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0404 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0404 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D D D D D The engine is running. Ignition voltage is between 11 and 16 volts. Intake Air Temp is more than 3C (37.4F). Desire EGR position is less than 3%. The difference between desired EGR and current EGR is less than 3%. D Difference EGR pintle position between current and commanded position becomes more than 15% and last more than 15 seconds, and this condition meets three times in a trip. Then it trigger, the PCM lights on.

Diagnostic Aids
Check for the following conditions: D Excessive carbon deposit on EGR valve shaft may cause EGR stuck open or unsmooth operation. Those carbon deposit may occur by unusual port operation. Clean up carbon may make smooth function of EGR valve. D Poor connection or damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the EGR actual position display on the Tech 2 while moving connectors and wiring harnesses related to EGR valve. A change in the display will indicate the location of the fault.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected the fault.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E287

DTC P0404 EGR Open Stuck

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition ON, engine OFF, review and record Tech 2 Failure Records Data. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor DTC info for DTC P0404 until the DTC P0404 test runs. Note the result. Does the Tech 2 indicates DTC P0404 failed this ignition? Go to Step 3

Go to OBD System Check

Check the Procedure Refer to Diagnostic Aids

1. Disconnect the EGR valve harness connector. 2. Inspect the EGR valve and connectors for damaged pin or terminals. Were there any damaged pins or terminals? Go to Step 4 Verify repair Go to Step 5 Is the action complete? Repair the damaged pin or terminal. 1. Remove EGR valve from Engine. 2. Inspect EGR valve whether there is any excessive carbon deposit on EGR shaft. Was excessive carbon deposit on EGR valve shaft? Go to Step 6 Go to Step 7 1. Clean up EGR valve shaft and inside of EGR valve. 2. Visually inspect damage of pintle and seat if is bent, leakage may occur. Was there any severe damage which affects function? Go to Step 8 1. 2. 3. 4. 5. 6. Reconnect. Ignition OFF. Install the Tech 2. Run the engine at idle. On the Tech 2, select EGR Control Test. Use the UP arrow to increase the EGR from 0% to 40%. Go to Step 9 Go to Step 8 Verify repair

4 5

Verify repair Go to Step 7

Did EGR work properly? 8 9 Replace the EGR valve. Does DTC P0404 still fail DTC test on the Tech 2? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?

Verify repair

6E288

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0405 EGR Low Voltage

D06R200087

Circuit Description
The powertrain control module (PCM) monitors the EGR valve pintle position input to ensure that the valve responds properly to command from the PCM. If current pintle position voltage indicates less than 0.1 V and last more than 10 seconds, then the PCM will set DTC P0405.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0402 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0405 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D Ignition voltage is between 11 and 16 volts. D Intake Air Temp is more than 3C (37.4F). D EGR pintle position is less than 2% and last more than 10 sec. Action taken when the DTC sets.

Diagnostic Aids
Check for the following conditions: D Poor connection or damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the EGR actual position display on the Tech 2 while moving connectors and wiring harnesses related to EGR valve. A change in the display will indicate the location of the fault.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected the fault. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in Failure Records data.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E289

DTC P0405 EGR Low Voltage

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition ON, engine OFF, review and record Tech 2 Failure Records Data. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor DTC info for DTC P0405 until the DTC P0405 test runs. Note the result. Does the Tech 2 indicates DTC P0405 failed this ignition? Go to Step 3

Go to OBD System Check

Check the Procedure Refer to Diagnostic Aids

1. Disconnect the EGR valve harness connector. 2. Inspect the EGR valve and connectors for damaged pin or terminals. Were there any damaged pins or terminals? Go to Step 4 Verify repair Go to Step 5 Repair the damaged pin or terminal. Is the action complete? 1. Disconnect the EGR harness connector. 2. Ignition ON. 3. At the EGR valve, use a DVM to check the voltage at the 5 volt reference wire (BLU/RED) and ground. Did the DVM indicate the specified value? 46 V Go to Step 6 Go to Step 7 1. Disconnect the EGR harness connector. 2. Measure resistance between terminal 5 volt reference wire and ground. Was resistance in range? 55.5 Km Go to Step 10 Go to Step 17 1. Ignition ON. 2. At the PCM connector, backprobe with a DVM at the 5 volt reference for the EGR valve. Did the DVM indicate the specified value? 46 V Go to Step 8 Verify repair Verify repair Go to Step 9 Repair the open 5 volt reference circuit. Is the action complete? Repair the damaged sensor ground wire. Is the action complete? 1. Disconnect the EGR harness 2. Use an ohmmeter to measure between the pintle position pin and the sensor ground pin on the EGR valve. NOTE: J-35616 Connector Test Adapter Kit may be useful for gaining access to the recessed pins on the valve. Was the ohmmeter reading approximately equal to the specified value? 1 to 1.25 Km Go to Step 13 Go to Step 17

4 5

8 9 10

11

1. Ignition ON. 2. Backprobe with a DVM to measure voltage at EGR valve pintle position pin and sensor ground pin. Was voltage in range?

Less than 0.1 V

Go to Step 17

Go to Step 12

6E290

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0405 EGR Low Voltage (Cont'd)

Step Action Value(s) Yes No

12

1. Ignition ON. 2. Backprobe with a DVM to measure voltage at PCM sensor ground pin and pintle position pin. Was voltage in range? 1. Ignition OFF. 2. Disconnect the EGR harness. 3. Check short circuit between EGR pintle position circuit and EGR ground circuit. Was any short circuit?

Less than 0.1 V

Go to Step 13

Go to Step 18

13

Go to Step 14

Go to Step 18

14

Locate and repair the short to ground in the pintle position circuit Is the action complete? Verify repair 1. 2. 3. 4. Ignition OFF. Disconnect the PCM. Ignition ON. Measure the voltage between the EGR pintle position circuit and ground.

15

Is the measured voltage near the specified value? 16 Check for a short circuit between other wires and the pintle position circuit Is there any short circuit?

Less than 0.1 V

Go to Step 17 Repair short circuit and then Verify repair Go to Step 18 Go to Step 4

Go to Step 16

17 18 19 Replace the EGR valve. Does DTC P1404 still fail DTC test on the Tech 2? Examine the PCM pin and terminal connection. Was there a damaged terminal? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?

Go to Step 17 Verify repair Go to Step 19

Verify repair

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E291

Diagnostic Trouble Code (DTC) P0406 EGR High Voltage

D06R200087

Circuit Description
The powertrain control module (PCM) monitors the EGR valve pintle position input to ensure that the valve responds properly to command from the PCM. If current pintle position voltage indicates more than 4.8 V and last more than 10 seconds, then the PCM will set DTC P0406.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0402 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0404 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D Ignition voltage is between 11 and 16 volts. D Intake Air temp is more than 3C (37.4F). D EGR pintle position is more than 99% and last more than 10 sec.

Diagnostic Aids
Check for the following conditions: D Poor connection or damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the EGR actual position display on the Tech 2 while moving connectors and wiring harnesses related to EGR valve. A change in the display will indicate the location of the fault.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected the fault. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in Failure Records data.

6E292

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0406 EGR High Voltage

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition ON, engine OFF, review and record Tech 2 Failure Records Data. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor DTC info for DTC P0406 until the DTC P0406 test runs. Note the result. Does the Tech 2 indicates DTC P0406 failed this ignition? Go to Step 3

Go to OBD System Check

Check the Procedure Refer to Diagnostic Aids

1. Disconnect the EGR valve harness connector. 2. Inspect the EGR valve and connectors for damaged pin or terminals. Were there any damaged pins or terminals? Go to Step 4 Verify repair Go to Step 5 Is the action complete? Repair the damaged pin or terminal. Is the action complete? 1. Disconnect the EGR harness connector. 2. Ignition ON. 3. At the EGR valve, use a DVM to check the voltage at the 5 volt reference wire (BLU/RED). Did the DVM indicate the specified value? 46 V Go to Step 8 Go to Step 6 1. Ignition ON. 2. At the PCM connector, backprobe with a DVM at the 5 volt reference for the EGR valve. Did the DVM indicate the specified value? 46 V Go to Step 7 Verify repair Go to Step 16 Repair the open 5 volt reference circuit Is the action complete? 1. Ignition OFF 2. Disconnect the EGR harness. 3. Use a DVM to check for an resistance between 5 V reference and Sensor Ground at EGR sensor terminals. NOTE: J-35616 Connector Test Adapter Kit may be useful for gaining access to the recessed pins on the valve. Was the measured resistance in range? 5 to 5 Km Go to Step 9 Go to Step 15

4 5

7 8

1. Ignition OFF. 2. Disconnect the EGR harness. 3. Use a DVM to check for an resistance between Sensor Ground and Signal Wire at EGR sensor terminal. Is there an open circuit? Go to Step 15 Go to Step 10 1. Ignition OFF. 2. Disconnect the EGR harness at PCM connector. 3. Use a DVM to check for shorted wire between S37 and F53. Is there a shorted wire? Go to Step 14 Go to Step 11

10

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E293

DTC P0406 EGR High Voltage (Cont'd)

Step Action Value(s) Yes No

11

1. Ignition ON. 2. Use a DVM to backprobe at terminal Connector of EGR valve for voltage. Was measured voltage more than 4.8 V? 1. Ignition ON. 2. Stay the EGR harness connected. 3. Check voltage by backprobing at PCM S37 terminal. Was voltage more than 4.8 V?

more than 4.8 V

Go to Step 12

Go to Step 12

12

4.8 V

Go to Step 16

Go to Step 13

13

1. Locate short circuit at EGR harness between BLU/RED to GRY/RED or GRY/RED to YEL, BLU/RED. 2. Replace EGR harness. Is the action complete? Verify repair Verify repair Go to Step 16 Verify repair Replace EGR harness. Is the action complete? Replace the EGR valve. Does DTC P1404 still fail DTC test on the Tech 2? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

14 15 16

6E294

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0420 TWC System Low Efficiency Bank 1

T321075

Circuit Description
To control emissions of hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx), a three-way catalyst (TWC) is used. The catalyst promotes a chemical reaction which oxidizes the HC and CO present in the exhaust gas, converting them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx, converting it to nitrogen. The powertrain control module (PCM) has the ability to monitor this process using the Bank 1 HO2S 1 and the Bank 1 HO2S 2 heated oxygen sensors. The Bank 1 HO2S 1 sensor produces an output signal which indicates the amount of oxygen present in the exhaust gas entering the three-way catalytic converter. The Bank 1 HO2S 2 sensor produces an output signal which indicates the oxygen storage capacity of the catalyst; this in turn indicates the catalysts ability to convert exhaust gases efficiently. If the catalyst is operating efficiently, the Bank 1 HO2S 1 signal will be far more active than that produced by the Bank 1 HO2S 2 sensor. If the PCM detects a level of Bank 1 HO2S 2 activity that indicates the catalyst is no longer operating efficiently, DTC P0420 will be set.

D Barometric Pressure is more than 72 kPa.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator lamp (MIL) the first time the fault is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0420 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0420 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition. The TWC Monitor Test Counter displayed on the Tech 2 may be used to monitor the progress of the TWC diagnostic. To complete the TWC diagnostic with a good catalyst, the counter must be allowed to increment to 49 samples and roll over to 0 at least twice. A failed catalyst

Conditions for Setting the DTC

D D D D D D D D D D No related DTCs. The engine is operating in closed loop, Engine air load is below 99%. Engine coolant temperature is between 70C (158F) and 120C (248F). Mass air flow is between 2.5 g/second and 10 g/second. Engine speed is below 200 RPM. Catalyst temperature is above 350C (662F). The PCM determines that the catalysts oxygen storage capacity is below the acceptable threshold. Intake Air Temperature is between 10C (14F) and 70C (158F). Throttle angle is less than 1.5%.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

will require three or more 50-sample tests to report a failure.

6E295

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 7. Difficulty completing the DTC P0420 Status This Ign, test may be encountered in areas where test conditions cannot be maintained easily, especially in urban areas. To minimize the amount of driving required to complete the DTC P0420 Status This Ign, test, use the following procedure: D Allow the engine to warm up completely.

D With the vehicle in Park, monitor mass air flow on the Tech 2 and hold part throttle to maintain a reading of over 12 g/second for at least 2 minutes. This will achieve the warm catalyst required for running the test. D Operate the vehicle in second or third gear to remain in the DTC P0420 test conditions described in Conditions for Setting the DTC as much as possible. If you must stop the vehicle, maintain the warm catalyst criteria as follows: Place the vehicle in Park or Neutral, Hold part throttle to maintain a mass air flow reading of over 15 g/second for the duration of the stop.

DTC P0420 TWC System Low Efficiency Bank 1

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Diagnose other DTC(s) first Are any other DTCs set (such as P0140)?

Go to OBD System Check

Go to Step 3

1. Visually and physically inspect the three-way catalytic converter for damage. Check for the following: D dents D severe discoloration caused by excessive temperatures D holes D internal rattle caused by damaged catalyst 2. Also, ensure that the three-way catalytic converter is a proper original equipment manufacturer part. Did your inspection reveal a problem? Go to Step 6 Go to Step 4 1. Visually and physically inspect the exhaust system between the three-way catalytic converter and the rear converter flange for leaks, damage, and loose or missing hardware. 2. If a problem is found, repair as necessary. Did your inspection reveal a problem? 1. Visually and physically inspect the Bank 1 HO2S 2. 2. Ensure that the Bank 1 HO2S 2 is secure and that the pigtail and wiring harness is not contacting the exhaust pipe or is not otherwise damaged. 3. If a problem is found, repair as necessary. Did your inspection reveal a problem?

Go to Step 7 to verify repair

Go to Step 5

Go to Step 7 to verify repair

Go to Step 6

6E296

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0420 TWC System Low Efficiency Bank 1 (Cont'd)

Step Action Value(s) Yes No

Replace the three-way catalytic converter. NOTE: Check for conditions which may cause catalyst damage (refer to Diagnostic Aids). Is the action complete? Go to Step 7 to verify repair

1. Review and record the Tech 2 Failure Records data. 2. Clear DTC P0420. 3. Start the engine and allow it to warm up until the engine coolant temperature monitored on the Tech 2 is above the specified value. 4. Run the engine to maintain the specified mass air flow range for at least 2 minutes. Engine 5. Operate the vehicle to maintain DTC P0420 test coolant temp: conditions (refer to DTC Test Description in greater than Diagnostic Support for detailed instructions). 60C 6. Using a Tech 2, monitor DTC info for DTC P0420 (140F). until the DTC P0420 test runs. Mass air flow: 7. Note the test result. between 8 Does the Tech 2 indicate DTC P0420 passed this g/second and ignition? 50 g/second

Complete repair. If a driveability symptom still exists, refer to Symptoms.

Check the Procedure Refer to Diagnostic Aids

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E297

Diagnostic Trouble Code (DTC) P0430 TWC System Low Efficiency Bank 2

T321075

Circuit Description
To control emissions of hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx), a three-way catalyst (TWC) is used. The catalyst promotes a chemical reaction which oxidizes the HC and CO present in the exhaust gas, converting them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx, converting it to nitrogen. The powertrain control module (PCM) has the ability to monitor this process using the Bank 2 HO2S 1 and the Bank 2 HO2S 2 heated oxygen sensors. The Bank 2 HO2S 1 sensor produces an output signal which indicates the amount of oxygen present in the exhaust gas entering the three-way catalytic converter. The Bank 2 HO2S 2 sensor produces an output signal which indicates the oxygen storage capacity of the catalyst; this in turn indicates the catalysts ability to convert exhaust gases efficiently. If the catalyst is operating efficiently, the Bank 2 HO2S 1 signal will be far more active than that produced by the Bank 2 HO2S 2 sensor. If the PCM detects a level of Bank 2 HO2S 2 activity that indicates the catalyst is no longer operating efficiently, DTC P0430 will be set.

D Engine coolant temperature is between 70C (158F) and 120C (248F). D Mass air flow is between 2.5 g/second and 10 g/second. D Change in engine load is below 8%. D Engine speed is below 200 RPM. D Catalyst temperature is above 350C (662F). D The PCM determines that the catalysts oxygen storage capacity is below the acceptable threshold. D Intake air temperature is between 20C (4F) and 70C (158F). D Throttle angle is less than 1.5%. D Barometric Pressure is more than 72 kPa.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator lamp (MIL) the first time the fault is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0430 will clear after 40 consecutive warm-up cycles have occurred without a fault.

Conditions for Setting the DTC

D No related DTCs. D The engine is operating in closed loop. D Engine air load is below 99%.

6E298

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

D Allow the engine to warm up completely. D With the vehicle in Park, monitor mass air flow on the Tech 2 and hold part throttle to maintain a reading of over 12 g/second for at least 2 minutes. This will achieve the warm catalyst required for running the test. D Operate the vehicle in second or third gear to remain in the DTC P0430 test conditions described in Conditions for Setting the DTC as much as possible. If you must stop the vehicle, maintain the warm catalyst criteria as follows: Place the vehicle in Park or Neutral, Hold part throttle to maintain a mass air flow reading of over 15 g/second for the duration of the stop. The TWC Monitor Test Counter displayed on the Tech 2 may be used to monitor the progress of the TWC diagnostic. To complete the TWC diagnostic with a good catalyst, the counter must be allowed to increment to 49 samples and roll over to 0 at least twice.

D DTC P0430 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 7. Difficulty completing the DTC P0430 Status This Ign, test may be encountered in areas where test conditions cannot be maintained easily, especially in urban areas. To minimize the amount of driving required to complete the DTC P0430 Status This Ign, test, use the following procedure:

DTC P0430 TWC System Low Efficiency Bank 2

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Diagnose other DTC(s) first Are any other DTCs set (such as P0160)?

Go to OBD System Check

Go to Step 3

1. Visually and physically inspect the three-way catalytic converter for damage. Check for the following: D dents D severe discoloration caused by excessive temperatures D holes D internal rattle caused by damaged catalyst 2. Also, ensure that the three-way catalytic converter is a proper original equipment manufacturer part. Did your inspection reveal a problem? Go to Step 6 Go to Step 4 1. Visually and physically inspect the exhaust system between the three-way catalytic converter and the rear converter flange for leaks, damage, and loose or missing hardware. 2. If a problem is found, repair as necessary. Did your inspection reveal a problem?

Go to Step 7 to verify repair

Go to Step 5

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E299

DTC P0430 TWC System Low Efficiency Bank 2 (Cont'd)

Step Action Value(s) Yes No

1. Visually and physically inspect the Bank 2 HO2S 2. 2. Ensure that the Bank 2 HO2S 2 is secure and that the pigtail and wiring harness is not contacting the exhaust pipe or is not otherwise damaged. 3. If a problem is found, repair as necessary. Did your inspection reveal a problem? Replace the three-way catalytic converter. NOTE: Check for conditions which may cause catalyst damage (refer to Diagnostic Aids). Is the action complete?

Go to Step 7 to verify repair

Go to Step 6

Go to Step 7 to verify repair

1. Review and record the Tech 2 Failure Records data. 2. Clear DTC P0430. 3. Start the engine and allow it to warm up until the engine coolant temperature monitored on the Tech 2 is above the specified value. 4. Run the engine to maintain the specified mass air flow range for at least 6 minutes. Engine 5. Operate the vehicle to maintain DTC P0430 test coolant temp: conditions (refer to DTC Test Description in greater than Diagnostic Support for detailed instructions). 70C 6. Using a Tech 2, monitor DTC info for DTC P0430 (158F). until the DTC P0430 test runs. Mass air flow: 7. Note the test result. between 2.5 Does the Tech 2 indicate DTC P0430 passed this g/second and ignition? 10 g/second

Complete repair. If a driveability symptom still exists, refer to Symptoms.

Check the Procedure Refer to Diagnostic Aids

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Diagnostic Trouble Code (DTC) P0440 EVAP System

D06R200084

Circuit Description
The evaporative system includes the following components: D Fuel tank D EVAP canister purge duty solenoid valve D Fuel tank (vapor) pressure sensor D Fuel pipes and hoses D Vapor lines D Fuel cap D Evaporative emissions canister D Purge lines D EVAP canister vent valve (purge solenoid) The evaporative leak detection diagnostic strategy is based on applying vacuum to the EVAP system and monitoring vacuum decay. The powertrain control module (PCM) monitors vacuum level via the fuel tank pressure sensor input. At an appropriate time, the EVAP canister purge solenoid and the EVAP canister vent solenoid are turned ON, allowing engine vacuum to draw a small vacuum on the entire evaporative emissions system. If a sufficient vacuum level cannot be achieved, a large leak or a faulty EVAP canister purge solenoid is indicated. This can be caused by the following conditions: D Disconnected or faulty fuel tank pressure sensor D Missing or faulty fuel cap D Disconnected, damaged, pinched, or blocked EVAP purge line D Disconnected or damaged EVAP vent hose

D Disconnected, damaged, pinched, or blocked fuel tank vapor line D Disconnected or faulty EVAP canister duty solenoid D Open ignition feed circuit to the EVAP canister vent solenoid D Damaged EVAP canister D Leaking fuel sender assembly O-ring D Leaking fuel tank or fuel filler neck Any of the above conditions can set DTC P0440.

Conditions for Setting the DTC

D No TP sensor, IAT sensor, ECT sensor, or MAP sensor DTCs set. D Start-up engine coolant temperature is less than 32C (90F). D Start-up engine coolant temperature is not more than 7C (13F) greater than start-up intake air temperature. D Start-up intake air temperature is greater than 4C (39F) . D Start-up intake air temperature is not more than 2C (4F) greater than start-up engine coolant temperature. D Vehicle speed is less than 5 mph (8 km/h). D Throttle position is greater than 3%. D Minimal fuel slosh. D BARO is greater than 70 kPa. D The EVAP system is unable to achieve or maintain vacuum during the diagnostic test.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

D Engine speed is less than 1200 RPM. D Above conditions are present for 60 to 180 seconds.

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Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected the fault. D The PCM will store conditions which were present when the DTC set as Freeze Frame and in the Failure Records data.

Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. If an EVAP canister vent solenoid or an EVAP canister purge solenoid electrical fault is present, the purge system will not operate correctly. Repairing the electrical fault will very likely correct the condition that set DTC P0440. 3. Checks the fuel tank pressure sensor at ambient pressure. 4. Determines whether or not the EVAP system can be sealed sufficiently to be pressurized. If not, the large leak must be located and corrected before continuing with diagnosis. 5. Verifies that the fuel tank pressure sensor accurately reacts to EVAP system pressure changes. 8. Checks for a blocked EVAP canister purge solenoid. The PCM commands the EVAP canister purge solenoid OFF (open) and the vent solenoid ON (closed) with the Tech 2 System Perf, EVAP output control function activated. Any pressure in the system should be released through the EVAP canister purge solenoid within a few seconds when System Perf, is activated. 9. Ensures that sufficient source vacuum is present at the EVAP canister purge solenoid.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF when the diagnostic has been run and the fault condition is no longer present. D A history DTC P0440 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0440 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Diagnostic Aids
Check for the following conditions: D Cracked or punctured EVAP canister. D Damaged or disconnected source vacuum line, EVAP purge line, vent hose or fuel tank vapor line. D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harnessInspect the wiring harness to the EVAP canister vent solenoid, EVAP canister purge solenoid and the fuel tank pressure sensor for an intermittent open or short circuit. D Kinked, pinched, or plugged vacuum source, EVAP purge, or fuel tank vapor lineVerify that the lines are not restricted.

DTC P0440 EVAP System

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Go to other DTC first Is DTC P0452 or P0453 also set? 1. 2. 3. 4. Ignition OFF. Remove the fuel cap. Ignition ON. Observe Fuel Tank Pressure on the Tech 2. 1.51 V Go to Step 4

Go to OBD System Check Go to Step 3

2 3

Does the Tech 2 indicate Fuel Tank Pressure at the specified value? 4 1. Replace the fuel cap. 2. Engine is running. 3. Observe Fuel Tank Vacuum on the Tech 2. Does Tech 2 indicate Fuel Tank Vacuum at the specified value?

Go to DTC P0452 or DTC P0453

1.471.51 V

Go to Step 5

Go to Step 6

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DTC P0440 EVAP System (Cont'd)

Step Action Value(s) Yes No

Ignition OFF. 1. Disconnect the fuel tank vapor line and the EVAP purge line from the EVAP canister. 2. Block the canister fitting for the fuel tank vapor line. 3. Connect a hand vacuum pump to the canister fitting for the EVAP purge line. 4. Ensure that the EVAP canister vent solenoid is still commanded ON (closed). 5. Attempt to apply vacuum to the EVAP canister. Observe Fuel tank pressure on the Tech 2. Does the Tech 2 indicate Fuel tank pressure at the specified value? 1.471.51 V Go to Step 8 Go to Step 7

1. Visually/physically check for the following conditions: D Restricted fuel tank vapor line. D Restricted EVAP purge line. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair 1. Visually/physically check for the following conditions: D Vent hose disconnected or the damaged. D EVAP canister damaged. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair

Go to DTC P0452 or DTC P0453

Go to Step 11

1. Visually/physically check for the following conditions: D Missing or faulty fuel cap. D Disconnected or leaking fuel tank vapor line. D Disconnected or damaged EVAP purge line. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Verify repair Go to Step 9 Replace the EVAP canister purge solenoid. Is the action complete? Locate and repair cause of no source vacuum to the EVAP canister purge solenoid. Is the action complete? Verify repair Verify repair Replace the EVAP canister vent solenoid. Is the action complete?

9 10

11

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E303

Diagnostic Trouble Code (DTC) P0442 EVAP System Small Leak Detected

D06R200084

Circuit Description
The evaporative system includes the following components: D Fuel tank D EVAP canister vent solenoid D Fuel tank (vapor) pressure sensor D Fuel pipes and hoses D Vapor lines D Fuel cap D Evaporative emissions canister D Purge lines D EVAP canister purge solenoid The evaporative leak detection diagnostic strategy is based on applying vacuum to the EVAP system and monitoring vacuum decay. The powertrain control module (PCM) monitors vacuum level via the fuel tank pressure sensor input. At an appropriate time, the EVAP canister purge solenoid and the EVAP canister vent solenoid are turned ON, allowing engine vacuum to draw a small vacuum on the entire evaporative emissions system. After the desired vacuum level has been achieved, the EVAP canister purge solenoid is turned OFF, sealing the system. A leak is detected by monitoring for a decrease in vacuum level over a given time period, all other variables remaining constant. A small leak in the system will cause DTC P0442 to be set.

Conditions for Setting the DTC

D No TP sensor, ECT sensor, Tank pressure sensor, IAT sensor, or MAP sensor DTCs set. D BARO is more than 70 kPa. D Engine speed is less than 1200 RPM. D Fuel level is between 15% and 85%. D Vehicle speed is less than 5 mph (8 km/h). D The DTC P0440 diagnostic test has passed. D A vacuum decay condition, indicating a small leak, is detected during the diagnostic test.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected fault. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0442 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0442 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

6E304

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Diagnostic Aids
Check for the following conditions: D Cracked or punctured EVAP canister. D Damaged source vacuum line, EVAP purge line, EVAP vent hose or fuel tank vapor line. D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harnessInspect the wiring harness to the EVAP canister vent solenoid, EVAP canister purge solenoid and the fuel tank pressure sensor for an intermittent open or short circuit. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. If an EVAP canister vent solenoid or an EVAP canister purge solenoid electrical fault is present, the purge system will not operate correctly. Repairing the electrical fault will very likely correct the condition that set DTC P0442. 3. Checks the fuel tank pressure sensor at ambient pressure. 4. Verifies that the fuel tank pressure sensor accurately reacts to EVAP system pressure changes.

DTC P0442 EVAP System Leak Detected

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. 2. 3. 4. Ignition OFF. Remove the fuel cap. Ignition ON. Observe Fuel Tank Pressure on the Tech 2. 1.51V Go to Step 3

Go to OBD System Check

Does the Tech 2 indicate Fuel Tank Pressure at the specified value? 3 IMPORTANT: Before continuing with diagnosis, zero the EVAP pressure and vacuum gauges on EVAP pressure/purge cart J 41413 (refer to tool operating instructions). 1. Replace the fuel cap. 2. Capture Failure Records data for DTC P0442 and clear DTCs. 3. Connect the EVAP pressure/purge cart J 41413 to the EVAP service port. 4. Using the Tech 2, command the EVAP canister vent solenoid ON (closed). 5. Using the EVAP pressure/purge cart J 41413, pressurize the EVAP system to the specified value. 6. Observe Fuel Tank Pressure on the Tech 2. Does the Tech 2 indicate Fuel Tank Pressure at the specified value? 4 1. Ignition ON, engine idling. 2. Using the Tech 2, command the EVAP canister vent solenoid ON (closed). 3. Using the EVAP pressure/purge cart J 41413, pressurize the EVAP system to 15 in. H2O. 4. Switch the rotary switch on the cart to HOLD and observe the EVAP pressure gauge. Does the pressure decrease to less than the specified value within 2 minutes?

Go to Fuel Tank Pressure System

1.47V

Go to Step 4

Go to Fuel Tank Pressure System

1.47 1.51V

Go to Step 5

Check the Procedure Refer to Diagnostic Aids

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E305

DTC P0442 EVAP System Leak Detected (Cont'd)

Step Action Value(s) Yes No

1. Disconnect the fuel tank vapor line and the EVAP purge line from the EVAP canister. 2. Block the canister fitting for the fuel tank vapor line. 3. Connect a hand vacuum pump to the canister fitting for the EVAP purge line. 4. Ensure that the EVAP canister vent solenoid is still commanded ON (closed). 5. Attempt to apply vacuum to the EVAP canister. Can the vacuum be maintained at the specific value? 1.46V Go to Step 8 Go to Step 6 1. Visually/physically check for the following conditions: D Vent hose disconnected or damaged. D EVAP canister damaged. 2. If a problem is found, repair as necessary. Was a problem found? Go to Step 10 Go to Step 10 Go to Step 7 Replace the EVAP canister vent solenoid. Is the action complete? 1. Visually/physically check for the following conditions: D Missing or faulty fuel cap. D Disconnected or leaking fuel tank vapor line. D Disconnected or damaged EVAP purge line. 2. If a problem is found, repair as necessary. Was a problem found? Go to Step 10 Go to Step 9 1. Using Tech 2, command the EVAP canister vent solenoid ON (closed). 2. With the cart connected to the EVAP service port, continuously attempt to pressurize the EVAP system by leaving the cart control knob in the pressurize position. 3. Using ultrasonic leak detector J 41416, locate and repair leak in EVAP system. (It may be necessary to partially lower the fuel tank to examine the connections on top of the tank.) Is the action complete? Go to Step 10 1. Ignition ON, engine not running. 2. Using the Tech 2, command the EVAP canister vent solenoid ON (closed). 3. Using the EVAP pressure/purge cart J 41413, pressurize and monitor the EVAP system to 15 in. H2O. 4. Switch the rotary switch on the cart to HOLD and observe the EVAP pressure gauge. Does the pressure decrease to less than the specified value within 2 minutes? 2.14V Go to Step 2 Verify repair

7 8

10

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TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0444 EVAP Purge Control Circuit Open

D06R200084

Circuit Description
The canister purge solenoid valve is controlled by the Power Train Control Module (PCM).The PCM monitors vacuum level via the fuel tank pressure sensor input. At an appropriate time, the EVAP canister purge solenoid is ON, allowing engine vacuum to draw a small vacuum on the entire evaporative emissions system.

D DTC P0444 can be cleared using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Diagnostic Aids
An intermittent may be caused by the following: D Poor connections. D Mis routed harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the EVAP purge solenoid display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0444 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P0444 Diagnostic Chart may isolate the cause of the fault.

Conditions for setting the DTC

D The Ignition is ON. D Engine is running. D System voltage is between 11.5 volts and 16 volts.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected the fault. D The PCM will store conditions which were present when the DTC set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0444 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E307

DTC P0444 EVAP Purge Control Circuit Open

Step Action Value(s) Yes No

Was the On-Board (OBD) System Check performed? Go to Step 2

Go to OBD System Check

1. Install the Tech 2. 2. Ignition is ON, 3. Engine is ON and operate the accelerator pedal for 3 or 4 times. 4. Observe the EVAP purge solenoid reading on the Tech 2. Is the EVAP purge solenoid reading near the specified More than 1% value?

Check the Procedure Refer to Diagnostic Aids

Go to Step 3

Check the power supply circuit. 1. 2. 3. 4. Ignition is OFF. Disconnect the canister purge solenoid valve. Ignition is ON. Using a DVM, measure at the EVAP purge solenoid connector between ground and voltage supply.

Was the measurement near the specified value? 4 Check the signal circuit for the EVAP purge solenoid. 1. 2. 3. 4. Ignition is OFF. Disconnect the canister purge solenoid valve. Disconnect the PCM. Check the circuit between EVAP purge solenoid connector and PCM connector.

Battery voltage

Go to Step 4

Go to Step 5

Is the problem found? 5 6 Repair the circuit as necessary. Is the action complete? Check the canister purge solenoid valve. Using a DVM, measure resistance for purge solenoid valve connector terminal. Is the purge solenoid valve resistance within the specified values? 7 8 Replace the canister purge solenoid valve. Is the action complete? Replace the IMPORTANT: The programmed. replacement PCM must be

Go to Step 5 Verify repair

Go to Step 6

2530 m (at 68F{20C})

Go to Step 8 Verify repair

Go to Step 7

Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

6E308

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0445 EVAP Purge Control Circuit Short

D06R200084

Circuit Description
The canister purge solenoid valve is controlled by the Power Train Control Module (PCM). The PCM monitors vacuum level via the fuel tank pressure sensor input. At an appropriate time, the EVAP canister purge solenoid is ON, allowing engine vacuum to draw a small vacuum on the entire evaporative emissions system.

D DTC P0445 can be cleared using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Diagnostic Aids
An intermittent may be caused by the following: D Poor connections. D Misrouted harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the EVAP purge solenoid display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0445 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P0445 Diagnostic Chart may isolate the cause of the fault.

Conditions for setting the DTC

D The Ignition is ON. D Engine is running. D System voltage is between 11.5 volts and 16 volts.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected the fault. D The PCM will store conditions which were present when the DTC set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0445 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E309

DTC P0445 EVAP Purge Control Circuit Short

Step Action Value(s) Yes No

Was the On-Board (OBD) System Check performed? Go to Step 2

Go to OBD System Check

1. Install the Tech 2. 2. Ignition is ON, 3. Observe the EVAP purge solenoid reading on the Tech 2. Is the EVAP purge solenoid reading near the specified value? 0%

Check the Procedure Refer to Diagnostic Aids

Go to Step 3

Check the signal circuit for canister purge solenoid valve. 1. 2. 3. 4. Ignition is OFF. Disconnect the canister purge solenoid valve. Disconnect the PCM. Check the circuit between EVAP purge solenoid connector and PCM connector. Go to Step 4 Verify repair Go to Step 5

Is the problem found? 4 5 Repair the circuit as necessary. Is the action complete? Check the canister purge solenoid valve. Using a DVM, measure resistance for purge solenoid valve connector terminal. Is the purge solenoid valve resistance within the specified values? 6 7 Replace the canister purge solenoid valve. Is the action complete? Replace the PCM. IMPORTANT: The programmed. replacement PCM must be

2530 (at 68F{20C})

Go to Step 7 Verify repair

Go to Step 6

Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

6E310

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0446 EVAP Canister Vent Control Malfunction

D06R200084

Circuit Description
The evaporative system includes the following components: D Fuel tank D EVAP canister vent solenoid D Fuel tank (vapor) pressure sensor D Fuel pipes and hoses D Vapor lines D Fuel cap D Evaporative emissions canister D Purge lines D EVAP canister purge solenoid An incorrect fuel tank pressure sensor signal is detected by monitoring fuel tank pressure when the key is first turned ON during a cold start. If the fuel tank pressure signal is out of range, DTC P0446 will set. A restricted or blocked EVAP vent path is detected by monitoring fuel tank pressure during normal operation (EVAP canister vent solenoid open, EVAP canister purge solenoid normal). With the EVAP canister vent solenoid open, vacuum level in the system should be very low unless the vent path is blocked. A blockage can be caused by the following condition: D Faulty EVAP canister vent solenoid (stuck closed). D Plugged, kinked or pinched vent hose. D Shorted EVAP canister vent solenoid driver circuit. D Plugged evaporative canister.

If any of these conditions are present, DTC P0446 will set.

Conditions for Setting the DTC

D No TP sensor, ECT sensor, Tank pressure sensor, IAT sensor, or MAP sensor DTCs set. D Start-up engine coolant temperature and start-up intake air temperature are more than 4C (39F) but less than 34C(93F). D Start-up engine coolant temperature is not more than 7C (13F) greater than start-up intake air temperature. D Fuel tank level is between 15% and 85%. D BARO is greater than 70 kPa.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected the fault. D The PCM will store conditions which were present when the DTC set as Freeze Frame and Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0446 will clear after 40 consecutive warm-up cycles have occurred without a fault.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

D DTC P0446 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

6E311

how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harnessInspect the wiring harness to the EVAP canister vent solenoid, EVAP canister purge solenoid and the fuel tank pressure sensor for an intermittent open or short circuit. D Kinked, pinched, or plugged vent hoseVerify that the vent hose between the EVAP canister and EVAP canister vent solenoid is not restricted. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. If a vent solenoid electrical fault is present, the purge system will not operate correctly. Repairing the electrical fault will very likely correct the condition that set DTC P0446. 3. Checks the fuel tank pressure sensor at ambient pressure. 4. Verifies that the fuel tank pressure sensor accurately reacts to EVAP system pressure changes. 6. Checks for a blocked EVAP canister.

DTC P0446 EVAP Canister Vent Control Malfunction

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition ON. 2. Capture Failure Records data for DTC P0446 and clear DTCs. 3. Ignition OFF. 4. Remove the fuel cap. 5. Ignition ON. 6. Observe Fuel Tank Pressure on the Tech 2. Does Tech 2 indicate Fuel Tank Pressure at the specified value? 1.51V Go to Step 3

Go to OBD System Check

Go to Fuel Tank Pressure System

IMPORTANT: Before continuing with diagnosis, zero the EVAP pressure and vacuum gauges on the EVAP pressure/purge cart J 41413 (refer to tool operating instructions). 7. Replace the fuel cap. 8. Using the Tech 2, command the EVAP vent solenoid ON (closed). 9. Connect the EVAP pressure/purge cart J 41413 to the EVAP service port. 10.Using the EVAP pressure/purge cart J 41413, pressurize the EVAP system to the specified value. 11. Observe Fuel Tank Pressure on the Tech 2. Does Tech 2 indicate Fuel Tank Pressure at the specified value? 1.52 1.69V Go to Step 4 Check the Procedure Refer to Diagnostic Aids

Go to Fuel Tank Pressure System

1. Maintain the EVAP pressure at 5 in. at H2O. 2. Using Tech 2, command the EVAP vent solenoid OFF (open) while observing the EVAP pressure gauge on the cart J 41413. Does the EVAP pressure return to the specified value within 5 seconds? 0 in. H2O

Go to Step 5

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TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0446 EVAP Canister Vent Control Malfunction (Cont'd)

Step Action Value(s) Yes No

1. Disconnect the large vent hose (marked AIR) from the EVAP canister. 2. Switch the rotary switch on the cart J 41413 to PURGE. 3. Ignition ON, engine idling at normal operating temperature. 4. Observe vacuum gauge for 5 seconds while holding the engine speed at 2500 RPM. Does the vacuum remain less than the specified value? 30 in. H2O Go to Step 6 Go to Step 8 1. Inspect the vent hose between the EVAP canister and the EVAP canister vent solenoid for kinks, pinched areas, or any other form of blockage. 2. If a problem is found, repair as necessary. Was a problem found? Go to Step 9 Go to Step 9 Go to Step 9 Go to Step 7 Replace the EVAP canister vent solenoid. Is the action complete? Replace the EVAP canister. Is the action complete? 1. Using Tech 2, command the EVAP canister vent solenoid ON (closed). 2. Using the EVAP pressure/purge cart J 41413, pressurize and monitor the EVAP system to 15 in. H2O. 3. Switch the rotary switch on cart J 41413 to HOLD. 4. Using the Tech 2, command the EVAP canister vent solenoid OFF (open) while observing the EVAP pressure gauge on cart J 41413. Does the EVAP pressure return to the specified value within 30 seconds? 0 in. H2O Verify repair Go to Step 2

7 8 9

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E313

Diagnostic Trouble Code (DTC) P0447 EVAP Vent Solenoid Circuit Open

D06R200084

Circuit Description
The canister purge solenoid valve is controlled by the Power Train Control Module (PCM).The PCM monitors vacuum level via the fuel tank pressure sensor input. At an appropriate time, the EVAP canister vent solenoid is ON, allowing engine vacuum to draw a small vacuum on the entire evaporative emissions system.

D DTC P0447 can be cleared using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Diagnostic Aids
An intermittent may be caused by the following: D Poor connections. D Misrouted harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the EVAP vent valve display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0447 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P0447 Diagnostic Chart may isolate the cause of the fault.

Conditions for setting the DTC

D The Ignition is ON. D Engine is running. D System voltage is between 11.5 volts and 16 volts.

Action Taken When the DTC Sets

D The PCM will not illuminate the malfunction indicator lamp (MIL). D The PCM will store conditions which were present when the DTC was set in the Failure Records data only.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0447 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault.

6E314

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0447 EVAP Vent Solenoid Circuit Open

Step Action Value(s) Yes No

Was the On-Board (OBD) System Check performed? Go to Step 2

Go to OBD System Check

1. Install the Tech 2. 2. Ignition is ON, 3. Engine is ONand operate the acceleration pedal for 3 or 4 times. 4. Observe the EVAP vent solenoid reading on the Tech 2. Is the EVAP vent solenoid reading to ON? Check the power supply circuit. 1. 2. 3. 4. Ignition is OFF. Disconnect the canister vent solenoid valve. Ignition is ON. Using a DVM, measure at the EVAP vent solenoid connector between ground and voltage supply.

Check the Procedure Refer to Diagnostic Aids

Go to Step 3

Was the measurement near the specified value? 4 Check the signal circuit for vent solenoid valve. 1. 2. 3. 4. Ignition is OFF. Disconnect the canister vent solenoid valve. Disconnect the PCM. Check the circuit between EVAP vent solenoid connector and PCM connector.

Battery voltage

Go to Step 4

Go to Step 5

Is the problem found? 5 6 Repair the circuit as necessary. Is the action complete? Check the canister vent solenoid valve. Using a DVM, measure resistance for vent solenoid valve connector terminal. Is the vent solenoid valve resistance within the specified values? 7 8 Replace the canister vent solenoid valve. Is the action complete? Replace the PCM. IMPORTANT: The programmed. replacement PCM must be

Go to Step 5 Verify repair

21.8-28.5m (at 68F{20C}) Verify repair

Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E315

Diagnostic Trouble Code (DTC) P0448 EVAP Vent solenoid Circuit Short

D06R200084

Circuit Description
The canister purge solenoid valve is controlled by the Power Train Control Module (PCM). The PCM monitors vacuum level via the fuel tank pressure sensor input. At an appropriate time, the EVAP canister vent solenoid is ON, allowing engine vacuum to draw a small vacuum on the entire evaporative emissions system.

D DTC P0448 can be cleared using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Diagnostic Aids
An intermittent may be caused by the following: D Poor connections. D Misrouted harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the EVAP vent valve display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0448 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P0448 Diagnostic Chart may isolate the cause of the fault.

Conditions for setting the DTC

D The Ignition is ON. D Engine is running. D System voltage is between 11.5 volts and 16 volts.

Action Taken When the DTC Sets

D The PCM will not illuminate the malfunction indicator lamp (MIL). D The PCM will store conditions which were present when the DTC was set in the Failure Records data only.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0448 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault.

6E316

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0448 EVAP Vent Solenoid Circuit Short

Step Action Value(s) Yes No

Was the On-Board (OBD) System Check performed? Go to Step 2

Go to OBD System Check

1. Install the Tech 2. 2. Ignition is ON, 3. Observe the EVAP vent solenoid reading on the Tech 2. Is the EVAP vent solenoid reading near the specified value? 0%

Check the Procedure Refer to Diagnostic Aids

Go to Step 3

Check the signal circuit for canister vent solenoid valve. 1. 2. 3. 4. Ignition is OFF. Disconnect the canister vent solenoid valve. Disconnect the PCM. Check the circuit between EVAP vent solenoid connector and PCM connector. Go to Step 4 Verify repair Go to Step 5

Is the problem found? 4 5 Repair the circuit as necessary. Is the action complete? Check the canister vent solenoid valve. Using a DVM, measure resistance for purge solenoid valve connector terminal. Is the vent solenoid valve resistance within the specified values? 6 7 Replace the canister vent solenoid valve. Is the action complete? Replace the PCM. IMPORTANT: The programmed. replacement PCM must be

21.8-28.5m (at 68F{20C})

Go to Step 7 Verify repair

Go to Step 6

Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E317

Diagnostic Trouble Code (DTC) P0452 Fuel Tank Pressure Sensor (Vapor Pressure Sensor) Low Voltage

D06R200087

Circuit Description
The powertrain control module (PCM) monitors fuel tank pressure sensor (Vapor pressure sensor) of the Enhanced Evap system. When the tank pressure output indicates low voltage, PCM will set DTC P0452.

D A history DTC P0402 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0404 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D Tank sensor output is less than 0.2 volts for 12.5 sec. D 100 test failures within a 200 tests.

Diagnostic Aids
Check for the following conditions: D Open circuit of 5 volt reference line Inspect wiring harness from PCM to the sensor. The PCM turns P0452, and P0107 at the same time. D Open circuit or short circuit to ground line Inspect wiring harness from PCM to the sensor. The PCM turns P0452 and P0107 at the same time. D Tank fuel pressure sensor malfunction may cause P0452. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected the fault. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present.

6E318

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0452 Tank Pressure Sensor Low Voltage

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition ON, engine OFF, review and record Tech 2 Failure Records Data. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor DTC info for DTC P0452 until the DTC P0452 test runs. Note the result. Does the Tech 2 indicates DTC P0452 or P0452/P0107 failed this ignition?

Go to OBD System Check

P0452/P0107 turn on Go to Step 3 P0452 turns on Go to Step 6

Check the Procedure Refer to Diagnostic Aids

1. 2. 3. 4.

Ignition OFF. Disconnect connector at the PCM. Ignition ON. At the PCM connector, measure voltage with a DVM at F54 and S37 terminals. 46 V Go to Step 4 Go to Step 10

Was the voltage in range? 4 1. Ignition OFF. 2. Connect the PCM connector to the PCM. 3. Backprobe with a DVM at fuel tank pressure sensor between 5 V reference terminal and sensor ground terminal. Was the voltage within range? 5 1. Locate open wiring of 5 volt reference circuit from the PCM to fuel tank pressure sensor. 2. Repair wiring harness. Is the action complete? 6 1. Ignition ON 2. At the PCM connector, backprobe with a DVM at the sensor output for the voltage. Was voltage within the range? 7 At the sensor output terminal, backprobe with a DVM at the sensor output Was voltage within range? 8 1. Locate open circuit or short circuit to ground line. 2. Repair the harness. Is the action complete?

46 V

For P0452 go to Step 5 and for P0107, go to diagnosis section.

Go to Step 5

Verify repair

Less than 0.2 V Less than 0.2 V

Go to Step 7

Go to Step 10

Go to Step 9

Go to Step 8

Verify repair

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E319

DTC P0452 Tank Pressure Sensor Low Voltage (Cont'd)

Step Action Value(s) Yes No

1. Locate open circuit or short circuit to ground line. 2. Repair the harness. Is the action complete? Verify repair Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

10

6E320

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0453 Fuel Tank Pressure Sensor (Vapor Pressure Sensor) High Voltage

D06R200087

Circuit Description
The powertrain control module (PCM) monitors fuel tank pressure sensor (Vapor pressure sensor) of the Enhanced Evap system. When the tank pressure output indicates high voltage , PCM will set DTC P0453.

D A history DTC P0453 will clear after 40 consecutive warm-up cycles have occurred without a fault. D Info function or by disconnecting the PCM battery feed.

Diagnostic Aids
Check for the following conditions: D Open circuit of sensor ground line Inspect wiring harness from PCM to the sensor. The PCM turns P0453, and P0108 at the same time. D Open circuit or short circuit to 5 volt reference line Inspect wiring harness from PCM to the sensor. The PCM turns P0453 and P0108 at the same time. D Tank fuel pressure sensor malfunction may cause P0453. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Conditions for Setting the DTC

D Tank sensor output is more than 4.9 volts for 12.5 sec. D 100 test failures within a 200 tests.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected the fault. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E321

DTC P0453 Fuel Tank Pressure Sensor High Voltage

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition ON, engine OFF, review and record Tech 2 Failure Records Data. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor DTC info for DTC P0453 until the DTC P0453 test runs. Note the result. Does the Tech 2 indicates DTC P0452 or P0452/P0107 failed this ignition?

Go to OBD System Check

P0453/P0108 turn on Go to Step 3 P0452 turns on Go to Step 6

Check the Procedure Refer to Diagnostic Aids

1. 2. 3. 4.

Ignition OFF. Disconnect connector at the PCM. Ignition ON. At the PCM connector, measure voltage with a DVM at F54 and S37 terminals. 46 V Go to Step 4 Go to Step 10

Was the voltage in range of voltage? 4 1. Ignition OFF. 2. Connect the PCM connector to the PCM. 3. Disconnect sensor harness at fuel pressure sensor. Measure voltage with a DVM at the end of the tank pressure wiring between 5 V reference terminal and sensor ground terminal. Was the voltage within range? 5 1. Locate open wiring of ground line from the PCM to fuel tank pressure sensor. 2. Repair wiring harness. Is the action complete? 6 1. Ignition ON. 2. At the PCM connector, backprobe with a DVM at the sensor output for the voltage. Was voltage within range? 7 At the sensor output terminal, backprobe with a DVM at the sensor output. Was the voltage within range? 8 1. Locate open circuit or short circuit to ground line. 2. Repair the harness. Is the action complete?

46 V

For P0453 go to Step 6 and for P0108, go to diagnosis section.

Go to Step 5

Verify repair

More than 4.9 V More than 4.9 V

Go to Step 7

Go to Step 10

Go to Step 9

Go to Step 8

Verify repair

6E322

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0453 Fuel Tank Pressure Sensor High Voltage (Cont'd)

Step Action Value(s) Yes No

9 10

Replace the tank pressure sensor. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair Verify repair

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E323

Diagnostic Trouble Code (DTC) P0456 EVAP Very Small Leak

D06R200087

Circuit Description
The evaporative system includes the following components: D Fuel tank D EVAP canister vent solenoid D Fuel tank (vapor) pressure sensor D Vapor lines D Fuel cap D Evaporative emissions canister D Purge lines D EVAP canister purge solenoid The evaporative leak detection diagnostic strategy is based on applying vacuum to the EVAP system and monitoring vacuum decay. The powertrain control module(PCM)monitors vacuum level via the fuel tank pressure sensor input. At an appropriate time, the EVAP canister purge solenoid and the EVAP canister vent solenoid are turned ON, allowing engine vacuum to draw a very small look on the entire evaporative emissions system. After the desired vacuum level has been achieved, the EVAP canister purge solenoid is turned OFF, sealing the system. A leak is detected by monitoring for a decrease in vacuum level over a given time period, all other variables remaining constant. A very small leak in the system will cause DTC P0456 to be set.

Conditions for setting the DTC

D D D D D D D D D D D No MAP DTCs set. No TPS DTCs set. No IAT DTCs set. No ECT DTCs set. No tank pressure sensor DTCs set. Baro is more than 70KPa. Fuel level is between 40% and 80%. Throttle angle is less than 3%. Engine speed is less than 1200 RPM. Vehicle speed is less than 5 mph (8 km/h). A vacuum decay condition, indicating a very small leak, is detected during the diagnostic test.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator lamp (MIL) after the second consecutive trip in which the fault is detected. D The PCM will store condition which were present when the DTC was set as Freeze Frame and in the Failure Records data. Warm up cycles have occurred without a fault.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present.

6E324

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

D Poor connection at PCMInspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harness-Inspect the wiring harness to the EVAP canister purge solenoid and the fuel tank pressure sensor for an intermittent open or short circuit. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

D A history DTC P0456 will clear after 40 consecutive trip cycle during which the warm up cycles have occurred without a fault. D DTC P0456 can be cleared using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Diagnostic Aids
Check for the following conditions: D Cracked or punctured EVAP canister. D Damaged source vacuum line, EVAP purge line, EVAP vent hose or fuel tank vapor line. to wire connection.

Diagnostic Trouble Code(DTC)P0456 EVAP Very Small Leak

Step Action Value(s) Yes No

Was the On-Board(OBD)System Check performed? Go to Step 2

Go to OBD System Check

1. 2. 3. 4.

Ignition OFF. Remove the fuel cap. Ignition ON. Observe Fuel Tank Pressure on the Tech 2. 1.51V Go to Step 3

Does the Tech 2 indicate Fuel Tank Pressure at the specified value? 3 1. Visually/physically check for the following conditions: D Vent hose disconnected or damaged. D EVAP canister damaged. D Fuel cap damaged 2. If a problem is found, repair as necessary. Was a problem found? 4 1. 2. 3. 4. Ignition ON, engine OFF. Install the fuel cap. Review and record Tech 2 Failure Records data. Operate the vehicle within Failure Records conditions as noted. 5. Using theTech 2,monitor the DTC info for DTC P0456. Does the Tech 2 indicate DTC P0456? 5 1. Ignition ON, engine idling. 2. Observe Fuel Tank Pressure on the Tech 2. Does the Tech 2 indicate Fuel Tank Pressure at the specified value?

Go to Fuel Tank Pressure System

Verify repair

Go to Step 4

Go to Step 5 Check the Procedure Refer to Diagnostic Aids

Check the Procedure Refer to Diagnostic Aids

Go to Step 6

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E325

Diagnostic Trouble Code(DTC)P0456 EVAP Very Small Leak (Cont'd)

Step Action Value(s) Yes No

1. Ignition ON, engine idling. 2. Using theTech 2, command the EVAP canister vent solenoid ON (closed) 3. Observe EVAP canister vent solenoid operation second value? 4. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 7 1. Visually/physically check for the following conditions: D Disconnected or leaking fuel tank vapor line. D Disconnected or damaged EVAP purge line. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair

Check the Procedure Refer to Diagnostic Aids

6E326

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0461 Fuel Level Sensor Performance

D06R200091

Circuit Description
The fuel level sensor is an important input to powertrain control module (PCM) for the enhanced evaporative system diagnostic. Fuel level information is needed for the PCM to know the volume of fuel in the tank. The fuel level affects the rate of change in air pressure in the evaporative system. The sending unit is a float in the fuel tank which moves a wiper arm across a variable resistor. Low fuel level causes high resistance in the sending unit, and this is recognized by the PCM because the circuit operates at a corresponding low voltage. When the circuit is continuously open or has a high resistance connection, DTC P0461 is set.

When there are 12 test failures within 80 test samples, it is stored.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator lamp (MIL) after the second consecutive trip in which the fault is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the DTC

D DTC P0461 can be cleared by using the scan tool Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D Sensor output change is more than 2% within 200km. Or Sensor movement position change is less than 15% within 200km. D IAT is more than 0C. D MAP changing in 3 sec is less than 10kPa. D Engine speed changing in 3 sec is less than 50rpm.

Diagnostic Aids
D Damaged harnessInspect the wiring harness for damage. If the harness appears to be OK, observe the fuel level display on the scan tool while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E327

DTC P0461 Fuel Level Sensor Performance

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. 2. 3. 4. Ignition Off, Engine Off. Install Tech 2. Ignition On, Engine Off. Check DTC P0462, P0463.

Go to OBD System Check

Was the DTC stored? 3 4 Check DTC P0464. Was the DTC stored? 1. Ignition Off, Engine Off. 2. Replace the fuel level sensor. Was the action complete?

Go to applicable DTC table Go to DTC P464 table

Go to Step 3 Go to Step 4

Verify repair

6E328

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0462 Fuel Level Sensor CircuitLow Voltage

D06R200091

Circuit Description
The fuel level sensor is an important input to powertrain control module (PCM) for the enhanced evaporative system diagnostic. Fuel level information is needed for the PCM to know the volume of fuel in the tank. The fuel level affects the rate of change in air pressure in the evaporative system. Several of the enhanced evaporative system diagnostic sub-tests are dependent upon correct fuel level information. The diagnostic will not run when the tank is more than 85% or less than 15% full. Fuel level DTCs should be diagnosed before other evaporative system DTCs because they can cause other DTCs to be set. The sending unit is a float in the fuel tank which moves a wiper arm across a variable resistor. Low fuel level causes high resistance in the sending unit, and this is recognized by the PCM because the circuit operates at a corresponding low voltage. When the circuit is continuously open or has a high resistance connection, DTC P0462 is set.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected the fault. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the DTC

D The PCM will turn the MIL OFF after three consecutive trips without a fault condition present. A history DTC will be cleared if no fault conditions have been detected for 40 warm-up cycles (engine coolant temperature has risen 4C (40F) from the start-up ECT, and ECT exceeds 71C (160F) during that same ignition cycle). D DTC P0462 can be cleared by using the scan tool Clear Info function or by disconnecting the PCM battery feed.

Diagnostic Aids
D Damaged harnessInspect the wiring harness for damage. If the harness appears to be OK, observe the fuel level display on the scan tool while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault.

Conditions for Setting the DTC

D D D D D Fuel tank level slosh test is completed. Fuel tank level main test is completed. Fuel tank level data is valid. Fuel tank level signal is less than a specified value. There are 100 test failures within a 200-test sample.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

8. The following chart can be used to check the sending unit:

6E329

DTC P0462 Fuel Level Sensor Circuit Low Voltage

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Disconnected the fuel level sensor harness from its connector at the fuel tank. 2. Ignition ON, engine OFF. 3. Using a DVM, measure the voltage between the sensor harness positive and ground wires. Is the voltage approximately equal to the specified value? 5V Go to Step 6

Go to OBD System Check

Go to Step 3

1. Ignition ON, engine OFF. 2. With a DVM, backprobe the PCM connector at the terminal which supplies 5 volts to the fuel level sensor. Is the voltage approximately equal to the specified value? 5V Go to Step 4 Go to Step 9

1. Ignition ON, engine OFF. 2. Fuel level sensor disconnected from wiring harness. 3. With a DVM, probe the 5-volt supply wire at the sensor harness. Is the voltage approximately equal to the value measured in Step 4? Go to Step 5 Go to Step 9

Check for open or high resistance connection in the ground wire between the PCM and the fuel level sensor. Is the action complete? Verify repair Remove the fuel level sensor and check the following: D Does the arm move freely? D Are the wires open or intermittently open when wiggled? D Do the resistance values match the specification chart? Was a problem found? Go to Step 7 Verify repair Go to Step 9 Replace the fuel level sensor. Is the action complete?

6E330

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0462 Fuel Level Sensor Circuit Low Voltage (Cont'd)

Step Action Value(s) Yes No

Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

Short to ground between the PCM connector and the fuel level sensor. Is the action complete? Verify repair

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E331

Diagnostic Trouble Code (DTC) P0463 Fuel Level Sensor CircuitHigh Voltage

D06R200091

Circuit Description
The fuel level sensor is an important input to powertrain control module (PCM) for the enhanced evaporative system diagnostic. Fuel level information is needed for the PCM to know the volume of fuel in the tank. The fuel level affects the rate of change in air pressure in the evaporative system. Several of the enhanced evaporative system diagnostic sub-tests are dependent upon correct fuel level information. The diagnostic will not run when the tank is more than 85% or less than 15%, full. Fuel level DTCs should be diagnosed before other evaporative system DTCs because they can cause other DTCs to be set. The sending unit is a float in the fuel tank which moves a wiper arm across a variable resistor. High fuel level causes low resistance in the sending unit. This is recognized by the PCM because the circuit operates at a corresponding high voltage. When the circuit is continuously shorted to a voltage source greater than a specified value, or when the 5 volt signal is shorted to ground, DTC P0463 is set.

D Fuel tank level signal is greater than a specified value. D There are 100 test failures within a 200-test sample.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected the fault. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the DTC

D The PCM will turn the MIL OFF after three consecutive trips without a fault condition present. A history DTC will be cleared if no fault conditions have been detected for 40 warm-up cycles (engine coolant temperature has risen 4C (40F) from the start-up ECT, and ECT exceeds 71C (160F) during that same ignition cycle) or the scan tool clearing function has been used. D DTC P0463 can be cleared by using the scan tool Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D Fuel tank level slosh test is completed. D Fuel tank level main test is completed. D Fuel tank level data is valid.

Diagnostic Aids
D Damaged harnessInspect the wiring harness for damage. If the harness appears to be OK, observe the fuel level display on the scan tool while moving connectors and wiring harnesses related to the sensor.

6E332

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

2. The ETC and MAP sensors share a ground at PCM terminal D9. 9. Equates the resistance values at various float positions to the following fuel gauge readings:

A change in the display will indicate the location of the fault.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart.

DTC P0463 Fuel Level Sensor Circuit High Voltage

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Disconnected the fuel level sensor harness from its connector at the fuel tank. 2. Ignition ON, engine OFF. 3. Using a DVM, measure the voltage between the sensor harness positive and ground wires. Is the voltage approximately equal to the specified value? 5V Go to Step 8

Go to OBD System Check

Go to Step 3

With the negative DVM lead connected to ground, use the positive DVM lead to probe the sensor ground wire with the harness still disconnected. Does the DVM indicate a short to a voltage source? Go to Step 4 Go to Step 5 Repair short to voltage between the sensor and the PCM. Is the repair complete? Verify repair With the negative DVM lead connected to ground, use the positive DVM lead to probe the sensor positive wire with the harness still disconnected. Does the DVM indicate a voltage greater than the specified value? 5V Go to Step 4 Verify repair Go to Step 6 Go to Step 7

6 7

Open circuit between the PCM connector and the fuel level sensor? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?

Verify repair

Remove the fuel level sensor and check the following: D Does the arm move freely? D Are the wire leads shorted together? D Do the resistance values match the specification chart? Was a problem found? Go to Step 9 Verify repair Go to Step 7 Replace the fuel level sensor. Is the repair complete?

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E333

Diagnostic Trouble Code (DTC) P0464 Fuel Level Sensor Noisy Signal

D06R200091

Circuit Description
The fuel level sensor is an important input to powertrain control module (PCM) for the enhanced evaporative system diagnostic. Fuel level information is needed for the PCM to know the volume of fuel in the tank. The fuel level affects the rate of change in air pressure in the evaporative system. The sending unit is a float in the fuel tank which moves a wiper arm across a variable resistor. Low fuel level causes high resistance in the sending unit, and this is recognized by the PCM because the circuit operates at a corresponding low voltage. When the circuit is continuously open or has a high resistance connection, DTC P0464 is set.

When there are 12 test failures within 80 test samples, it is stored.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator lamp (MIL) after the second consecutive trip in which the fault is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the DTC

D DTC P0464 can be cleared by using the scan tool Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D D D D D Sensor output changing is more than 15%. Fuel volume level is more than 0.01%. IAT is more than 0C. Vehicle speed is more than 1km/h. Throttle position is more than 2%.

Diagnostic Aids
D Damaged harnessInspect the wiring harness for damage. If the harness appears to be OK, observe the fuel level display on the scan tool while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault.

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DTC P0464 Fuel Level Sensor Noisy Signal

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition Off, Engine Off. 2. Perform Visual/Physical Check for following points. D Lose harness connector D Clacked harness connector D Poor wire condition D Fuel tank condition D Poor sensor condition 3. If a problem is found, repair as necessary. Was a problem found? Verify repair

Go to OBD System Check

Go to Step 3

1. Disassemble fuel tank on the vehicle. 2. Check the below items. D Fuel sender Was a problem found? Go to Step 4 Verify repair Go to Step 5 Go to Step 5 Replace the Fuel sender. Was the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Was the action completed? Verify repair

4 5

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6E335

Diagnostic Trouble Code (DTC) P0502 VSS Circuit Low Input

D06RY00070

Circuit Description
The vehicle speed sensor has a magnet rotated by the transmission output shaft. Attached to the sensor is a hall effect circuit the interacts with the magnetic field treated by the rotating magnet. A 12-volt operating supply for the speed sensor hall circuit is supplied from the meter fuse. The VSS pulses to ground the 9-volt signal sent from the powertrain control module (PCM) on the reference circuit. The PCM interprets vehicle speed by the number of pulses to ground per second on the reference circuit.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0502 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0502 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart. 10. To avoid backprobing the VSS and possibly damaging a seal or terminal, the VSS output can be tested at the point where the transmission harness connects to the engine harness. Power and ground are applied by jumpers to the VSS through the connectors which are located to the rear of the air cleaner assembly. The VSS signal is monitored with a DVM as the rear driveshaft turns. The wheels can be turned to rotate the driveshaft, or in 2-wheels-drive vehicles the driveshaft can be turned directly.

Conditions for Setting the DTC

D D D D D Engine is running. Engine speed is between 1800 RPM and 2500 RPM. Throttle angle is between 10% and 40%. Engine load is greater than 50 kPa. PCM detects no VSS signal for 12.5 seconds over a period of 15 seconds.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected the fault. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

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DTC P0502 VSS Circuit Low Input

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Go to Step 10 Does the speedometer work? 1. Disconnect the VSS connector. 2. Ignition ON. 3. Using a test light to battery +, probe the connector ground wire. Did the light illuminate? Go to Step 5 Verify repair

Go to OBD System Check Go to Step 3

2 3

Go to Step 4

4 5

Repair the sensor ground. Is the action complete? 1. Ignition ON, sensor disconnected. 2. Using a DVM, measure at the VSS connector between ground and voltage supply. Was the measurement near the specified value? Repair the open or short to ground which may have blown the meter fuse. Is the action complete? Verify repair 1. Ignition ON, VSS disconnected. 2. Using a DVM, measure at the VSS connector between ground and the wire from the speedometer. Was the measurement near the specified value? 7.5-8 V Go to Step 9 Go to Step 8 Check for an open or short circuit between the speedometer and the VSS. Was an open or short circuit located? Verify repair Verify repair Go to Step 9 Replace the speedometer. Is the action complete?

Battery voltage

Go to Step 7

Go to Step 6

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DTC P0502 VSS Circuit Low Input (Cont'd)

Step Action Value(s) Yes No

10

1. Ignition OFF. 2. Disconnect the MAF sensor. The connector attaches the VSS wires from the transmission harness to the left-side engine harness. 3. Disconnect the black 16-way connector. 4. Select a terminal adapter from kit J 35616 that can be used with a jumper to supply B+ to the blue wire with a yellow tracer (transmission side of the connector). 5. Use another terminal adapter to attach a voltmeter to the light-green wire with a white tracer (next to the wire in the previous step.) 6. Disconnect the blue connector next to the black 16-way connector, and locate the black/red tracer wire at one corner of the blue connector. The black/red wire is the VSS ground. Use a terminal adapter to attach a jumper to ground to the black/red VSS ground wire at the transmission side of the blue connector. 7. Raise the rear wheels off the ground with transmission in neutral. Does the DVM toggle back and forth between 0.6 V and 10 V as the wheels (and driveshaft) are rotated? Go to Step 11 Verify repair Go to Step 12

11 12

Replace the VSS. Is the action complete? Check for an open or short between the PCM and the speedometer. Was a problem found? Verify repair Go to Step 13 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

13

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Diagnostic Trouble Code (DTC) P0506 Idle Air Control System Low RPM

D06RY00158

Circuit Description
The powertrain control module (PCM) controls engine speed by adjusting the position of the throttle control valve (DC motor). The throttle motor is a DC motor driven by one coil. The PCM applies current to the DC motor coil in position (%) to adjustment the throttle valve into a passage in the throttle body to air flow. This method allows highly accurate control of engine speed and quick response to changes in engine load. If the PCM detects a condition where too low of an idle speed is present and the PCM is unable to adjust idle speed by increasing the throttle position, DTC P0506 will set, indicating a problem with the idle control system.

D All conditions are met for 10 seconds. D Barometric pressure is more than 74.5 kPa. D Engine speed is more than 100-200 RPM lower than desired idle based upon coolant temperature.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator lamp (MIL) after the second consecutive trip in which the fault is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D DTC P0506 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D No TPS, VSS, ECT, EGR, MAF, MAP, IAT, low voltage, fuel system, canister purge, injector control, or ignition control DTCs are set. D MAP is less than 60 kPa. D Canister purge duty cycle is above 10%. D Engine running time is more than 125 seconds. D Vehicle speed is less than 1 mph. D Engine coolant temperature (ECT) is above 50C (122F). D Ignition voltage is between 9.5 volts and 16.7 volts. D The throttle is closed. D EVAP purge duty cycle more than 10%.

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM or throttle DC motor Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

D Restricted air intake system Check for a possible collapsed air intake duct, restricted air filter element, or foreign objects blocking the air intake system. D Throttle body Check for objects blocking the ETC passage or throttle bore, excessive deposits in the ETC passage and on the ETC position, and excessive deposits in the throttle bore and on the throttle plate.

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D Large vacuum leak Check for a condition that causes a large vacuum leak, such as an incorrectly installed or faulty PCV valve or brake booster hose disconnected. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0506 Idle Air Control System Low RPM

Step Action Value(s) Yes No

Was the On-Board (OBD) System Check performed? Go to Step 2

Go to OBD System Check

Visually/physically inspect for the following conditions: D Throttle body tampering. D Restricted intake throttle system. Check for a possible collapsed air intake duct, restricted air filter element, or foreign objects blocking the air intake system. D Throttle body: Check for objects blocking the throttle passage or throttle bore, excessive deposits in the throttle passage and on the throttle valve, and excessive deposits in the throttle bore and on the throttle plate. D Throttle body with lever: Check for objects send round the throttle spring lever that lever is smooth movement, and spring lever has not excessive play Do any of the above require a repair? Visually/physically inspect for the following conditions: D Acceleration pedal tampering. D Acceleration pedal : Check for objects blocking the spring or pedal arm. D Acceleration pedal : Check for objects move the acceleration pedal that pedal is smooth movement, and acceleration pedal arm has not excessive play. Do any of the above require a repair? 1. Check for a poor connection at the throttle body harness connector. 2. Check for a poor connection at the acceleration position sensor harness connector. 3. If a problem is found, replace faulty terminals as necessary. Was a problem found?

Refer to appropriate section for onvehicle service

Go to Step 3

Refer to appropriatese ction for on-vehicle service

Go to Step 4

Verify repair

Go to Step 5

Check the following circuits for an open, short to voltage, short to ground, or poor connection at the PCM: D Throttle position sensor 1 circuit. D Throttle position sensor 2 circuit. D Throttle DC motor circuit. Vcc-GND 17km D Throttle position sensor resistance. SIG-DND D Throttle DC motor resistance. change D If a problem is found, repair as necessary. resistance0.3 100m Was a problem found?

Verify repair

Go to Step 6

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DTC P0506 Idle Air Control System Low RPM (Cont'd)

Step Action Value(s) Yes No

6 7

Replace the throttle valve. Is the action complete? 1. Check the following circuits for an open, short to voltage, short to ground, or poor connection at the PCM: Accelerator position sensor 1 circuit. Accelerator position sensor 2 circuit. Sensor resistance. 2. If a problem is found, repair as necessary. Was a problem found? Vcc-GND 46km SIG-DND change resistance Go to Step 7

Verify repair Go to Step 9 Go to applicable DTC table Go to applicable DTC table

Go to Step 8

8 9

Replace the acceleration position sensor. Is the action complete? Following below the DTCs stored: P1125, P1290, P1295, P1299 Following below the DTCs stored:P1514, P1515, P1516, P1523, P1271, P1272, P1273 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

Go to Step 10

10

Go to Step 11

11

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Diagnostic Trouble Code (DTC) P0507 Idle Air Control System High RPM

D06RY00158

Circuit Description
The powertrain control module (PCM) controls engine speed by adjusting the position of the throttle control valve (DC motor). The throttle motor is a DC motor driven by one coil. The PCM applies current to the DC motor coil in position (%) to adjustment the throttle valve into a passage in the throttle body to air flow. This method allows highly accurate control of engine speed and quick response to changes in engine load. If the PCM detects a condition where too high of an idle speed is present and the PCM is unable to adjust idle speed by increasing the throttle position, DTC P0507 will set, indicating a problem with the idle control system.

D All conditions are met for 10 seconds. D Engine speed is more than 100-200 RPM higher than desired idle based upon coolant temperature. D Barometric pressure is more than 74.5 kPa.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator lamp (MIL) after the second consecutive trip in which the fault is detected. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0507 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0507 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D No TPS, VSS, ECT, EGR, MAF, MAP, IAT, low voltage, fuel system, canister purge, injector control or ignition control DTCs are set. D Barometric pressure is above 75 kPa. D Canister purge duty cycle is above 10%. D Engine running time is more than 125 seconds. D Vehicle speed is less than 1 mph. D Engine coolant temperature (ECT) is above 50C (122F). D Ignition voltage is between 9.5 volts and 16.7 volts. D The throttle is closed. D EVAP purge duty cycle is more than 10%.

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM or throttle DC motor Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or

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D Throttle body Check for sticking throttle plate. Also inspect the air passage for deposits or objects which will not allow the ETC position to fully extend or properly seat. If DTC P0507 cannot be duplicated, reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. D Vacuum leak Check for a condition that causes a vacuum leak, such as disconnected or damaged hoses, leaks at EGR valve and EGR pipe to intake manifold, leak at the throttle body, a faulty or incorrectly installed PCV valve, leaks at the intake manifold, etc.

DTC P0507 Idle Air Control System High RPM

Step Action Value(s) Yes No

Was the On-Board (OBD) System Check performed? Go to Step 2

Go to OBD System Check

Visually/physically inspect for the following conditions: D Throttle body tampering. D Restricted intake throttle system. Check for a possible collapsed air intake duct, restricted air filter element, or foreign objects blocking the air intake system. D Throttle body: Check for objects blocking the throttle passage or throttle bore, excessive deposits in the throttle passage and on the throttle valve, and excessive deposits in the throttle bore and on the throttle plate. D Throttle body with lever: Check for objects send round the throttle spring lever that lever is smooth movement, and spring lever has not excessive play Do any of the above require a repair? Visually/physically inspect for the following conditions: D Accelerator pedal tampering. D Accelerator pedal : Check for objects blocking the spring or pedal arm. D Accelerator pedal : Check for objects move the accelerator pedal that pedal is smooth movement, and accelerator pedal arm has not excessive play. Do any of the above require a repair? 1. Check for a poor connection at the throttle body harness connector. 2. Check for a poor connection at the accelerator position sensor harness connector. 3. If a problem is found, replace faulty terminals as necessary. Was a problem found?

Refer to appropriate section for on-vehicle service

Go to Step 4

Refer to appropriate section for on-vehicle service

Go to Step 3

Verify repair

Go to Step 5

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DTC P0507 Idle Air Control System High RPM (Cont'd)

Step Action Value(s) Yes No

Check the following circuits for an open, short to voltage, short to ground, or poor connection at the PCM: D Throttle position sensor 1 circuit. D Throttle position sensor 2 circuit. D Throttle DC motor circuit. Vcc-GND 17km D Throttle position sensor resistance. SIG-GND D Throttle DC motor resistance. change D If a problem is found, repair as necessary. resistance 0.3 100m Was a problem found? Replace the throttle valve. Is the action complete?

Verify repair Go to Step 7

Go to Step 6

6 7

1. Check the following circuits for an open, short to voltage, short to ground, or poor connection at the PCM: D Accelerator position sensor 1 circuit. D Accelerator position sensor 2 circuit. D Sensor 3 circuit. D Sensor resistance. 2. If a problem is found, repair as necessary. Was a problem found? Replace the accelerator position sensor. Is the action complete?

Vcc-GND 46km SIG-GND change resistance

Verify repair Go to Step 9 Go to applicable DTC table Go to applicable DTC table

Go to Step 8

8 9

Stored DTCs: P1125, P1290, P1295, P1299

Go to Step 10

10

Stored DTCs: P1514, P1515, P1516, P1523, P1271, P1272, P1273 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?

Go to Step 11

11

Verify repair

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TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0562 System Voltage Low

D06R200017

Circuit Description
The powertrain control module (PCM) monitors the system voltage on the ignition feed terminal to the PCM. A system voltage DTC will set whenever the voltage is below a calibrated value.

Conditions for Clearing the MIL/DTC

D A history DTC P0562 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0562 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D Ignition ON. D System voltage is below 11.5 volts for 40 seconds.

Diagnostic Aids
If the DTC sets when an accessory is operated, check for a poor connection or excessive current draw.

Action Taken When the DTC Sets

D The PCM will not illuminate the malfunction indicator lamp (MIL). D The PCM will store as Failure Records conditions which were present when the DTC was set. This information will not be stored as Freeze Frame data.

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DTC P0562 System Voltage Low

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Using a DVM, measure the battery voltage at the battery. Is the battery voltage greater than the specified value? 11.5 V Go to Step 3 1. Install a Tech 2. 2. Select Ignition Volts on the Tech 2. 3. Start the engine and raise the engine speed to the specified value. 4. Load the electrical system by turning on the headlights, high blower, etc. Is the ignition voltage approximately equal to the specified value? 2000 RPM 12.8-14.1 V Go to Step 4

Go to OBD System Check Charge battery, then go to Step 3

Go to Starting/Char ging

1. Ignition OFF. 2. Disconnect the PCM connector at the PCM. 3. Using a DVM, measure the battery voltage at the PCM connector F-20 and F-57. Is it approximately equal to battery voltage? Go to Step 5 Go to Step 6 1. Check for faulty connections at the PCM harness terminals. 2. Repair as necessary. Was a repair necessary? Verify repair Verify repair Go to Step 7 Go to Step 7 Check for an open battery feed circuit to the PCM. Is the action complete? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

6 7

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Diagnostic Trouble Code (DTC) P0563 System Voltage High

D06R200017

Circuit Description
The powertrain control module (PCM) monitors the system voltage on the ignition feed terminals to the PCM. A system voltage DTC will set whenever the voltage is above a calibrated value.

Conditions for Clearing the MIL/DTC

D A history DTC P0563 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0563 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D Ignition ON. D System voltage is above 16 volts for 40 seconds.

Diagnostic Aids
If the DTC sets when an accessory is operated, check for a poor connection or excessive current draw.

Action Taken When the DTC Sets

D The PCM will ON the MIL after second trip with detected the fault. D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

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DTC P0563 System Voltage High

Step Action Value(s) Yes No

Was the ON-Board Diagnostic (OBD) System Check performed? Go to Step 2 Using a DVM, measure the battery voltage at the battery. Is the battery voltage less than the specified value? 11.5 V Go to Step 3

Go to OBD System Check

Go to Step 4

1. Charge the battery and clean the battery terminals. 2. Clean the battery ground cable connection if corrosion is indicated. Is the battery voltage less than the specified value? 11.5 V 1. 2. 3. 4. Turn OFF all the accessories. Install a Tech 2. Select the ignition voltage parameter on the Tech 2. Start the engine and raise the engine RPM to the specified value. 2000 RPM

Replace battery

Go to Step 4

Is the voltage more than 2.5 volts greater than the measurement taken in step 2 or 3? 5 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?

Go to Starting/ Charging

Go to Step 5

Verify repair

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Diagnostic Trouble Code (DTC) P0565 Cruise Main Switch Circuit Error

D06R200018

Circuit Description
The cruise control keeps the vehicle running at a fixed speed until a signal canceling this fixed speed is received. When the main switch is turned on with the vehicle in the running mode, the battery voltage is applied to power train control module(PCM). When a signal from the control switch is input to PCM while the vehicle is in this state, the cruise control system is activated. Also, while the PCM is operating, the CRUISE MAIN indicator light in the meter assembly lights up.

Action Taken When the DTC Sets

D The PCM will not illuminate the malfunction indicator lamp (MIL). D The PCM will store conditions which were present when the DTC was set in the Failure Records data only.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0565 will clear after 40 consecutive trip cycle during which the warm up cycles have occurred without a fault. D DTC P0565 can be cleared using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for setting the DTC

D D D D D The Ignition is ON. Engine is running. System voltage is between 11.5 volts and 16 volts. The switch contact remains on for 15 seconds or more. Noises are generated by poor switch contact 60 times within 1 second.

Diagnostic Aids
An intermittent may be caused by the following:

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

D Poor connections. D Mis routed harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the

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cruise main switch display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0565 cannot be duplicated, the information included n the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P0565 Diagnostic Chart may isolate the cause of the fault.

DTC P0565 Cruise Main Switch Circuit Error

Step Action Value(s) Yes No

Was the On-Board (OBD) System Check performed? Go to Step 2

Go to OBD System Check

1. Ignition ON, engine ON. 2. Observe the cruise main lamp in the switch. Is the cruise main lamp ON? Go to Step 3 Check the Procedure Refer to Diagnostic Aids Go to Step 4 1. Push the auto cruise main switch. 2. Observe the cruise main lamp in the switch. Is the cruise main lamp OFF?

Go to Step 4

Check the signal circuit for auto cruise main switch. 1. Ignition is OFF. 2. Disconnect the powertrain control module(PCM). 3. Disconnect the cruise main switch. Check for an open cruise main switch signal circuit between the PCM and the cruise main switch. Is a problem found? Go to Step 5 Verify repair Go to Step 7 Go to Step 6 Go to Step 8

5 6 7

Repair the auto cruise main switch signal circuit. Is the action complete? Check the auto cruise main switch and lamp circuit. Is a problem found? Repair or replace the auto cruise main switch and lamp circuit. Is the action complete? PCM must be Verify repair Replace the PCM. IMPORTANT: The programmed. replacement

Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

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Diagnostic Trouble Code (DTC) P0566 Cruise Cancel Switch Circuit Error

D06R200018

Circuit Description
The cruise control keeps the vehicle running at a fixed speed until a signal canceling this fixed speed is received. When the main switch is turned on with the vehicle in the running mode, the battery voltage is applied to powertrain control module(PCM). When a signal from the control switch is input to PCM while the vehicle is in this state, the cruise control system is activated. Also, while the PCM is operating, the CRUISE MAIN indicator light in the meter assembly lights up. When the cancel switch is ON, cruise system is OFF.

D Noises are generated by poor switch contact 100 times within 1.6 seconds.

Action Taken When the DTC Sets

D The PCM will not illuminate the malfunction indicator lamp (MIL). D The PCM will store conditions which were present when the DTC was set in the Failure Records data only.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0566 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault.

Conditions for setting the DTC

D D D D The Ignition is ON. Engine is running. System voltage is between 11.5 volts and 16 volts. The switch contact remains on for 40 seconds or more.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

D DTC P0566 can be cleared using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

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Diagnostic Aids
An intermittent may be caused by the following: D Poor connections. D Mis routed harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection.

D Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the cruise cancel switch display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0566 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTCP0566 Diagnostic Chart may isolate the cause of the fault.

DTC P0566 Cruise Cancel Switch Circuit Error

Step Action Value(s) Yes No

Was the On-Board (OBD) System Check performed? Go to Step 2

Go to OBD System Check

Check the signal circuit for auto cruise cancel switch. 1. Ignition is OFF. 2. Disconnect the powertrain control module(PCM). 3. Disconnect the cruise cancel switch. Check for cruise cancel switch signal circuit between the PCM and the cruise cancel switch. Is a problem found? PCM must be Go to Step 3 Verify repair Go to Step 5 Verify repair Go to Step 4 Go to Step 6

3 4 5 6

Repair the main cruise cancel switch signal circuit. Is the action complete? Check the auto cruise main switch. Is a problem found? Repair or replace the main cruise main switch. Is the action complete? Replace the PCM. IMPORTANT: The programmed. replacement

Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

6E352

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0567 Cruise Resume Switch Circuit Error

D06R200018

Circuit Description
The cruise control keeps the vehicle running at a fixed speed until a signal canceling this fixed speed is received. When the main switch is turned on with the vehicle in the running mode, the battery voltage is applied to powertrain control module(PCM). When a signal from the control switch is input to PCM while the vehicle is in this state, the cruise control system is activated. Also, while the PCM is operating, the CRUISE MAIN indicator light in the meter assembly lights up. When the resume switch is ON, vehicle speed is reset to the previous set speed.

D Noises are generated by poor switch contact 100 times within 1.6 seconds.

Action Taken When the DTC Sets

D The PCM will not illuminate the malfunction indicator lamp (MIL). D The PCM will store conditions which were present when the DTC was set in the Failure Records data only.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0567 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault. D DTC P0567 can be cleared using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for setting the DTC

D D D D The Ignition is ON. Engine is running. System voltage is between 11.5 volts and 16 volts. The switch contact remain on for 50 seconds or more.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E353

Diagnostic Aids
An intermittent may be caused by the following: D Poor connections. D Misrouted harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harness-Inspect the wiring harness for damage.

If the harness appears to be OK, observe the Cruise resume switch display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0567 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTCP0567 Diagnostic Chart may isolate the cause of the fault.

DTC P0567 Cruise Resume Switch Circuit Error

Step Action Value(s) Yes No

Was the On-Board (OBD) System Check performed? Go to Step 2

Go to OBD System Check

Check the signal circuit for auto cruise resume switch. 1. Ignition is OFF. 2. Disconnect the powertrain control module (PCM). 3. Disconnect the cruise resume switch. Check for cruise resume switch signal circuit between the PCM and the cruise resume switch. Is a problem found? Go to Step 3 PCM must be Verify repair Go to Step 5 Verify repair Go to Step 4 Go to Step 6

3 4 5 6

Repair the main cruise resume switch signal circuit. Is the action complete? Check the auto cruise resume switch. Is a problem found? Repair or replace the main cruise resume switch. Is the action complete? Replace the PCM. IMPORTANT: The programmed. replacement

Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

6E354

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0568 Cruise Set Switch Circuit Error

D06R200018

Circuit Description
The cruise control keeps the vehicle running at a fixed speed until a signal canceling this fixed speed is received. When the main switch is turned on with the vehicle in the running mode, the battery voltage is applied to powertrain control module (PCM). When a signal from the control switch is input to PCM while the vehicle is in this state, the cruise control system is activated. Also, while the PCM is operating, the CRUISE MAIN indicator light in the meter assembly lights up. When the set switch is ON, vehicle speed is set.

D Noises are generated by poor switch contact 100 times within 1.6 seconds.

Action Taken When the DTC Sets

D The PCM will not illuminate the malfunction indicator lamp (MIL). D The PCM will store conditions which were present when the DTC was set in the Failure Records data only.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0568 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault.

Conditions for setting the DTC

D D D D The Ignition is ON. Engine is running. System voltage is between 11.5 volts and 16 volts. The switch contact remain on for 120 seconds or more.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

D DTC P0568 can be cleared using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

6E355

Diagnostic Aids
An intermittent may be caused by the following: D Poor connections. D Misrouted harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection.

D Damaged harnessInspect the wiring harness for damage. If the harness appears to be OK, observe the cruise set switch display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0568 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTCP0568 Diagnostic Chart may isolate the cause of the fault.

DTC P0568 Cruise Set Switch Circuit Error

Step Action Value(s) Yes No

Was the On-Board (OBD) System Check performed? Go to Step 2

Go to OBD System Check

1. Ignition ON, engine ON. 2. Observe the cruise indicator lamp in the meter. Is the cruise indicator lamp ON? Go to Step 3 Check the Procedure Refer to Diagnostic Aids Go to Step 4 1. Push the auto cruise set switch. 2. Observe the cruise indicator lamp in the meter. Is the cruise indicator lamp OFF ?

Go to Step 5

Check the signal circuit for auto cruise set switch. 1. Ignition is OFF. 2. Disconnect the powertrain control module (PCM). 3. Disconnect the cruise set switch. Check for cruise set switch signal circuit between the PCM and the cruise set switch. Is a problem found? Go to Step 5 PCM must be Verify repair Go to Step 7 Verify repair Go to Step 6 Go to Step 8

5 6 7 8

Repair the main cruise set switch signal circuit. Is the action complete? Check the auto cruise set switch. Is a problem found? Repair or replace the main cruise set switch. Is the action complete? Replace the PCM. IMPORTANT: The programmed. replacement

Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

6E356

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0571 No Brake Switch Signal

D06R200076

Circuit Description
The brake switch has 3 functions. D Brake pedal operation check D Brake light operation (On and off) D Cruise control (Cancel) The PCM receives vehicle speed and switch position signals from the brake switch. The PCM sets brake operating conditions in response to these signals. If the brake switch is on, the brake system is in normal operation (cruise control cancelled).

Action Taken When the DTC Sets

D The PCM will not turn the malfunction indicator lamp (MIL) ON. D The PCM will store conditions which were present when the DTC was set as Failure Records only. This information will not be stored as Freeze Frame data.

Conditions for Clearing the DTC

D DTC P0571 can be cleared by using the scan tool Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D Two brake switch signals not acknowledged after signal changed. D VSS not defective. D Engine is running. D Vehicle speed above 20km/h.

Diagnostic Aids
D Damaged harnessInspect the wiring harness for damage. If the harness appears to be OK, observe the fuel level display on the scan tool while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E357

DTC P0571 No Brake Switch Signal

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 1. Ignition Off. Engine Off. 2. Check following fuses. D BACK 15A D STOP LAMP 15A Was a problem found? Verify repair

Go to OBD System Check

Go to Step 3

1. Make adjustment to the brake switch. The brake switch is installed to the brake pedal assembly. (Refer to Brake switch in 10A CRUISE CONTROL SYSTEM.) Was the problem found? Verify repair Go to Step 4 1. Push the shaft at brake switch. 2. Check shaft operation for smooth movements. Was the problem found? Verify repair Go to Step 5 1. Disconnect the connector at brake switch. 2. Check following terminal pin at ohmmeter. (Leave the shaft position at brake switch. Dont Between pin1 push it.) and pin2 is D Between pin 1 and pin 2 0m, Between D Between pin 3 and pin 4 pin3 and pin4 Was it specified value? is m 1. Disconnect the connector at brake switch. 2. Check following terminal pin at ohmmeter. (Push the shaft position at brake switch and hold it) Between pin1 and pin2 is D Between pin 1 and pin 2 m, Between D Between pin 3 and pin 4 pin3 and pin4 is 0m Was it specified value? 1. Probe related circuits for open or short to ground. 2. If a problem was found, repair as necessary. Was a problem found? Verify repair Go to Step 8 1. Replace the ECM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Was the action completed? Verify repair Verify repair

Go to Step 6

Go to Step 9

Go to Step 7

Go to Step 9

1. Replace the brake switch. Was the action completed?

6E358

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0601 PCM Memory

060RY014

Circuit Description
The powertrain control module (PCM) used in this vehicle utilizes an electrically erasable programmable read-only memory (EEPROM). The EEPROM contains program information and the calibrations required for engine, transmission, and powertrain diagnostics operation. Unlike the PROM used in past applications, the EEPROM is not replaceable. When the PCM is replaced or a calibration update is required, the PCM must be programmed using a Tech 2. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for the EEPROM programming procedure.

D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0601 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0601 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D The PCM detects an internal program fault (check sum error).

Diagnostic Aids
D DTC P0601 indicates that the contents of the EEPROM have changed since the PCM was programmed. The only possible repair is PCM replacement. Remember to program the replacement PCM with the correct software and calibration for the vehicle.

Action Taken When the DTC Sets

D The PCM will illuminate the malfunction indicator lamp (MIL) the first time the fault is detected.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E359

DTC P0601 PCM Memory

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

Go to OBD System Check

6E360

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0602 PCM Programming Error

060RY014

Circuit Description
The powertrain control module (PCM) uses Main CPU and Watchdog CPU software/calibration.

D The PCM will store conditions which were present when the DTC was set in the Failure Records data only.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0602 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0602 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D This code detects inconsistencies between Main CPU and Watchdog CPU software/calibration.

Action Taken When the DTC Sets

D The PCM will not illuminate the malfunction indicator lamp (MIL).

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E361

DTC P0602 PCM Programming Error

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

Go to OBD System Check

6E362

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0604 PCM RAM Error

060RY014

Circuit Description
The powertrain control module (PCM) uses Main CPU RAM and Watchdog CPU RAM.

D The PCM will store conditions which were present when the DTC was set in the Failure Records data only.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0604 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0604 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D This code detects inconsistencies between Main CPU RAM and Watchdog CPU RAM.

Action Taken When the DTC Sets

D The PCM will not illuminate the malfunction indicator lamp (MIL).

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E363

DTC P0604 PCM RAM Error

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

Go to OBD System Check

6E364

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0606 PCM Internal Performance

060RY014

Circuit Description
The input/output devices in the PCM include analog-to-digital converters, signal buffers, counters, and special drivers. The PCM controls most components with electronic switches which complete a ground circuit when turned ON. These switches are arranged in groups of 4 and 7, called either a surface-mounted quad driver module (QDM), which can independently control up to 4 output terminals, or QDMs which can independently control up to 7 outputs.

Action Taken When the DTC Sets

D The PCM will not illuminate the malfunction indicator lamp (MIL). D The PCM will store conditions which were present when the DTC was set in the Failure Records data only.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A history DTC P0606 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P0606 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D This code detects inconsistencies between Main CPU A/D converters and Watchdog CPU A/D converters.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E365

DTC P0606 PCM Internal Performance

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

Go to OBD System Check

6E366

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0660 VIM Solenoid Circuit Open

D06R200089

Circuit Description
The VIM (Variable Intake Manifold) solenoid (intake air VSV) circuit controls the induction control valve that the length of a port is switched. The VIM solenoid is controlled by the Power Train Control Module (PCM). When the engine speed is less than 3600 RPM, the VIM solenoid is ON and when the engine speed is more than 3600 RPM, the VSV is OFF. The induction control valve is closed at the VIM solenoid is ON, and it is opened at the VSV is OFF. If the VIM solenoid circuit is opened, DTC P0660 will set.

D The PCM will store conditions which were present when the DTC was set in the Failure Records data only.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run an the fault condition is no longer present. D A history DTC P0660 will clear after 40 consecutive trip cycles during which the warm up cycles have occurs without a fault.

Diagnostic Aids
Check for following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harness inspect the wiring harness to the solenoid and the fuel tank pressure sensor for an intermittent open short circuit.

Conditions for Setting the DTC

D The Ignition is ON. D Ignition voltage is more than 11V. D There are 20 test failures within a 28test sample.

Action Taken When the DTC Sets

D The PCM will not illuminate the malfunction indicator lamp (MIL).

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E367

DTC P0660 VIM Solenoid Circuit Open

Step Action Value(s) Yes No

Was the OnBoard Diagnostic (OBD) System Check performed? Go to Step 2 1. Check the DTC. Was the DTC for the Mass Air Flow (MAF) sensor or the purge duty solenoid valve stored? Go to Step 3

Go to OBD System Check

Go to Step 4 Check the Procedure Refer to Diagnostic Aids

1. Check the circuit between the ENGINE fuse and the MAD sensor or the Variable Intake Manifold solenoid (intake air VSV). 2. If a problem found, repair or replace as necessary. Was a problem found? Verify repair 1. Using the Tech 2, perform the Variable Intake Manifold Test. Refer to Variable Intake Manifold Test Was a problem found? Go to Step 7 Check the Procedure Refer to Diagnostic Aids Verify repair

Go to Step 5

1. Using the Tech 2, command the VIM solenoid ON and OFF. 2. Observe working noise for the VIM solenoid. Was working noise detected?

Go to Step 6

6 7

1. Replace the VIM solenoid. Is the action complete? 1. Check the circuit between the ENGINE fuse and the VIM solenoid. 2. If a problem found, repair or replace as necessary. Was a problem found? Verify repair Go to Step 8 1. Check the circuit between the PCM fuse and the VIM solenoid. 2. If a problem found, repair or replace as necessary. Was a problem found? Verify repair Go to Step 9 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

6E368

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0662 VIM Solenoid Circuit Short

D06R200089

Circuit Description
The VIM (Variable Intake Manifold) solenoid (intake air VSV) circuit controls the induction control valve that the length of a port is switched. The VIM solenoid is controlled by the Power Train Control Module (PCM). When the engine speed is less than 3600 RPM, the VIM solenoid is ON and when the engine speed is more than 3600 RPM, the VSV is OFF. The induction control valve is closed at the VIM solenoid is ON, and it is opened at the VSV is OFF. If the VIM solenoid circuit is opened, DTC P0660 will set.

D The PCM will store conditions which were present when the DTC was set in the Failure Records data only.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run an the fault condition is no longer present. D A history DTC P0660 will clear after 40 consecutive trip cycles during which the warm up cycles have occurs without a fault.

Diagnostic Aids
Check for following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. D Damaged harness inspect the wiring harness to the solenoid and the fuel tank pressure sensor for an intermittent open short circuit.

Conditions for Setting the DTC

D The Ignition is ON. D Ignition voltage is more than 11V. D There are 20 test failures within a 28test sample.

Action Taken When the DTC Sets

D The PCM will not illuminate the malfunction indicator lamp (MIL).

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E369

DTC P0662 VIM Solenoid Circuit Short

Step Action Value(s) Yes No

Was the OnBoard Diagnostic (OBD) System Check performed? Go to Step 2 1. Check the DTC. Was the DTC for the Mass Air Flow (MAF) sensor or the purge duty solenoid valve stored? Go to Step 3

Go to OBD System Check

Go to Step 4 Check the Procedure Refer to Diagnostic Aids

1. Check the circuit between the ENGINE fuse and the MAD sensor or the Variable Intake Manifold solenoid (intake air VSV). 2. If a problem found, repair or replace as necessary. Was a problem found? Verify repair 1. Using the Tech 2, perform the Variable Intake Manifold Test. Refer to Variable Intake Manifold Test Was a problem found? Go to Step 7 Check the Procedure Refer to Diagnostic Aids Verify repair

Go to Step 5

1. Using the Tech 2, command the VIM solenoid ON and OFF. 2. Observe working noise for the VIM solenoid. Was working noise detected?

Go to Step 6

6 7

1. Replace the VIM solenoid. Is the action complete? 1. Check the circuit between the ENGINE fuse and the VIM solenoid. 2. If a problem found, repair or replace as necessary. Was a problem found? Verify repair Go to Step 8 1. Check the circuit between the PCM fuse and the VIM solenoid. 2. If a problem found, repair or replace as necessary. Was a problem found? Verify repair Go to Step 9 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete? Verify repair

6E370

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P1106 MAP Sensor Circuit Intermittent High Voltage

D06R200048

Circuit Description
The manifold absolute pressure (MAP) sensor responds to changes in intake manifold pressure (vacuum). The MAP sensor signal voltage to the PCM varies from below 2 volts at idle (high vacuum) to above 4 volts with the ignition ON, engine not running or at wide-open throttle (low vacuum). The MAP sensor is used to determine manifold pressure changes while the liner EGR flow test diagnostic is being run (refer to DTC P0401), to determine engine vacuum level for some other diagnostics and to determine barometric pressure (BARO). The PCM compares the MAP sensor signal to a calculated MAP based on throttle position and various engine load factors. If the PCM detects a MAP signal that is intermittently above the calculated value, DTC P1106 will set.

Action Taken When the DTC Sets

D The PCM will not illuminate the malfunction indicator lamp (MIL). D The PCM will store conditions which were present when the DTC was set as Failure Records data only. This information will not be stored as Freeze Frame data.

Conditions for Clearing the MIL/DTC

D A history DTC P1106 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P1106 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Diagnostic Aids
Check for the following conditions: D Leaking or plugged vacuum supply line to the MAP sensor. D Inspect PCM harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Inspect the wiring harness for damage. If the harness appears to be OK, observe the MAP display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often

Conditions for Setting the DTC

D No TP sensor DTCs are present. D Engine is running for at least 10 seconds. D Throttle angle is below 3% if engine speed is below 1000 RPM. D Throttle angle is below 10% if engine speed is above 1000 RPM. D The MAP sensor indicates an intermittent manifold absolute pressure above 80 kPa for a total of approximately 5 seconds over a 16-second period of time.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition. D The MAP sensor shares a 5 Volt Reference with the Fuel Tank Pressure sensor. Check the 5 Volt reference if this DTC is also set.

6E371

D The MAP sensor shares a ground with the Fuel Tank Pressure sensor and the ECT Sensor. Check the ground if these other DTCs are also set.

DTC P1106 MAP Sensor Circuit Intermittent High Voltage

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Go to DTC P0108 chart first Go to Step 6 Is DTC P0108 also set?

Go to OBD System Check

Go to Step 3 Go to Step 4

3 4

Are DTC P1111, P1115, and/or P1120 also set? Check for a poor sensor ground circuit terminal connection at the MAP sensor. Was a problem found?

Go to Step 9

Go to Step 5

Check the MAP signal circuit between the MAP sensor connector and the PCM for an intermittent short to voltage. Was a problem found? Go to Step 10 Go to Step 8 Check for an intermittent short to voltage on the 5 volt reference circuit between the PCM and the following components: D MAP sensor D EGR valve D TP sensor Was a problem found? Go to Step 10 Go to Step 7 Check for a poor sensor ground circuit terminal connection at the PCM. Was a problem found? Go to Step 9 Go to Step 8 Check the Procedure Refer to Diagnostic Aids Check for an intermittent open or a faulty splice in the sensor ground circuit. Was a problem found? Go to Step 10

Replace the faulty harness connector terminal for the sensor ground circuit. Is the action complete? Verify repair Locate and repair the intermittent open/short circuit in the wiring harness as necessary. Is the action complete? Verify repair

10

6E372

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P1107 MAP Circuit Intermittent Low Voltage

D06R200048

Circuit Description
The manifold absolute pressure (MAP) sensor responds to changes in intake manifold pressure (vacuum). The MAP sensor signal voltage to the powertrain control module (PCM) varies from below 2 volts at idle (high vacuum) to above 4 volts with the ignition ON, engine not running or at wide-open throttle (low vacuum). The MAP sensor is used to determine manifold pressure changes while the linear EGR flow test diagnostic is being run (refer to DTC P0401), to determine engine vacuum level for some other diagnostics and to determine barometric pressure (BARO). The PCM compares the MAP sensor signal to a calculated MAP based on throttle position and various engine load factors. If the PCM detects a MAP signal that is intermittently below the calculated value, DTC P1107 will be set.

approximately 5 seconds over a 16-second period of time.

Action Taken When the DTC Sets

D The PCM will not illuminate the malfunction indicator lamp (MIL). D The PCM will store conditions which were present when the DTC was set as Failure Records data only. This information will not be stored as Freeze Frame data.

Conditions for Clearing the MIL/DTC

D A history DTC P1107 will Clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P1107 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

D D D D No TP sensor DTCs are present. Engine is running. Ignition voltage is more than 11 volts. Throttle angle is above 1% if engine speed is less than 1000 RPM. D Throttle angle is above 3% if engine speed is above 1000 RPM. D The MAP sensor indicates an intermittent manifold absolute pressure below 11 kPa for a total of

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D The MAP Sensor shares a 5 Volt reference with the EGR Valve. If these codes are also set, it could indicate a problem with the 5 Volt reference circuit or components itself. D The MAP Sensor share a ground with the EGR Valve and the IAT Sensor.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the MAP display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault.

6E373

Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P1107 MAP Sensor Circuit Intermittent Low Voltage

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Go to DTC P0108 chart first Go to Step 6 Is DTC P0108 also set?

Go to OBD System Check

Go to Step 3 Go to Step 4

3 4

Are DTC P1111, P1115, and/or P1120 also set? Check for a poor sensor ground circuit terminal connection at the MAP sensor. Was a problem found?

Go to Step 9

Go to Step 5

Check the MAP signal circuit between the MAP sensor connector and the PCM for an intermittent short to voltage. Was a problem found? Go to Step 10 Go to Step 8 Check for an intermittent short to voltage on the 5 volt reference circuit between the PCM and the following components: D MAP sensor D EGR valve D TP sensor Was a problem found? Go to Step 10 Go to Step 7 Check for a poor sensor ground circuit terminal connection at the PCM. Was a problem found? Go to Step 9 Go to Step 8 Check the Procedure Refer to Diagnostic Aids Check for an intermittent open or a faulty splice in the sensor ground circuit. Was a problem found? Go to Step 10

Replace the faulty harness connector terminal for the sensor ground circuit. Is the action complete? Verify repair Locate and repair the intermittent open/short circuit in the wiring harness as necessary. Is the action complete? Verify repair

10

6E374

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P1111 IAT Sensor Circuit Intermittent High Voltage

D06RY00168

Circuit Description
The intake air temperature (IAT) sensor is a thermistor which measures the temperature of the air entering the engine. The powertrain control module (PCM) applies 5 volts through a pull-up resistor to the IAT sensor. When the intake air is cold, the sensor resistance is high and the PCM will monitor a high signal voltage on the IAT signal circuit. If the intake air is warm, the sensor resistance is lower causing the PCM to monitor a lower voltage. DTC P1111 will set when the PCM intermittently detects an excessively high signal voltage on the intake air temperature sensor signal circuit.

D The PCM will store conditions which were present when the DTC set as Failure Records data only. This information will not be stored as Freeze Frame data. D DTC P1111 does not illuminate the MIL.

Conditions for Clearing the MIL/DTC

D A history DTC P1111 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P1111 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the IAT display on the Tech 2 while moving connectors and wiring harnesses related to the IAT sensor. A change in the IAT display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Conditions for Setting the DTC

D D D D D The engine has been running for over 30 seconds. Vehicle speed is less than 32 km/h (20 mph). Engine coolant temperature is above 60C (140F). Mass air flow is less than 20g/second. IAT signal voltage indicates and intake air temperature intermittently less than 39C (38F) (about 5 volts) for approximately 2.5 seconds over a 25-second period of time.

Action Taken When the DTC Sets

D The PCM will substitute a default value for intake air temperature.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E375

Intake Air Temperature Sensor

C F OHMS Temperature vs. Resistance Values (approximate) 100 80 60 45 35 25 15 5 5 15 30 40 212 176 140 113 95 77 59 41 23 5 22 40 177 332 667 1188 1802 2796 4450 7280 12300 21450 52700 100700

6E376

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P1111 IAT Sensor Circuit Intermittent High Voltage

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Go to DTC P0113 chart first Go to Step 6 Is DTC P0113 also set?

Go to OBD System Check

Go to Step 3 Go to Step 4

3 4

Is DTC P1115, also set? 1. Check for a poor sensor ground circuit terminal connection at the IAT sensor. 2. If a problem is found, repair as necessary. Was a problem found?

Verify repair

Go to Step 5

1. Check for a poor IAT signal circuit terminal connection at the IAT sensor. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 6 1. Check the IAT signal circuit between the IAT sensor connector and the PCM for an intermittent open. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 7 1. Check the IAT signal circuit between the IAT sensor connector and the PCM for an intermittent short to voltage. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 8 1. Check for a poor sensor ground circuit terminal connection at the PCM. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 9 Check the Procedure Refer to Diagnostic Aids 1. Check for an intermittent open or a faulty splice in the sensor ground circuit. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E377

Diagnostic Trouble Code (DTC) P1112 IAT Sensor Circuit Intermittent Low Voltage

D06RY00168

Circuit Description
The intake air temperature (IAT) sensor is a thermistor which measures the temperature of the air entering the engine. The powertrain control module (PCM) applies 5 volts through a pull-up resistor to the IAT sensor. When the intake air is cold, the sensor resistance is high and the PCM will monitor a high signal voltage on the IAT signal circuit. If the intake air is warm, the sensor resistance becomes lower, causing the PCM to monitor a lower voltage. DTC P1112 will set when the PCM intermittently detects an excessively low signal voltage on the intake air temperature sensor signal circuit.

D The PCM will substitute a default value for intake air temperature.

Conditions for Clearing the MIL/DTC

D A history DTC P1112 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P1112 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the IAT display on the Tech 2 while moving connectors and wiring harnesses related to the IAT sensor. A change in the IAT display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Conditions for Setting the DTC

D The engine has been running for over 15 seconds. D Vehicle speed is greater than 48 km/h (30 mph). D IAT signal voltage is greater than 148C (298F) (about 0.10 volt) for a total of 2.5 seconds over a 25-second period of time.

Action Taken When the DTC Sets

D The PCM will not illuminate the malfunction indicator lamp (MIL). D The PCM will store conditions which were present when the DTC was set as Failure Records data only. This information will not be stored as Freeze Frame data.

Test Description
Number(s) below refer to the step number(s) on the Diagnostic Chart.

6E378

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

2. Verifies that the fault is present. 3. If DTC P1112 can be repeated only by duplicating the Failure Records conditions, refer to the Temperature vs. Resistance Value Chart. The chart may be used to test the IAT sensor at various temperatures to evaluate the possibility of a shifted sensor that may be shorted above or below a certain temperature. If this is the case, replace the IAT sensor.

Intake Air Temperature Sensor

C F OHMS Temperature vs. Resistance Values (approximate) 100 80 60 45 35 25 15 5 5 15 30 40 212 176 140 113 95 77 59 41 23 5 22 40 177 332 667 1188 1802 2796 4450 7280 12300 21450 52700 100700

DTC P1112 IAT Sensor Circuit Intermittent Low Voltage

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Go to DTC P0112 first Is DTC P0112 also set? 1. Check the IAT signal circuit between the IAT sensor connector and the PCM for an intermittent short to ground. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair

Go to OBD System Check Go to Step 3 Check the Procedure Refer to Diagnostic Aids

2 3

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E379

Diagnostic Trouble Code (DTC) P1114 ECT Sensor Circuit Intermittent Low Voltage

D06R200049

Circuit Description
The engine coolant temperature (ECT) sensor is a thermistor mounted in the engine coolant stream. The powertrain control module (PCM) applies a voltage (about 5.0 volts) through a pull-up resistor to the ECT signal circuit. When the engine coolant is cold, the sensor (thermistor) resistance is high, therefore the PCM will measure a high signal voltage. As the engine coolant warms, the sensor resistance becomes less, and the ECT signal voltage measured at the PCM drops. With a fully warmed up engine, the ECT signal voltage should measure about 1.5 to 2.0 volts. If the PCM detects an ECT signal that is intermittently below the range of the ECT sensor, DTC P1114 will set.

D The PCM will store conditions which were present when the DTC set as Failure Records data only. This information will not be stored as Freeze Frame data.

Conditions for Clearing the MIL/DTC

D A history DTC P1114 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P1114 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the ECT display on the Tech 2 while moving connectors and wiring harnesses related to the ECT sensor. A change in the ECT display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often

Conditions for Setting the DTC

D Engine run time longer than 120 seconds. D The ECT sensor signal is intermittently greater than 150C (302F) (about 0.10 volt) for a total of 10 seconds over a 100-second period.

Action Taken When the DTC Sets

D The PCM will not illuminate the malfunction indicator lamp (MIL).

6E380

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Engine Coolant Temperature Sensor

C F OHMS Temperature vs. Resistance Values (approximate) 100 80 60 45 35 25 15 5 5 15 30 40 212 176 140 113 95 77 59 41 23 5 22 40 177 332 667 1188 1802 2796 4450 7280 12300 21450 52700 100700

DTC P1114 ECT Circuit Intermittent Low Voltage

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Go to DTC P0117 first Is DTC P0117 also set? 1. Check the ECT signal circuit between the ECT sensor connector and the PCM for an intermittent short to ground. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair

Go to OBD System Check Go to Step 3 Check the Procedure Refer to Diagnostic Aids

2 3

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E381

Diagnostic Trouble Code (DTC) P1115 ECT Sensor Circuit Intermittent High Voltage

D06R200049

Circuit Description
The engine coolant temperature (ECT) sensor is a thermistor mounted in the engine coolant stream. The powertrain control module (PCM) applies a voltage (about 5.0 volts) through a pull-up resistor to the ECT signal circuit. When the engine coolant is cold, the sensor (thermistor) resistance is high, therefore the PCM will measure a high signal voltage. As the engine coolant warms, the sensor resistance becomes less, and the ECT signal voltage measured at the PCM drops. With a fully warmed up engine, the ECT signal voltage should measure about 1.5 to 2.0 volts. If the PCM detects an ECT signal that is intermittently above the range of the ECT sensor, DTC P1115 will set.

D The PCM will store conditions which were present when the DTC was set as Failure Records data only. This information will not be stored as Freeze Frame data.

Conditions for Clearing the MIL/DTC

D A history DTC P1115 will clear after 40 consecutive warm-up cycles have occurred without a fault. D DTC P1115 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Diagnostic Aids
Check for the following conditions: D Poor connection at PCM Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. D Damaged harness Inspect the wiring harness for damage. If the harness appears to be OK, observe the ECT display on the Tech 2 while moving connectors and wiring harnesses related to the ECT sensor. A change in the ECT display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often

Conditions for Setting the DTC

D Engine running time longer than 90 seconds. D The ECT sensor signal is intermittently greater than 39C (38F) (about 5 volts) for a total of 10 seconds over a 100-second period.

Action Taken When the DTC Sets

D The PCM will not illuminate the malfunction indicator lamp (MIL).

6E382

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Engine Coolant Temperature Sensor

C F OHMS Temperature vs. Resistance Values (approximate) 100 80 60 45 35 25 15 5 5 15 30 40 212 176 140 113 95 77 59 41 23 5 22 40 177 332 667 1188 1802 2796 4450 7280 12300 21450 52700 100700

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E383

DTC P1115 ECT Sensor Circuit Intermittent High Voltage

Step Action Value(s) Yes No

Was the On-Board Diagnostic (OBD) System Check performed? Go to Step 2 Go to DTC P0118 chart first Go to Step 8 Is DTC P0118 also set?

Go to OBD System Check

Go to Step 3 Go to Step 4

3 4

Is DTC P1111 also set? 1. Check for a poor sensor ground circuit terminal connection at the ECT sensor. 2. If a problem is found, repair as necessary. Was a problem found?

Verify repair

Go to Step 5

1. Check for a poor ECT signal circuit terminal connection at the ECT sensor. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 6 1. Check the ECT signal circuit between the ECT sensor connector and the PCM for an intermittent open. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 7 1. Check the ECT signal circuit between the ECT sensor connector and the PCM for an intermittent short to voltage. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 8 1. Check for a poor sensor ground circuit terminal connection at the PCM. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair Go to Step 9 Check the Procedure Refer to Diagnostic Aids 1. Check for an intermittent open or a faulty splice in the sensor ground circuit. 2. If a problem is found, repair as necessary. Was a problem found? Verify repair

6E384

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code(DTC) P1120-TPS 1 Throttle Position Sensor (TPS1) Circuit Fault

D06RY00088

Circuit Description
D The throttle position (TP) sensor circuit provides a voltage signal relative to throttle blade angle. The throttle blade angle will vary about 8 % at closed throttle to about 92 % at wide open throttle(WOT). This code detects a continuous short to ground or high in either the cicuit or the sensor.

D DTC P1120 can be cleared using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Diagnostic Aids
An intermittent may be caused by the following: D Poor connectons. D Mis routed harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D The MAP sensor shares a 5 Volt reference with the Fuel Tank Pressure, APS1, APS3 and EGR value. D The MAP sensor shares a ground with the Fuel Tank Pressure, the ECT sensor, and the Transmission Fluid. D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals,and poor terminal to wire connection. D Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK,observe the TPS 1 display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault.

Conditions for setting the DTC

D The Ignition is ON. D The throttle blade angle is less than 2.5 % or more tnan 97.5 % for 18 failres within 500 test samples (15.6m sec)

Action Taken When the DTC Sets

D The PCM will store condition which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. D A histror DTC P1120 will clear after 40 cosecutive trip cycle during which the warm up cycles have occurred without a fault.

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

If DTC P1120 cannot be duplicated,the information included in the Faillure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P1120 Diagnostic Chart may isolate the cause of the fault.

6E385

Diagnostic Trouble Code(DTC)P1120-TPS 1 Circuit Fault

Step Action Value(s) Yes No

Was the On-Board(OBD)System Check performed? Go to Step 2

Go to OBD System Check Go to ETC System check

Was the Electric Throttle Control (ETC) System Check performed? Go to Step 3 1. Ignition ON, engine not running. 2. Observe the MAP reading on the Tech 2. Is the MAP reading less than the specified value? 100kPa Go to Step 4

Go to Step 7

1. Disconnect the MAP sensor. 2. Connect a test 5 volt reference circuit and the MAP signal at the MAP sensor harness connector. 3. Observe the MAP reading on the Tech 2. Is the MAP reading less than the specified value? (If no, start with diagnosis chart forother sensors in the circuit and see if 5V returns.)

Go to Step 6

Go to Step 5

1. Check the MAP signal circuit between the PCM and MAP grund circuit. 2. If the MAP signal circuit is open or shoted, repair it as necessary. Was the MAP signal circuit open or shorted? Verify repair Verify repair Go to Step 13 Replace the MAP sensor. Is the action complete? 1. 2. 3. 4. Warming up the engine until the ECT rise at 80C Ignition OFF. Ignition ON but not engine run. Observe the TP angle reading on the Tech 2 while alowly opening the throttle.

6 7

NOTE: The value check of TPS must be performed in less than 15 seconds. Does the TP angle increase steadily and evenly from the closed throttle value to the wide open throttle value? 8 Was the DTC P1120 stored?

Closed throttle TPS1= 612% Wide open throttle TPS1= 7983%

Go to Step 8

Go to Step 9 Check the procedure. Refer to Diagnostic Aids

9 1. Connect a DVM between the 5Volt reference circuit and the TP sensor ground circuit at the TP1sensor harness connector. 2. Observe the voltage using a DVM. Is the voltage near the specified value? 5V

Go to Step 13

Go to Step 10

Go to Step 11

6E386

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code(DTC)P1120-TPS 1 Circuit Fault (Cont'd)

Step Action Value(s) Yes No

10

Check the following items; 1. TP1 signal circuit for a short to voltage. 2. TP1 sensor ground circuit for high resistance between the PCM and the TP sensor. 3. TP1 sensor ground circuit for a poor connection. 4. If a problem is found,repair wiring harness as necessary. Was a problem found? Verify repair Go to Step 11

11

Check the following items; 1. TP signal circuit or 5 volt reference circuit for a poor connection. 2. TP signal circuit or 5 volt reference circuit for high resistance between the PCM and the TP sensor. 3. If a problem is found, repair wiring harness as necessary. Was a problem found? PCM must be Verify repair Verify repair Go to Step 12 Go to Step 13

12 13

Replace the TP sensor. Was a problem corrected? Replace the PCM. IMPORTANT: The programmed. replacement

Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not. And then Down Load the LATEST PROGRMMED SOFTWARE to the replasement PCM. Is the action complete? Verify repair

TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E387

Diagnostic Trouble Code (DTC) P1125 ETC (Electric throttle control) Limit Performance Mode

D06RY00157

Circuit Description
D The acceleration position (AP1) sensor circuit provides a voltage signal relative to acceleration pedal angle. The acceleration pedal angle will vary about 13 % at idle position to about 87 % at wide open throttle (WOT). This code detects if the system is in Limit Performance Mode (Fail safe Mode) and Multiple DTCs performance Mode.

D DTC P1125 can be cleared using the Tech 2 Clear Info function or by disconnecting the PCM battery feed.

Diagnostic Aids
An intermittent may be caused by the following: D Poor connectons. D Mis routed harness. D Rubbed through wire insulation. D Broken wire inside the insulation. Check for the following conditions: D Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals,and poor terminal to wire connection. D Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the APP sensor 1, APP sensor 2, APP sensor 3 display on the Tech 2 While moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P1125 cannot be duplicated,the information includedin the Faillure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently,performing the DTC P1125 Diagnostic Chart may isolate the cause of the fault.

Conditions for setting the DTC

D The Ignition is ON. D Limit Performance Mode is active. (Fail safe Mode)

Action Taken When the DTC Sets

D The PCM will store condition which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC

D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been ru