Isuzu Axiom 2002 Workshop Manual

Isuzu Axiom 2002 Workshop Manual
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SECTION
0A
0B
WORKSHOP MANUAL
1A
2A
AXIOM
(UPR/S)
3C
3D
3E
3F
4A1
4A2
4B1
4B2
4C
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
5D1
5D2
6A
6B
6C
6D1
6D2
6D3
6E
6F
6G
6H
6J
7A
7A1
8A
8B
This manual applies to 2002 models.
8C
8D
8E
8F
8G
8H
8I
8J
9A
9J
9J1
10A
TABLE OF CONTENTS
GENERAL INFORMATION
General Information
Maintenance and Lubrication
HEATING, VENTILATION AND AIR
CONDITIONING
HVAC System
STEERING
Power-Assisted System
SUSPENSION
Front Suspension
Rear Suspension
Wheel and Tire System
Intelligent Suspension System
DRIVELINE/AXLE
Differential (Front)
Differential (Rear)
Driveline Control System
Driveline Control System (TOD)
Drive Shaft System
Transfer Case (TOD)
BRAKE
Brake Control System
Anti-Lock Brake System
Power-Assisted Brake System
Parking Brake System (4×4 model)
Parking Brake System (4×2 model)
ENGINE
Engine Mechanical
Engine Cooling
Engine Fuel
Engine Electrical
Ignition System
Starting and Charging System
Driveability and Emissions
Engine Exhaust
Engine Lubrication
Engine Speed Control System
Induction
TRANSMISSION
Automatic Transmission
Transmission Control System
BODY AND ACCESSORIES
Lighting System
Wiper/Washer System
Entertainment
Wiring System
Meter and Gauge
Body Structure
Seats
Security and Locks
Sun Roof/Convertible Top
Exterior/Interior Trim
RESTRAINTS
Seat Belt System
Supplemental Restraint System (Air Bag System)
Restraint Control System
CONTROL SYSTEM
Cruise Control System
SECTION
GENERAL INFORMATION
0A–1
AXIOM
GENERAL INFORMATION
CONTENTS
General Information . . . . . . . . . . . . . . . . . . . . .
Maintenance and Lubrication . . . . . . . . . . . . .
0A
0B
General Information
CONTENTS
General Repair Instruction . . . . . . . . . . . . . . . .
Illustration Arrows . . . . . . . . . . . . . . . . . . . . . . .
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Theft Prevention Standard . . . . . . . . . . . . . . . .
0A–1
0A–2
0A–3
0A–5
General Repair Instruction
1. If a floor jack is used, the following precautions are
recommended.
Park vehicle on level ground, “block” front or rear
wheels, set jack against the recommended lifting
points (see “Lifting Instructions” in this section), raise
vehicle and support with chassis stands and then
perform the service operations.
2. Before performing service operations, disconnect
ground cable from the battery to reduce the chance of
cable damage and burning due to short circuiting.
3. Use a cover on body, seats and floor to protect them
against damage and contamination.
4. Brake fluid and anti–freeze solution must be handled
with reasonable care, as they can cause paint
damage.
5. The use of proper tools and recommended essential
and available tools, where specified, is important for
efficient and reliable performance of service repairs.
6. Use genuine Isuzu parts.
7. Used cotter pins, plastic clips, gaskets, O–rings, oil
seals, lock washers and self–locking nuts should be
discarded and new ones should be installed, as
normal function of the parts cannot be maintained if
these parts are reused.
8. To facilitate proper and smooth reassembly
operation, keep disassembled parts neatly in groups.
Keeping fixing bolts and nuts separate is very
important, as they vary in hardness and design
depending on position of installation.
9. Clean the parts before inspection or reassembly. Also
clean oil ports, etc. using compressed air, and make
certain they are free from restrictions.
10. Lubricate rotating and sliding faces of the parts with
oil or grease before installation.
11. When necessary, use a sealer on gaskets to prevent
leakage.
12. Carefully observe all specifications for bolt and nut
torques.
Lifting Instructions . . . . . . . . . . . . . . . . . . . . . . .
Standard Bolts Torque Specifications . . . . . .
Abbreviations Charts . . . . . . . . . . . . . . . . . . . .
Service Parts Identification Plate . . . . . . . . . .
0A–9
0A–11
0A–12
0A–13
13. When removing or replacing parts that require
refrigerant to be discharged from the air conditioning
system, be sure to use the Vehicle Refrigerant
Recovery and Recycling Equipment (VRRRE) to
recover and recycle Refrigerant–134a.
14. When a service operation is completed, make a final
check to be sure the service has been done properly
and the problem has been corrected.
15. SUPPLEMENTAL RESTRAINT SYSTEM
The vehicle is equipped with a Supplemental
Restraint System (SRS) – Air Bags. This system is
not to be serviced without consulting the appropriate
service information. Consult Section 9J “SRS
System” if work is to be done on the front of the
vehicle such as bumper, sheet metal, seats, wiring,
steering wheel or column. Also review SRS system
information if any arc welding is to be done on the
vehicle. The SRS system equipped vehicle can be
identified by:
1. “AIR BAG” warning light on the instrument
cluster.
2. A Code “K” or “M” for fifth digit of Vehicle
Identification Number.
0A–2
GENERAL INFORMATION
Illustration Arrows
Arrows are designed for specific purposes to aid your understanding of technical illustrations.
Arrow Type
Application
Arrow Type
Application
Front of vehicle
B Ambient/Clean air
flow
B Cool air flow
Up Side
B Gas other than
ambient air
B Hot air flow
Task Related
B Ambient air mixed
with another gas
B 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
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.
710RW003
0A–3
0A–4
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.
240R200014
Automatic : Stamped on the identification plate, located
on the left side of the transmission above the mode
switch.
240R200013
GENERAL INFORMATION
0A–5
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.
COMPONENT
INDICATION
PRODUCTION
0A-10
ENGINE
1– 6VE1
VIN plate
0A-11
TRANSMISSION
2– Automatic transmission
VIN plate
0A-11
BODY
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 label
SERVICE PARTS
Anti Theft Stamping/Plate/Label
STAMPING/PLATE
PRODUCTION
SERVICE PARTS
LABEL
0A–6
GENERAL INFORMATION
Anti Theft Stamping/Label/Plate Location
The stamping, label and plate locations are indicated by
arrows in the illustration below.
NOTE:
1. VIN plate locations for production.
2. Stamping locations for service parts.
Engine
901RW195
Automatic Transmission
240R200012
GENERAL INFORMATION
0A–7
Body
604R200007
0A–8
GENERAL INFORMATION
Body Label Instructions
Do not peel off the masking tape until completion of paint
work when replacing these parts, as the tape is affixed on
the label attached to service parts for body of the
anti–theft component.
NOTE: Be sure to pull off the masking tape after paint
work has been completed.
Do not attempt to remove this label for any reason.
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 anti–theft label.
2. Be careful not to damage the paint around the label.
901RW084
GENERAL INFORMATION
0A–9
Lifting Instructions
CAUTION:
B If a lifting device other than the original jack is
used, it is most important that the device be
applied only to the correct lifting points. Raising
the vehicle from any other point may result in
serious damage.
B When jacking or lifting a vehicle at the frame side
rail or other prescribed lift points, be certain that
lift pads do not contact the catalytic converter,
brake pipes or cables, or fuel lines. Such contact
may result in damage or unsatisfactory vehicle
performance.
Lifting Points and Supportable Point Locations
C00RX002
Lifting Point: Front
B When using a floor jack, lift on the Convex portion of
the skid plate.
545RS001
0A–10
GENERAL INFORMATION
Supportable Point: Front
Supportable Point: Rear
B Position the chassis stands at the bottom of the frame
sidemember, behind the front wheel.
B Position the chassis stands at the bottom of the frame
sidemember, just behind the trailing link bracket.
501RS003
Lifting Point: Rear
B Position the floor jack at the center of the rear axle
case when lifting the vehicle.
501RW002
Legend
(1) Trailing Link Bracket
Supportable Point: Rear
B Position the chassis stands at the bottom of the rear
axle case.
420RS002
420RS001
GENERAL INFORMATION
0A–11
Standard Bolts Torque Specifications
The torque values given in the following table should be
applied where a particular torque is not specified.
Strength Class
8.8
4.8
Refined
9.8
Non-Refined
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
4 – 8 N·m (3 – 6 lb ft)
8 – 18 N·m (6 – 13 lb ft)
21 – 34 N·m (15 – 25 lb ft)
20 – 33 N·m (14 – 25 lb ft)
49 – 74 N·m (36 – 54 lb ft)
45 – 69 N·m (33 – 51 lb ft)
77 – 115 N·m (56 – 85 lb ft)
72 – 107 N·m (53 – 79 lb ft)
104 – 157 N·m (77 – 116 lb ft)
100 – 149 N·m (74 – 110 lb ft)
151 – 226 N·m (111 – 166 lb ft)
206 – 310 N·m (152 – 229 lb ft)
251 – 414 N·m (185 – 305 lb ft)
359 – 539 N·m (265 – 398 lb ft)
5 – 10 N·m (4 – 7 lb ft)
12 – 23 N·m (9 – 17 lb ft)
28 – 46 N·m (20 – 34 lb ft)
28 – 45 N·m (20 – 33 lb ft)
61 – 91 N·m (45 – 67 lb ft)
57 – 84 N·m (42 – 62 lb ft)
93 – 139 N·m (69 – 103 lb ft)
88 – 131 N·m (65 – 97 lb ft)
135 – 204 N·m (100 – 150 lb ft)
130 – 194 N·m (95 – 143 lb ft)
195 – 293 N·m (144 – 216 lb ft)
270 – 405 N·m (199 – 299 lb ft)
363 – 544 N·m (268 – 401 lb ft)
431 – 711 N·m (318 – 524 lb ft)
The asterisk * indicates that the bolts are used for
female–threaded parts that are made of soft materials
such as casting, etc.
–
17 – 30 N·m (12 – 22 lb ft)
37 – 63 N·m (27 – 46 lb ft)
36 – 60 N·m (27 – 44 lb ft)
76 – 114 N·m (56 – 84 lb ft)
72 – 107 N·m (53 – 79 lb ft)
114 – 171 N·m (84 – 126 lb ft)
107 – 160 N·m (79 – 118 lb ft)
160 – 240 N·m (118 – 177 lb ft)
153 – 230 N·m (113 – 169 lb ft)
230 – 345 N·m (169 – 255 lb ft)
317 – 476 N·m (234 – 351 lb ft)
425 – 637 N·m (313 – 469 lb ft)
554 – 831 N·m (409 – 613 lb ft)
0A–12
GENERAL INFORMATION
Abbreviations Charts
List of automotive abbreviations which may be used
in this manual
A — Ampere(s)
ABS — Antilock Brake System
AC — Alternating Current
A/C — Air Conditioning
ACCEL — Accelerator
ACC — Accessory
ACL — Air Cleaner
Adj — Adjust
A/F — Air Fuel Ratio
AIR — Secondary Air Injection System
Alt — Altitude
AMP — Ampere(s)
ANT — Antenna
ASM — Assembly
A/T — Automatic Transmission/Transaxle
ATDC — After Top Dead Center
ATF — Automatic Transmission Fluid
Auth — Authority
Auto — Automatic
BARO — Barometric Pressure
Bat — Battery
B+ — Battery Positive Voltage
Bbl — Barrel
BHP — Brake Horsepower
BPT — Backpressure Transducer
BTDC — Before Top Dead Center
° C — Degrees Celsius
CAC — Charge Air Cooler
Calif — California
cc — Cubic Centimeter
CID — Cubic Inch Displacement
CKP — Crankshaft Position
CL — Closed Loop
CLCC — Closed Loop Carburetor Control
CMP — Camshaft Position
CO — Carbon Monoxide
Coax — Coaxial
Conn — Connector
Conv — Converter
Crank — Crankshaft
Cu. In. — Cubic Inch
CV — Constant Velocity
Cyl — Cylinder(s)
DI — Distributor Ignition
Diff — Differential
Dist — Distributor
DLC — Data Link Connector
DOHC — Double Overhead Camshaft
DTC — Diagnostic Trouble Code
DTM — Diagnostic Test Mode
DTT — Diagnostic Test Terminal
DVM — Digital Voltmeter (10 meg.)
DVOM — Digital Volt Ohmmeter
EBCM — Electronic Brake Control Module
ECM — Engine Control Module
ECT — Engine Coolant Temperature
EEPROM — Electronically Erasable Programmable
Read Only Memory
EGR — Exhaust Gas Recirculation
EI — Electronic Ignition
ETR — Electronically Tuned Receiver
EVAP — Evaporation Emission
Exh — Exhaust
° F — Degrees Fahrenheit
Fed — Federal (All States Except Calif.)
FF — Front Drive Front Engine
FL — Fusible Link
FLW — Fusible Link Wire
FP — Fuel Pump
FRT — Front
ft — Foot
FWD — Front Wheel Drive
4WD — Four Wheel Drive
4 x 4 — Four Wheel Drive
4 A/T — Four Speed Automatic Transmission/Transaxle
Gal — Gallon
GEN — Generator
GND — Ground
Gov — Governor
g — Gram
Harn — Harness
HC — Hydrocarbons
HD — Heavy Duty
Hg — Hydrargyrum (Mercury)
HiAlt — High Altitude
HO2S — Heated Oxygen Sensor
HVAC — Heater–Vent–Air–Conditioning
IAC — Idle Air Control
IAT — Intake Air Temperature
IC — Integrated Circuit / Ignition Control
ID — Identification / Inside Diameter
IGN — Ignition
INJ — Injection
IP — Instrument Panel
IPC — Instrument Panel Cluster
Int — Intake
ISC — Idle Speed Control
J/B — Junction Block
kg — Kilograms
km — Kilometers
km/h — Kilometer per Hour
kPa — Kilopascals
kV — Kilovolts (thousands of volts)
kW — Kilowatts
KS — Knock Sensor
L — Liter
lb ft — Foot Pounds
lb in — Inch Pounds
LF — Left Front
LH — Left Hand
LR —Left Rear
LS — Left Side
LWB — Long Wheel Base
L–4 — In–Line Four Cylinder Engine
MAF — Mass Air Flow
MAN — Manual
MAP — Manifold Absolute Pressure
Max — Maximum
MC — Mixture Control
MFI — Multiport Fuel Injection
MIL — Malfunction Indicator Lamp
Min — Minimum
mm — Millimeter
MPG — Miles Per Gallon
MPH — Miles Per Hour
M/T — Manual Transmission/Transaxle
MV — Millivolt
GENERAL INFORMATION
N — Newtons
NA — Natural Aspirated
NC — Normally Closed
N·M — Newton Meters
NO — Normally Open
NOX — Nitrogen, Oxides of
OBD — On-Board Diagnostic
OD — Outside Diameter
O/D — Over Drive
OHC — Overhead Camshaft
OL — Open Loop
O2 — Oxygen
O2S — Oxygen Sensor
PAIR — Pulsed Secondary Air Injection System
P/B — Power Brakes
PCM — Powertrain Control Module
PCV — Positive Crankcase Ventilation
PRESS — Pressure
PROM — Programmable Read Only Memory
PNP — Park/Neutral Position
P/S — Power Steering
PSI — Pounds per Square Inch
PSP — Power Steering Pressure
Pt. — Pint
Pri — Primary
PWM — Pulse Width Modulate
Qt. — Quart
REF — Reference
RF — Right Front
RFI — Radio Frequency Interference
RH — Right Hand
RPM — Revolutions Per Minute
RPM Sensor — Engine Speed Sensor
RPO — Regular Production Option
RR — Right Rear
RS — Right Side
RTV — Room Temperature Vulcanizing
RWAL — Rear Wheel Antilock Brake
RWD — Rear Wheel Drive
SAE — Society of Automotive Engineers
Sec — Secondary
SFI — Sequential Multiport Fuel Injection
SI — System International
SIR — Supplemental Inflatable Restraint System
SOHC — Single Overhead Camshaft
Sol — Solenoid
SPEC — Specification
Speedo — Speedometer
SRS — Supplemental Restraint System
ST — Start / Scan Tool
Sw — Switch
SWB — Short Wheel Base
SYN — Synchronize
Tach — Tachometer
TB — Throttle Body
TBI — Throttle Body Fuel Injection
TCC — Torque Converter Clutch
TCM — Transmission Control Module
TDC — Top Dead Center
Term — Terminal
TEMP — Temperature
TOD— Torque On Demand
TP — Throttle Position
TRANS — Transmission/Transaxle
TURBO — Turbocharger
0A–13
TVRS — Television & Radio Suppression
TVV — Thermal Vacuum Valve
TWC — Three Way Catalytic Converter
3 A/T — Three Speed Automatic Transmission/Transaxle
2WD — Two Wheel Drive
4 x 2 — Two Wheel Drive
U–joint — Universal Joint
V — Volt(s)
VAC — Vacuum
VIN — Vehicle Identification Number
VRRRE — Vehicle Refrigerant Recovery and Recycling
Equipment
V–ref — ECM Reference Voltage
VSS — Vehicle Speed Sensor
VSV — Vacuum Switch Valve
V–6 — Six Cylinder “V” Engine
V–8 — Eight Cylinder ”V” Engine
W — Watt(s)
w/ — With
w/b — Wheel Base
w/o — Without
WOT — Wide Open Throttle
Service Parts Identification Plate
The Vehicle Information Plate (Service Parts ID plate) is
provided on all vehicle models.
It is located on the center dash wall inside the engine
compartment.
The plate lists the VIN (Vehicle
Identification Number), paint information and all
production options and special equipment on the vehicle
when it was shipped from the factory.
905R200002
SECTION
MAINTENANCE AND LUBRICATION
0B–1
AXIOM
GENERAL INFORMATION
Maintenance and Lubrication
CONTENTS
Maintenance Schedule List . . . . . . . . . . . . . . .
Explanation of Complete Vehicle Maintenance
Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Fluids and Lubricants . . . .
Lubricant Viscosity Chart . . . . . . . . . . . . . . . . .
0B–1
0B–5
0B–8
0B–9
Recommended Liquid Gasket . . . . . . . . . . .
Recommended Thread Locking Agents . . .
Maintenance Service Data . . . . . . . . . . . . . . . .
0B–11
0B–11
0B–12
Maintenance Schedule List
Severe Driving Conditions
Normal Vehicle Use
If the vehicle is usually operated under any of the severe
driving conditions listed below, it is recommended that the
applicable maintenance services be performed at the
specified interval shown in the chart below.
Severe driving conditions:
The maintenance instructions in this Maintenance
Schedule are based on the assumption that the vehicle
will be used as designed:
B to carry passengers and cargo within the limitations
specified on the tire placard located on the inside of
the glove compartment door;
B to be driven on reasonable road surfaces within legal
operating limits;
B to be driven on a daily basis, as a general rule, for at
least several miles/kilometers;
B to be driven on unleaded fuel
Unusual or severe operating conditions will require more
frequent vehicle maintenance, as specified in the
following sections.
ITEMS
B Towing a trailer, using a camper or car top carrier.
B Repeated short trips of less than 8 Km (5 miles) with
outside temperature remaining below freezing.
B Extensive idling and/or low speed driving for long
distances, such as police, taxi or door–to–door
delivery use.
B Operating on dusty, rough, muddy or salt spread
roads.
INTERVAL
CHANGE ENGINE OIL AND OIL FILTER
Every 3,000 miles (4,800 km) or 3 months
CHANGE AUTOMATIC TRANSMISSION FLUID
Every 20,000 miles (32,000 km)
CHANGE REAR AXLE OIL
Every 15,000 miles (24,000 km)
REPLACE TIMING BELT
Every 75,000 miles (120,000 km)
REPLACE AIR CLEANER FILTER
See explanation of service, page 0B–5
CHANGE POWER STEERING FLUID
Every 30,000 miles (48,000 km)
0B–2
MAINTENANCE AND LUBRICATION
Mileage Only Items
MAINTENANCE AND LUBRICATION
Mileage/Months
0B–3
0B–4
MAINTENANCE AND LUBRICATION
MAINTENANCE AND LUBRICATION
Explanation of Complete
Maintenance Schedule
Vehicle
0B–5
Radiator Core and Air Conditioning
Condenser Cleaning
Brief explanations of the services listed in the preceding
Maintenance Schedule are presented below.
Replace all questionable parts and note any necessary
repairs as you perform these maintenance procedures.
Clean the front of the radiator core and air conditioning
condenser, at 60,000 miles (96,000 km) intervals.
Front and Rear Axle Lubricant
Replacement
A fluid loss in any system (except windshield
washer) may indicate a problem. Repair the system
at once.
Engine oil level
Check level and add if necessary. The best time to check
the engine oil level is when the oil is warm. After stopping
the engine with the vehicle on a level surface, wait a few
minutes for the oil to drain back to the oil pan. Pull out the
oil level indicator (dipstick). Wipe it clean and push the oil
level indicator back down all the way. Pull out the oil level
indicator, keeping the tip down, and look at the oil level on
it.
Add oil, if needed, to keep the oil level above the “ADD”
mark and between the “ADD” and “FULL” marks in the
operating range area. Avoid overfilling the engine since
this may cause engine damage. Push the oil level
indicator back down all the way after taking the reading.
If you check the oil level when the oil is cold, do not run the
engine first. The cold oil will not drain back to the pan fast
enough to give a true oil level.
Engine coolant level and condition
Check engine coolant level in the coolant reservoir and
add engine coolant if necessary. Inspect the engine
coolant and replace it if dirty or rusty.
Check the lubricant level after every 7,500 miles (12,000
km) of operation and add lubricant to level of filler hole if
necessary.
Replace the front and rear axle lubricant at 15,000 miles
(24,000 km) and 30,000 miles (48,000 km) and after
every 30,000 miles (48,000 km) of operation thereafter.
Air Cleaner Element Replacement
Replace the air cleaner under normal operating
conditions every 30,000 miles (48,000 km).
Operation of the vehicle in dusty areas will necessitate
more frequent replacement.
Spark Plug Replacement
Replace the plugs at 100,000 miles (160,000 km)
intervals with the type specified at the end of this section.
Cooling System Service
Drain, flush and refill system with new engine coolant.
Refer to “Recommended Fluids and Lubricants” in this
section, or ENGINE COOLING (SEC.6B).
Timing Belt Replacement
Replacement of the timing belt is recommended at every
100,000 miles (160,000 km).
Failure to replace the timing belt may result in serious
damage to the engine.
Valve Clearance Adjustment
Incorrect valve clearance will result in increased engine
noise and reduced engine output.
Retorque the camshaft bracket bolts before checking and
adjusting the valve clearance.
Check and adjust the valve clearance whenever
increased engine noise is heard.
Tire Rotation
Rotate tires every 7,500 miles (12,000 km).
Front Wheel Bearings Lubricant
Replacement (Vehicles Produced Before
July/31/2001)
Clean and repack the front wheel bearings at 30,000
miles (48,000 km) intervals.
Refer to DRIVE SHAFT SYSTEM (SEC. 4C).
Front Wheel Bearings Check (Vehicles
Produced After Aug./1/2001)
Inspect hub unit bearing at every 60,000 miles (96,000
km).
If there is abnormal condition, replace hub unit bearing.
Fluid Level Check
Windshield washer fluid level
Check washer fluid level in the reservoir and add if
necessary.
Power steering system reservoir level
Check and keep at the proper level.
Brake master cylinder reservoir level
Check fluid. Keep fluid at proper level. A low fluid level can
indicate worn disc brake pads which may need to be
serviced.
Hydraulic clutch system
Check fluid level in the reservoir. Add fluid as required.
Battery fluid level
Check fluid level in the battery.
Fluid Leak Check
Check for fuel, water, oil or other fluid leaks by looking at
the surface beneath the vehicle after it has been parked
for a while. Water dripping from the air conditioning
system after use is normal. If you notice gasoline fumes or
fluid at any time, locate the source and correct it at once.
Engine Oil and Oil Filter Replacement
Always use API SE, SF, SG, SH or ILSAC GF–1 quality
oils of the proper viscosity.
When choosing an oil, consider the range of
temperatures the car will be operated in before the next oil
change. Then, select the recommended oil viscosity from
the chart.
0B–6
MAINTENANCE AND LUBRICATION
Always change the oil and the oil filter as soon as possible
after driving in a dust storm.
Engine Cooling System Inspection
Inspect the coolant/anti–freeze. If the coolant is dirty or
rusty, drain, flush and refill with new coolant. Keep coolant
at the proper mixture for proper freeze protection,
corrosion inhibitor level and best engine operating
temperature. Inspect hoses and replace if cracked,
swollen or deteriorated. Tighten the hose clamps if
equipped with screw–type clamps. Clean outside of
radiator and air conditioning condenser. Wash filler cap
and neck. To help ensure proper operation, a pressure
test of both the cooling system and the cap is also
recommended.
Exhaust System Inspection
Visually inspect the exhaust pipes, muffler, heat shields
and hangers for cracks, deterioration, or damage.
Be alert to any changes in the sound of the exhaust
system or any smell of fumes. These are signs the system
may be leaking or overheating. Repair the system at
once, if these conditions exist. (See also “Engine Exhaust
Gas Safety” and “Three Way Catalytic Converter” in the
Owner’s manual.)
Fuel Cap, Fuel Lines, and Fuel Tank
Inspection
Inspect the fuel tank, the fuel cap and the fuel lines every
60,000 miles (96,000 km) for damage which could cause
leakage.
Inspect the fuel cap and the gasket for correct sealing and
physical damage. Replace any damaged parts.
Drive Belt Inspection
Check the serpentine belt driving for cracks, fraying,
wear, and correct tension every 30,000 miles (48,000
km). Replace as necessary.
Wheel Alignment, Balance and Tires
Operation
Uneven or abnormal tire wear, or a pull right or left on a
straight and level road may show the need for a wheel
alignment. A vibration of the steering wheel or seat at
normal highway speeds means a wheel balancing is
needed. Check tire pressure when the tires are “cold”
(include the spare).
Maintain pressure as shown in the tire placard, which is
located on the driver’s door lock pillar.
Steering System Operation
Be alert for any changes in steering operation. An
inspection or service is needed when the steering wheel
is harder to turn or has too much free play, or if there are
unusual sounds when turning or parking.
Brake Systems Operation
Watch for the “BRAKE” light coming on. Other signs of
possible brake trouble are such things as repeated pulling
to one side when braking, unusual sounds when braking
or between brake applications, or increased brake pedal
travel. If you note one of these conditions, repair the
system at once.
For convenience, the following should be done when
wheels are removed for rotation: Inspect lines and hoses
for proper hookup, bindings, leaks, crack, chafing etc.
Inspect disc brake pads for wear and rotors for surface
condition.
Inspect other brake parts, including parking brake drums,
linings etc., at the same time. Check parking brake
adjustment.
Inspect the brakes more often if habit or conditions
result in frequent braking.
Parking Brake and Transmission Park
Mechanism Operation
Park on a fairly steep hill and hold the vehicle with the
parking brake only. This checks holding ability. On
automatic transmission vehicles, shifting from “P”
position to the other positions cannot be made unless the
brake pedal is depressed when the key switch is in the
“ON” position or the engine is running.
WARNING: BEFORE CHECKING THE STARTER
SAFETY SWITCH OPERATION BELOW, BE SURE TO
HAVE ENOUGH ROOM AROUND THE VEHICLE.
THEN FIRMLY APPLY BOTH THE PARKING BRAKE
AND THE REGULAR BRAKE. DO NOT USE THE
ACCELERATOR PEDAL. IF THE ENGINE STARTS,
BE READY TO TURN OFF THE KEY PROMPTLY.
TAKE THESE PRECAUTIONS BECAUSE THE
VEHICLE COULD MOVE WITHOUT WARNING AND
POSSIBLY CAUSE PERSONAL INJURY OR
PROPERTY DAMAGE.
Starter Safety Switch Operation
Check by trying to start the engine in each gear while
setting the parking brake and the foot brake. The starter
should crank only in “P” (Park) or “N” (Neutral).
Accelerator Linkage Lubrication
Lubricate the accelerator pedal fulcrum pin with chassis
grease.
Steering and Suspension Inspection
Inspect the front and rear suspension and steering
system for damaged, loose or missing parts or signs of
wear. Inspect power steering lines and hoses for proper
hookup, binding, leaks, cracks, chafing, etc.
Body and Chassis Lubrication
Lubricate the key lock cylinders, the hood latch, the hood
and door hinges, the door check link, the parking cable
guides, the underbody contact points, and the linkage.
Propeller Shaft Inspection and Lubrication
Check the propeller shaft flange–to–pinion bolts for
proper torque to 63 N•m (46 lb ft) for front and rear
propeller shaft.
MAINTENANCE AND LUBRICATION
Automatic Transmission Fluid
Replacement
Under harsh operating conditions, such as constant
driving in heavy city traffic during hot weather, or in hilly or
mountainous terrain, change the transmission fluid and
service the sump filter after every 20,000 miles (32,000
km) of operation.
More over, the remaining life percentage of ATF can be
estimated by using TECH–II as an auxiliary tool to judge
the right time for ATF replacement.
The remaining life percentage is calculated from ATF’S
heat history. When it is close to 0%, ATF replacement is
recommended.
Auto Cruise Control Inspection
Check to see if the clearance between cruise link and
accelerator link is normal. Also check that the connected
properly.
Accelerator Linkage Inspection
Inspect for interference, binding, and damaged or
missing parts. Check accelerator pedal for smooth
operation and even pedal effort. Replace parts as
needed.
0B–7
0B–8
MAINTENANCE AND LUBRICATION
Recommended Fluids and Lubricants
USAGE
Engine
FLUID/LUBRICANT
API SE, SF, SG, SH or ILSAC GF-1 Engine oil (See oil
chart on the following page for proper viscosity)
Engine coolant
Mixture of water and good quality ethylene glycol base
type antifreeze.
Brake system
DOT-3 hydraulic brake fluid.
Power steering system
DEXRON -III Automatic transmission fluid.
Automatic transmission
DEXRON -III Automatic transmission fluid.
TOD SYSTEM (TOD system model only)
DEXRON -IIE or DEXRON -III Automatic transmission fluid.
Rear axle and front axle
GL-5 gear lubricant (Standard differential)
GL-5 Limited slip differential gear lubricant together
with limited slip differential lubricant additive (Part No.
8-01052-358-0) or equivalent (If equipped with optional
limited slip differential) (See oil chart in this section for
proper viscosity)
Hood latch assembly
a. Pivots and spring anchor
Engine oil
b. Release pawl
Chassis grease
Hood and door hinges
Engine oil
Chassis lubrication
Chassis grease
Parking brake cables
Chassis grease
Front wheel bearings
Multipurpose grease
Shift on the fly system
GL-5 gear lubricant (SAE 75W-90)
Body door hinge pins and linkage, fuel door hinge, rear
compartment lid hinges
Engine oil
Windshield washer solvent
Washer fluid
Key lock cylinder
Synthetic light weight engine oil (SAE 5W-30)
Accelerator linkage
Chassis grease
MAINTENANCE AND LUBRICATION
0B–9
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 Front Axle
B00RW003
0B–10
MAINTENANCE AND LUBRICATION
Oil Viscosty Chart for Rear Axle
B00RW004
MAINTENANCE AND LUBRICATION
0B–11
Recommended Liquid Gasket
Type
Brand Name
Manufacturer
Remarks
Three Bond
Three Bond
Three Bond
Three Bond
Three Bond
For Engine Repairs
RTV*
Silicon Base
Three Bond 1207B
Three Bond 1207C
Three Bond 1215
Three Bond 1280
Three Bond 1281
Water Base
Three Bond 1141E
Three Bond
For Engine Repairs
Solvent
Three Bond 1104
Belco Bond 4
Belco Bond 401
Belco Bond 402
Three Bond
Isuzu
Isuzu
Isuzu
For Engine Repairs
Anaerobic
LOCTITE 515
LOCTITE 518
LOCTITE 17430
Loctite
Loctite
Loctite
All
* RTV: Room Temperature Vulcanizer
For Axle Case
Repairs T/M
Repairs T/M
Application Steps
NOTE:
1. It is very important that the liquid gaskets listed above
or their exact equivalent be used on the vehicle.
2. Be careful to use the specified amount of liquid
gasket.
Follow the manufacturer’s instructions at all times.
1. Completely remove all lubricant and moisture from
the bolts and the female-threaded surfaces of the
parts to be joined.
The surfaces must be perfectly dry.
2. Apply LOCTITE to the bolts.
3. Be absolutely sure to remove all lubricants and
moisture from the connecting surfaces before
applying the liquid gasket.
The connecting surfaces must be perfectly dry.
4. Do not apply LOCTITE 17430, LOCTITE 515 and
LOCTITE 518 between two metal surfaces having a
clearance of greater than 0.25 mm (0.01 in). Poor
adhesion will result.
Recommended Thread Locking
Agents
LOCTITE Type
LOCTITE Color
LOCTITE 242
Blue
LOCTITE 262
Red
LOCTITE 271
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.
0B–12
MAINTENANCE AND LUBRICATION
Maintenance Service Data
Service Data and Specifications
Valve clearance (cold)
Intake 0.28±0.05 mm (0.011±0.002 in)
Exhaust 0.3±0.05 mm (0.012±0.002 in)
Spark plug type
K16PR-P11/PK16PR11/RC10PYP4
Spark plug gap
1.05 mm (0.04 in)
Brake pedal free play
6–10 mm (0.24–0.39 in)
Parking brake travel
6–7 notches
Toe-in (Front)
0 to +2 mm (0 to +0.08 in)
Toe-in (Rear)
0±5 mm (0±0.2 in)
Camber (Front)
0°±30’
Camber (Rear)
0°±1°
Caster (Front)
2°30’±45’
Toe–Axis (Rear)
±1°
PROPELLER SHAFT
Flange torque
63 N·m (46 lb ft)
WHEEL AND TIRES
Size
ENGINE
BRAKE
WHEEL ALIGNMENT
P235/65R17
Wheel nut torque
118 N·m (87 lb ft)
Tire inflation pressure (Front)
180 kPa (26 psi)
* Tire inflation pressure (Rear)
180 kPa (26 psi)
* Unless otherwise specified on tire information label on the vehicle.
Approximate Capacities
Items
Metric Measure
U.S. Measure
74 L
19.5 Gal.
Oil Change with Filter
4.7 L
5.0 Qt
Oil Change without Filter
4.0 L
4.2 Qt
Coolant
A/T
11.1 L
11.7 Qt
Transmission
Automatic
8.6 L
9.1 Qt
1.35 L
1.4 Qt
Rear
1.77 L
1.87 Qt
Front
1.25 L
1.33 Qt
Shift on the fly system
0.12 L
0.13 Qt
Power steering
1.0 L
1.1 Qt
Air conditioning (R-134a)
0.6 L
1.32 Qt
Fuel tank
* Crankcase
Transfer
Axle
*Crankcase capacities shown are approximate refill capacities. After refill, recheck oil level.
SECTION
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A–1
AXIOM
HEATING, VENTILATION AND AIR
CONDITIONING (HVAC)
HVAC SYSTEMS
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . .
Heating and Ventilation System . . . . . . . . . . .
General Description . . . . . . . . . . . . . . . . . . . . .
Heater Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Unit and Associated Parts . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Core and / or Mode Door . . . . . . . . . .
Disassembled View . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Mode Control Link Unit . . . . . . . . . . . .
Disassembled View . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Temperature Control Link Unit . . . . . .
Disassembled View . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Assembly . . . . . . . . . . . . . . . . . . . . . . . .
Blower Assembly and Associated Parts . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Link Unit and / or Mode door . . . . . . .
Disassembled View . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor and Associated Parts . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Heater Duct, Defroster Nozzle and
Ventilation Duct . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Heater Duct, Defroster Nozzle,
Ventilation Duct and Associated Parts . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Conditioning System . . . . . . . . . . . . . . . . . .
General Description . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Conditioning System . . . . . . . . . . . . . . . . . .
1A–3
1A–3
1A–3
1A–6
1A–6
1A–6
1A–6
1A–7
1A–7
1A–8
1A–8
1A–8
1A–9
1A–9
1A–9
1A–10
1A–11
1A–11
1A–11
1A–11
1A–12
1A–12
1A–12
1A–12
1A–13
1A–13
1A–13
1A–14
1A–15
1A–15
1A–15
1A–15
1A–16
1A–16
1A–16
1A–17
1A–18
1A–18
1A–24
1A–31
Individual Inspection . . . . . . . . . . . . . . . . . . . . .
General Repair Procedure . . . . . . . . . . . . . .
Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Assembly . . . . . . . . . . . . . . . . . . .
Compressor Assembly and Associated
Parts (6VE1) . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
New Compressor Installation . . . . . . . . . . . .
Condenser Assembly . . . . . . . . . . . . . . . . . . . .
Condenser Assembly and Associated
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condenser Fan Motor . . . . . . . . . . . . . . . . . . . .
Condenser Fan Motor and Associated
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receiver / Drier . . . . . . . . . . . . . . . . . . . . . . . . .
Receiver / Drier and Associated Parts . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Switch and Associated Parts . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evaporator Assembly . . . . . . . . . . . . . . . . . . . .
Evaporator Assembly and Associated
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duct Sensor, Evaporator Core and/or
Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Line . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Line and Associated Parts . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data And Specifications . . . . . . . . . . . . .
1A–31
1A–31
1A–33
1A–38
1A–38
1A–38
1A–39
1A–39
1A–40
1A–40
1A–40
1A–41
1A–42
1A–42
1A–42
1A–42
1A–43
1A–43
1A–43
1A–43
1A–44
1A–44
1A–44
1A–44
1A–45
1A–45
1A–45
1A–46
1A–47
1A–47
1A–47
1A–48
1A–49
1A–49
1A–49
1A–50
1A–51
1A–2
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution . . . . . . . . . . . . . . . . . . . .
General Description . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Magnetic Clutch Assembly (DKV-14G Type)
Parts Location View . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Specification . . . . . . . . . . . . . . . . . . . . . . .
Handling of Oil . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Oil Check . . . . . . . . . . . . . . . . .
Checking and Adjusting Oil Quantity for
Used Compressor . . . . . . . . . . . . . . . . . . . . .
Checking and Adjusting for Compressor
Replacement . . . . . . . . . . . . . . . . . . . . . . . . .
Contamination of Compressor Oil . . . . . . . .
Oil Return Operation . . . . . . . . . . . . . . . . . . .
Replacement of Component Parts . . . . . . .
Main Data and Specifications . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Air Conditioning System . . . . . . . .
General Description . . . . . . . . . . . . . . . . . . . . . .
Automatic Air Conditioner Parts
Configuration . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . .
Functions and Features . . . . . . . . . . . . . . . .
Automatic Air Conditioner Block Diagram .
Control Panel Layout . . . . . . . . . . . . . . . . . . .
Air Control Functions . . . . . . . . . . . . . . . . . . .
Control Panel Switch Operation . . . . . . . . .
Overview of Construction, Movement and
Control of Major Parts of Automatic Air
Conditioner System . . . . . . . . . . . . . . . . . . .
Overview of Automatic Control of Automatic
Air Conditioner . . . . . . . . . . . . . . . . . . . . . . .
Automatic Air Conditioning System . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting, Its Overview and
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . .
Auto Air Conditioner Control Unit Power
Supply Diagnosis . . . . . . . . . . . . . . . . . . . . .
1A–53
1A–53
1A–53
1A–54
1A–55
1A–55
1A–55
1A–57
1A–57
1A–59
1A–59
1A–59
1A–59
1A–59
1A–60
1A–60
1A–60
1A–60
1A–61
1A–63
1A–64
1A–64
1A–64
1A–65
1A–70
1A–71
1A–72
1A–73
1A–74
1A–77
1A–81
1A–82
1A–86
1A–86
1A–87
Performance and Movement checklist for
Automatic Air Conditioner Related Parts .
Troubleshooting With Self-Diagnosis
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection By Failed Location . . . . . . . . . . . . .
Inspection of the Sensors . . . . . . . . . . . . . . .
Inspection of the Intake Actuator System .
Inspection of the Mix Actuator System . . . .
Inspection of the Mode Actuator System . .
Inspection of the Fan Motor System . . . . . .
Inspection of the Magnetic Clutch System
Individual Inspection . . . . . . . . . . . . . . . . . . .
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . .
Power Transistor . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Heater/Air Conditioner Control
Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
In Car Sensor . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ambient Sensor . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sun Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duct Sensor . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mode Actuator . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mix Actuator . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake Actuator . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1A–89
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HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
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.
1A–3
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
Heating and Ventilation System
General Description
Heater
When the engine is warming up, the warmed engine
coolant is sent into the heater core. The heater system
supplies warm air into the passenger compartment to
warm it up.
Outside air is circulated through the heater core of the
heater unit and then into the passenger compartment. By
controlling the mixture of outside air and heater core air,
the most comfortable passenger compartment
temperature can be selected and maintained.
The temperature of warm air sent to the passenger
compartment is controlled by the temperature control
knob. This knob acts to open and close the air mix door,
thus controlling the amount of air passed through the
heater core.
The air selector switch (Mode SW), with its different
modes, also allows you to select and maintain the most
comfortable passenger compartment temperature.
The air source select switch is used to select either
“FRESH” for the introduction of the outside air, or “CIRC”
for the circulation of the inside air. When the switch is set
to “FRESH”, the outside air is always taken into the
passenger compartment. When setting the switch to
“CIRC” position, the circulation of air is restricted only to
the inside air with no introduction of the outside air and the
air in the passenger compartment gets warm quickly.
However, the switch is normally set to “FRESH” to
prevent the windshield from clouding.
1A–4
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
840R200007
Legend
(1) Defroster Nozzle
(2) Ventilation Duct
(3) Blower Assembly
(4)
(5)
(6)
(7)
Evaporator Assembly
Ventilation Lower Duct
Heater Unit
Rear Heater Duct
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A–5
C01RW001
Air Source Select Switch
Temperature Control Switch
Press this button to select either Fresh Air Intake or CIRC
(inside air circulation). There is an indicator light inside the
button. This light indicates that the CIRC mode is “ON”.
Fresh Air Intake is the default setting for both DEFROST
and FOOT/DEFROST.
When the temperature control switch is in the “18°C
(65°F)” position, the air mix door closes to block the air
flow to the heater core.
When the temperature control switch is in the “32°C
(90°F)” position, the air mix door opens to allow air to pass
through the heater core and heat the passenger
compartment.
Selecting the desired temperature will control the air flow
through the heater core, allowing control of the cabin
temperature.
Fan Control Switch
This switch controls the blower motor speed to regulate
the amount of air delivered to the defrost, foot, and
ventilation ducts:
1. L0
2. M1
3. M2
4. M3
5. HI
1A–6
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Heater Unit
Heater Unit and Associated Parts
840R200008
Legend
(1) Instrument Panel Assembly
(2) Cross Beam Assembly
(3) Instrument Panel Bracket W/Suspension
Control Unit
(4) Ventilation Lower Duct
Removal
1. Disconnect the battery ground cable.
2. Drain the engine coolant.
3. Discharge and recover refrigerant (with air
conditioning).
B Refer to Refrigerant Recovery in this section.
4. Remove the Instrument panel assembly.
B Refer to Instrument Panel Assembly in Body and
Accessories section.
5. Remove instrument panel bracket w/suspension
control unit.
B Refer to Cross Beam Assembly in Body and
Accessories section.
6. Cross Beam Assembly.
B Refer to Cross Beam Assembly in Body and
Accessories section.
(5)
(6)
(7)
(8)
(9)
Rear Heater Duct
Evaporator Assembly
Heater Unit Assembly
Heater Hose
Power Transistor Connector
7. Disconnect power transistor connector.
8. Remove evaporator assembly.
B Refer to Evaporator Assembly in this section.
9. Remove ventilation lower duct.
10. Remove rear heater duct.
B Remove foot rest, carpet and 3 clips.
11. Disconnect mode/mix actuator connector.
12. Remove heater unit assembly.
B Disconnect heater hoses at heater unit.
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
1. When handling the PCM and the control unit, be
careful not to make any improper connection of the
connectors.
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A–7
2. When installing the heater unit, defroster nozzle and
center vent duct, be sure that the proper seal is made,
without any gap between them.
Heater Core and / or Mode Door
Disassembled View
860R200001
Legend
(1) Heater Core
(2) Case (Temperature Control)
(3) Heater Unit
(4) Mix Actuator
(5)
(6)
(7)
(8)
Mode Door
Duct
Mode Actuator
Case (Mode Control)
1A–8
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
11. Pull out the mode door while raising up the catch of
the door lever.
Removal
1. Disconnect the battery ground cable.
2. Drain the engine coolant.
3. Discharge and recover refrigerant (with air
conditioning).
B Refer to Refrigerant Recovery in this section.
4. Remove heater unit.
B Refer to Heater Unit in this section.
5. Remove duct.
6. Remove mix actuator.
7. Remove mode actuator.
8. Remove case (Mode control) and do not remove link
unit at this step.
9. Remove case (Temperature control) separate two
halves of core case.
860RS004
Inspection
Check for foreign matter in the heater core, stain or the
core fin defacement.
Installation
To install, follow the removal steps in the reverse order,
noting the following point:
1. Check that each mode door operates properly.
860RS002
10. Remove heater core (1).
860RS003
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A–9
Heater Mode Control Link Unit
Disassembled View
860R200002
Legend
(1) Case (Mode Control)
(2) Heater Unit
(3) Mode Sub-lever
(4) Clip
(5)
(6)
(7)
(8)
Door Lever
Rod
Mode Actuator
Washer and Mode Main Lever
Removal
1. Disconnect the battery ground cable.
2. Drain engine coolant.
3. Discharge and recover refrigerant (with air
conditioning)
B Refer to Refrigerant Recovery in this section.
4. Remove heater unit.
B Refer to Heater Unit in this section.
5. Remove mode actuator.
6. Remove the case (Mode control) from heater unit.
7. Remove washer and the mode main lever.
8. Remove rod.
9. Press the tab of the sub-lever inward, and take out the
sub-lever.
860RS006
1A–10 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
10. Pull out the door lever while raising up the catch of the
door lever.
11. Remove clip.
Installation
To install, follow the remove steps in the reverse order,
noting the following points:
1. Apply grease to the mode sub-lever and to the
abrasive surface of the heater unit.
2. After installing the link unit, check to see if the link unit
operates correctly.
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–11
Heater Temperature Control Link Unit
Disassembled View
860R200003
Legend
(1) Case (Temperature control)
(2) Door Lever
(3) Clip
(4) Rod
(5)
(6)
(7)
(8)
Clip
Sub-lever
Mix Actuator
Heater Unit
Removal
Installation
1. Disconnect the battery ground cable.
2. Drain engine coolant.
3. Discharge and recover refrigerant (with air
conditioning).
B Refer to Refrigerant Recovery in this section.
4. Remove heater unit.
B Refer to Heater Unit in this section.
5. Remove mix actuator.
6. Remove the case (Temperature control) from the
heater unit.
7. Remove rod.
8. Remove sub-lever.
9. Pull out the door lever while raising up the catch of the
door lever.
10. Remove clip.
To install, follow the removal steps in the reverse order,
noting the following points:
1. Apply grease to the sub-lever and to the abrasive
surface of the heater unit.
2. After installing the link unit, check to see if the link unit
operates correctly.
1A–12 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Blower Assembly
Blower Assembly and Associated Parts
873R200004
Legend
(1) Instrument Panel Assembly
(2) Blower Assembly
Removal
1. Disconnect the battery ground cable.
2. Discharge and recover refrigerant (with air
conditioning).
B Refer to Refrigerant Recovery in this section.
3. Remove instrument panel assembly.
B Refer to Instrument Panel Assembly in Body and
Accessories section.
4. Disconnect power transistor connector.
5. Remove evaporator assembly.
B Refer to Evaporator Assembly in this section.
(3) Evaporator Assembly
(4) Heater Unit
6. Disconnect blower motor/intake actuator connector.
7. Remove blower assembly.
Installation
To install, follow the removal steps in the reverse order.
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–13
Blower Link Unit and / or Mode door
Disassembled View
873R200001
Legend
(1) Blower Assembly
(2) Upper Case
(3) Mode Door
(4) Lower Case
(5)
(6)
(7)
(8)
Max High Relay
Intake Actuator
Sub Lever
Door Lever
Removal
1. Disconnect the battery ground cable.
2. Discharge and recover refrigerant (with air
conditioning).
B Refer to Refrigerant Recovery in this section.
3. Remove blower assembly.
B Refer to Blower Assembly in this section.
4. Remove intake actuator.
5. Remove max high relay.
6. Remove lower case.
7. Separate the upper case and slit the lining parting
face with a knife.
873RS002
1A–14 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
8. Pull out the mode door while raising up the catch of
door lever.
9. Remove sub-lever.
10. Remove door lever.
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
1. Apply grease to the door lever and to the abrasive
surface of the upper case.
2. Apply an adhesive to the parting face of the lining
when assembling the upper case.
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–15
Blower Motor
Blower Motor and Associated Parts
873RS004
Legend
(1) Blower Motor Connector
(2) Blower Motor Assembly
(3) Clip
Removal
1. Disconnect the battery ground cable.
2. Remove blower motor connector.
3. Remove attaching screw.
4. Remove blower motor assembly.
5. Remove clip.
6. Remove fan.
7. Remove blower motor.
(4) Fan
(5) Blower Motor
(6) Attaching Screw
Installation
To install, follow the removal steps in the reverse order.
1A–16 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Rear Heater Duct, Defroster Nozzle and Ventilation Duct
Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts
840R200009
Legend
(1) Defroster Nozzle
(2) Cross Beam Assembly
(3) Center Ventilation Duct and Side Defroster
Duct
Removal
1. Disconnect the battery ground cable.
2. Remove instrument panel assembly.
B Refer to Instrument Panel Assembly in Body and
Accessories section.
3. Remove center ventilation duct and side defroster
duct.
B Remove 5 screws.
(4) Instrument Panel Bracket W/Suspension
Control Unit
(5) Instrument Panel Assembly
(6) Rear Heater Duct
(7) Ventilation Lower Duct
4. Remove instrument panel brackets w/suspension
control unit.
B Refer to Cross Beam Assembly in Body and
Accessories section.
5. Remove cross beam assembly.
B Refer to Cross Beam Assembly in Body and
Accessories section.
6. Remove ventilation lower duct.
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–17
7. Remove rear heater duct.
B Remove foot rest carpet and 3 clips.
8. Remove defroster nozzle.
Installation
To install, follow the removal steps in the reverse order,
noting the following point:
1. Connect each duct and nozzle securely leaving no
clearance between them and making no improper
matching.
1A–18 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Air Conditioning System
General Description
Air Conditioning Refrigerant Cycle Construction
C01RY00013
Legend
(1) Duct Sensor
(2) Evaporator Core
(3) Evaporator Assembly
(4) Temperature Sensor
(5) Blower Motor
(6) Expansion Valve
(7) Pressure Switch
(8) Receiver/Drier
The refrigeration cycle includes the following four
processes as the refrigerant changes repeatedly from
liquid to gas and back to liquid while circulating.
(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
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–19
Evaporation
The refrigerant is changed from a liquid to a gas inside the
evaporator.
The refrigerant mist that enters the
evaporator vaporizes readily. The liquid refrigerant
removes the required quantity of heat (latent heat of
vaporization) from the air around the evaporator core
cooling fins and rapidly vaporizes. Removing the heat
cools the air, which is then radiated from the fins and
lowers the temperature of the air inside the vehicle.
The refrigerant liquid sent from the expansion valve and
the vaporized refrigerant gas are both present inside the
evaporator as the liquid is converted to gas.
With this change from liquid to gas, the pressure inside
the evaporator must be kept low enough for vaporization
to occur at a lower temperature. Because of that, the
vaporized refrigerant is sucked into the compressor.
Compression
The refrigerant is compressed by the compressor until it is
easily liquefied at normal temperature.
The vaporized refrigerant in the evaporator is sucked into
the compressor. This action maintains the refrigerant
inside the evaporator at a low pressure so that it can
easily vaporize, even at low temperatures close to 0°C
(32°F).
Also, the refrigerant sucked into the compressor is
compressed inside the cylinder to increase the pressure
and temperature to values such that the refrigerant can
easily liquefy at normal ambient temperatures.
It compresses low-pressure and low-temperature
refrigerant vapor from the evaporator into high-pressure
and high-temperature refrigerant vapor to the condenser.
It pumps refrigerant and refrigerant oil through the air
conditioning system.
This vehicle is equipped with a five-vane rotary
compressor.
The specified amount of the compressor oil is 150cc
(5.0 fl. oz.).
The oil used in the HFC-134a system compressor differs
from that used in R-12 systems.
Also, compressor oil to be used varies according to the
compressor model. Be sure to avoid mixing two or more
different types of oil.
If the wrong oil is used, lubrication will be poor and the
compressor will seize or malfunction.
The magnetic clutch connector is a waterproof type.
Magnetic Clutch
The compressor is driven by the drive belt from the crank
pulley of the engine. If the compressor is activated each
time the engine is started, this causes too much load to
the engine. The magnetic clutch transmits the power from
the engine to the compressor and activates it when the air
conditioning is ON. Also, it cuts off the power from the
engine to the compressor when the air conditioning is
OFF. Refer to Compressor in this section for magnetic
clutch repair procedure.
Condensation
The refrigerant inside the condenser is cooled by the
outside air and changes from gas to liquid.
The high temperature, high pressure gas coming from the
compressor is cooled and liquefied by the condenser with
outside air and accumulated in the receiver/drier. The
heat radiated to the outside air by the high temperature,
high pressure gas in the compressor is called heat of
condensation. This is the total quantity of heat (heat of
vaporization) the refrigerant removes from the vehicle
interior via the evaporator and the work (calculated as the
quantity of heat) performed for compression.
Expansion
The expansion valve lowers the pressure of the
refrigerant liquid so that it can easily vaporize.
The process of lowering the pressure to encourage
vaporization before the liquefied refrigerant is sent to the
evaporator is called expansion. In addition, the expansion
valve controls the flow rate of the refrigerant liquid while
decreasing the pressure.
That is, the quantity of refrigerant liquid vaporized inside
the evaporator is determined by the quantity of heat which
must be removed at a prescribed vaporization
temperature. It is important that the quantity of refrigerant
be controlled to exactly the right value.
Compressor
The compressor performs two main functions:
871RX026
Legend
(1) Magnetic Clutch
(2) Magnetic Clutch Connector
(3) Compressor
Condenser
The condenser assembly is located in front of the radiator.
It provides rapid heat transfer from the refrigerant to the
cooling fins.
Also, it functions to cool and liquefy the high-pressure and
high-temperature vapor sent from the compressor by the
radiator fan or outside air.
1A–20 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
A condenser may malfunction in two ways: it may leak, or
it may be restricted. A condenser restriction will result in
excessive compressor discharge pressure. If a partial
restriction is present, the refrigerant expands after
passing through the restriction.
Thus, ice or frost may form immediately after the
restriction. If air flow through the condenser or radiator is
blocked, high discharge pressures will result. During
normal condenser operation, the refrigerant outlet line will
be slightly cooler than the inlet line.
The vehicle is equipped with the parallel flow type
condenser. A larger thermal transmission area on the
inner surface of the tube allows the radiant heat to
increase and the ventilation resistance to decrease.
The refrigerant line connection has a bolt at the block
joint, for easy servicing.
A receiver/drier may fail due to a restriction inside the
body of the unit. A restriction at the inlet to the
receiver/drier will cause high pressure.
Outlet restrictions will be indicated by low pressure and
little or no cooling. An excessively cold receiver/drier
outlet may indicate a restriction.
The receiver/drier of this vehicle is made of aluminum
with a smaller tank. It has a 300cc refrigerant capacity.
The refrigerant line connection has a bolt at the block
joint, for easy servicing.
Triple Pressure Switch (V6, A/T)
Triple pressure switch is installed on the upper part of the
receiver/drier. This switch is constructed with a unitized
type of two switches. One of them is a low and high
pressure switch (Dual pressure switch) to switch “ON” or
“OFF” the magnetic clutch as a result of irregularly
high–pressure or low pressure of the refrigerant. The
other one is a medium pressure switch (Cycling switch) to
switch “ON” or “OFF” the condenser fan sensing the
condenser high side pressure.
Compressor
ON
(kPa/psi)
OFF
(kPa/psi)
Low-pressure
control
206.0±30.0
(29.8±4.3)
176.5±24.5
(25.6±3.6)
High-pressure
control
2353.6±196.1
(341.3±28.4)
2942.0±196.1
(426.6±28.4)
Condenser fan
ON
(kPa/psi)
OFF
(kPa/psi)
Medium-pressure
control
1471.0±98.1
(213.3±14.2)
1078.7±117.7
(156.4±17.1)
875R200015
Legend
(1) Pressure Switch
(2) Receiver Drier
(3) Condenser & Receiver Tank Assembly
(4) Condenser Fan
Receiver / Drier
The receiver/drier performs four functions:
B As the quantity of refrigerant circulated varies
depending on the refrigeration cycle conditions,
sufficient refrigerant is stored for the refrigeration
cycle to operate smoothly in accordance with
fluctuations in the quantity circulated.
B The liquefied refrigerant from the condenser is mixed
with refrigerant gas containing air bubbles. If
refrigerant containing air bubbles. If refrigerant
containing air bubbles is sent to the expansion valve,
the cooling capacity will decrease considerably.
Therefore, the liquid and air bubbles are separated
and only the liquid is sent to the expansion valve.
B The receiver/drier utilizes a filter and drier to remove
the dirt and water mixed in the cycling refrigerant.
Expansion Valve
This expansion valve is an external pressure type and it is
installed at the evaporator intake port.
The expansion valve converts the high pressure liquid
refrigerant sent from the receiver/drier to a low pressure
liquid refrigerant by forcing it through a tiny port before
sending it to the evaporator.
This type of expansion valve consists of a temperature
sensor, diaphragm, ball valve, ball seat, spring
adjustment screw, etc.
The temperature sensor contacts the evaporator outlet
pipe, and converts changes in temperature to pressure. It
then transmits these to the top chamber of the
diaphragm.
The refrigerant pressure is transmitted to the diaphragm’s
bottom chamber through the external equalizing pressure
tube.
The ball valve is connected to the diaphragm. The
opening angle of the expansion valve is determined by
the force acting on the diaphragm and the spring
pressure.
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–21
The expansion valve regulates the flow rate of the
refrigerant. Accordingly, when a malfunction occurs to
this expansion valve, both discharge and suction
pressure decreases, resulting in insufficient cooling
capacity of the evaporator.
The calibration has been changed to match the
characteristics of HFC-134a.
The evaporator core with a laminate louver fin is a
single-sided tank type where only one tank is provided
under the core.
874RY00015
Legend
(1) Evaporator Core
(2) Expansion Valve
874R200003
Legend
(1) Expansion Valve
(2) Evaporator Assembly
Evaporator
The evaporator cools and dehumidifies the air before the
air enters the passenger compartment. High-pressure
liquid refrigerant flows through the expansion valve into
the low-pressure area of the evaporator. The heat in the
air passing through the evaporator core is lost to the
cooler surface of the core, thereby cooling the air.
As heat is lost between the air and the evaporator core
surface, moisture in the vehicle condenses on the outside
surface of the evaporator core and is drained off as water.
When the evaporator malfunctions, the trouble will show
up as an inadequate supply of cool air. The cause is
typically a partially plugged core due to dirt, or a
malfunctioning blower motor.
1A–22 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Duct Sensor
Refrigerant Line
The duct sensor is the sensor to detect temperature
change of the side of evaporator blower coming by fresh
recirculation of intake door or “on” “off” of compressor.
The temperature is converted to resistant rate.
And it works as thermostat to control to prevent freezing
of evaporator.
This sensor is installed in the upper case of evaporator.
Restriction in the refrigerant line will be indicated by:
1. Suction line — A restricted suction line will cause low
suction pressure at the compressor, low discharge
pressure and little or no cooling.
2. Discharge line — A restriction in the discharge line
generally will cause the discharge line to leak.
3. Liquid line — A liquid line restriction will be evidenced
by low discharge and suction pressure and
insufficient cooling.
Refrigerant flexible hoses that have a low permeability to
refrigerant and moisture are used. These low
permeability hoses have a special nylon layer on the
inside.
852RS001
874R200010
Legend
(1) Sensor Part
(2) Evaporator Core
(3) Duct Sensor Assembly
(4) Evaporator Assembly
Legend
(1) Reinforcement Layer (Polyester)
(2) External Rubber Layer
(3) Internal Rubber Layer
(4) Resin Layer (Nylon)
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–23
Air Conditioning Parts
852R200008
Legend
(1) Liquid Line (High-Pressure Pipe)
(2) Clip
(3) Discharge Line (High-Pressure Hose)
(4) Pressure Switch
(5) Receiver/Drier
(6)
(7)
(8)
(9)
(10)
(11)
Condenser Air Guide
Condenser & Receiver Tank Assembly
Condenser Fan
Compressor
Suction Line (Low-Pressure Hose)
Evaporator Assembly
1A–24 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Diagnosis
Air Conditioning Cycle Diagnosis
Condition
No cooling or insufficient cooling.
Insufficient velocity of cooling air.
Possible cause
Correction
Magnetic clutch does not run.
Refer to “Magnetic Clutch Diagnosis”
in this section.
Compressor is not rotating properly.
Drive belt is loose or broken.
Adjust the drive belt to the specified
tension or replace the drive belt.
Compressor is not rotating properly.
Magnetic clutch face is not clean and
slips.
Clean the magnetic clutch face or
replace.
Compressor is not rotating properly.
Incorrect
clearance
between
magnetic drive plate and pulley.
Adjust the clearance. Refer to
Compressor in this section.
Compressor is not rotating properly.
Compressor oil leaks from the shaft
seal or shell.
Replace the compressor
Compressor is not rotating properly.
Compressor is seized.
Replace the compressor
Insufficient or excessive charge of
refrigerant.
Discharge and recover the
refrigerant.
Recharge to the
specified amount.
Leaks in the refrigerant system.
Check the refrigerant system for
leaks and repair as necessary.
Discharge and recover the
refrigerant.
Recharge to the
specified amount.
Condenser is clogged or insufficient
radiation.
Clean the condenser or replace as
necessary.
Temperature control link unit of the
heat unit is defective.
Repair the link unit.
Unsteady operation due to a foreign
substance in the expansion valve.
Replace the expansion valve.
Poor operation of the electronic
thermostat.
Check the electronic thermostat and
replace as necessary.
Evaporator clogged or frosted.
Check the evaporator core and
replace or clean the core.
Air leaking from the cooling unit or air
duct.
Check the evaporator and duct
connection, then repair as
necessary.
Blower motor
properly.
Refer to Fan Control Lever (Fan
Switch) Diagnosis in this section.
*For the execution of the charging and discharging
operation in the table above, refer to Recovery,
Recycling, Evacuating and Charging in this section.
does
not
rotate
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–25
Checking The Refrigerant System With Manifold Gauge
Since Refrigerant-134a (HFC-134a) is used in the air
conditioning system in this vehicle, be sure to use
manifold gauges, charging hoses and other air
conditioning service tools for HFC-134a when
checking the refrigerant system.
Conditions:
B
B
B
B
B
B
B
Run the engine at idle
Air conditioning switch is “ON”
Run the blower motor at “HIGH” position (5 positions)
Temperature control set to “MAX COLD” (65°F)
Air source selector at “CIRC”
Open the engine hood
Close all the doors
Normal Pressure:
B At ambient temperature: approx. 25–30°C
(77–86°F).
B At low-pressure side: approx. 147.1–294.2 kPa
(21.3–42.7 psi).
B At high-pressure side: approx. 1372.9–1863.3 kPa
(199.1–270.2 psi).
Refer to the table on the refrigerant pressure-temperature
relationship.
HFC-134a Pressure-Temperature Relationship
Pressure
Temperature
(kPa)
(psi)
(°C)
(°F)
36
5.3
–20
–4.4
67
9.7
–15
5
104
15
–10
14
147
21
–5
23
196
28
0
32
255
37
5
41
314
45
10
50
392
57
15
59
471
68
20
68
569
82
25
77
677
98
30
86
785
114
35
95
912
132
40
104
1059
154
45
113
1216
176
50
122
1A–26 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Connect The Manifold Gauge
Low-pressure hose (LOW) — Suction side
High pressure hose (HI) — Discharge side
901R100020
Legend
(1) Low Side
(2) High Side
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–27
Condition
Possible cause
Correction
Discharge (High Gauge) Pressure
Abnormally High
Condenser clogged or dirty.
Discharge (High Gauge) Pressure
Abnormally High.
Insufficient cooling.
Excessive refrigerant in system.
Discharge and recover refrigerant.
Recharge to specified amount.
Discharge (High Gauge) Pressure
Abnormally High.
High pressure gauge drop. (After
stopping A/C, the pressure drops
approx. 196 kPa (28 psi) quickly)
Air in system.
Evacuate and charge refrigerant
system.
Discharge (High Gauge) Pressure
Abnormally Low.
Insufficient cooling
Insufficient refrigerant in system.
Check for leaks. Discharge and
recover the refrigerant. Recharge to
the specified amount.
Discharge (High Gauge) Pressure
Abnormally Low.
Low pressure gauge indicates
vacuum.
Clogged or defective expansion
valve.
Replace the expansion valve.
Discharge (High Gauge) Pressure
Abnormally Low.
Frost or dew on refrigerant line
before and after the receiver/drier or
expansion valve, and low pressure
gauge indicates vacuum.
Restriction caused by debris or
moisture in the receiver/drier.
Check system for restriction and
replace the receiver/drier.
Discharge (High Gauge) Pressure
Abnormally Low.
High and low pressure gauge
balanced quickly. (After turned off
A/C)
Compressor seal defective
Repair or replace the compressor.
Poor compression due to a defective
compressor gasket.
Repair or replace the compressor.
Suction (Low Gauge) Pressure
Abnormally High.
Low pressure gauge (Low pressure
gauge is lowered after condenser is
cooled by water.)
Excessive refrigerant in system.
Discharge and recover refrigerant
Recharge to specified amount.
Suction (Low Gauge) Pressure
Abnormally High.
Low pressure hose temperature.
(Low pressure hose temperature
compressor
around the com
ressor refrigerant
line connector is lower than around
evaporator.)
Unsatisfactory valve operation due
to defective temperature sensor of
expansion valve.
Replace the expansion valve.
Expansion valve opens too long.
Replace the expansion valve.
Suction (Low Gauge) Pressure
Abnormally High.
High and low pressure gauge
balanced quickly. (After turned off
A/C)
Compressor gasket is defective.
Repair or replace the compressor.
Suction (Low Gauge)
Abnormally Low.
Insufficient cooling.
Insufficient refrigerant in system.
Check for leaks. Discharge and
recover the refrigerant. Recharge to
specified amount.
Expansion valve clogged.
Replace the expansion valve.
Pressure
Suction (Low Gauge) Pressure
Abnormally Low.
Frost on the expansion valve inlet
line
Cooling fan
properly.
does
not
Clean the condenser fins
operate
Check the cooling fan operation.
1A–28 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Condition
Possible cause
Correction
Suction (Low Gauge) Pressure
Abnormally Low
Receiver/drier inlet and outlet
refrigerant line temperature. (A
distinct difference in temperature
develops.)
Receiver/Drier clogged.
Replace the receiver/drier.
Suction (Low Gauge) Pressure
Abnormally Low.
Expansion valve outlet refrigerant
line. (Not cold and low pressure
gauge indicates vacuum.)
Expansion valve temperature sensor
is defective.
Replace the expansion valve.
Suction (Low Gauge) Pressure
Abnormally Low.
When the refrigerant line is clogged
or blocked, the low pressure gauge
reading will decrease, or a vacuum
reading may be shown.
Clogged or blocked refrigerant line.
Replace refrigerant line.
Suction (Low Gauge) Pressure
Abnormally Low.
Evaporator core is frozen.
Thermo switch defective.
Replace thermo switch.
Suction (Low Gauge) and Discharge
(High Gauge) Pressure Abnormally
High.
Insufficient cooling.
Excessive refrigerant in system.
Discharge and recover the
refrigerant, the Recharge to the
specified amount.
Condenser clogged or dirty.
Clean the condenser fin.
Suction (Low Gauge) and Discharge
(High Gauge) Pressure Abnormally
High.
Suction (Low) pressure hose (Not
cold).
Air in system.
Evacuate and charge refrigerant.
Suction (Low Gauge) and Discharge
(High Gauge) Pressure Abnormally
Low.
Insufficient cooling
Insufficient refrigerant in system.
Check for leaks. Discharge and
recover refrigerant. Recharge to
specified amount.
A/C — Air Conditioning
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–29
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.
D08R200041
Condition
Condenser fan does not run.
Possible cause
Correction
–
Refer to “Chart A”.
–
Refer to “Chart B”.
1A–30 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Chart “A” Condenser Fan Does Not Run
Step
Action
Yes
No
1
Are 30A fuse normal?
Go to Step 2
Replace
2
Is relay (X-16) normal?
Go to Step 3
Replace
3
Is pressure switch normal?
Go to Step 4
Switch defective
or insufficient
refrigerant.
Go to Step 5
Replace
Go to Step 6
Repair open
circuit between
Condenser Fan
fuse (30A) and
No.X16-5.
Go to Step 7
Repair open
circuit between
fuse (10A) and
C21-3.
Go to Step 8
Repair open
circuit.
Poor ground or
open circuit
between chassis
side connector
terminal
No.X16-4 (or
No.C16-2) and
body ground
(No.C10).
Repair open
circuit.
Yes
No
Replace the triple
pressure switch.
Replace the
condenser fan
relay.
4
Is fan motor normal?
5
1. Disconnect condenser fan relay (X-16).
2. Check to see if battery voltage is present at the chassis side
relay terminal NO. X16-5.
Is there a battery voltage?
6
1. Reconnect condenser fan relay (X-16).
2. Check to see if battery voltage is present at chassis side
connector terminal No.C21-3.
Is there a battery voltage?
7
Check to see if continuity between chassis side relay terminal
No.X16-2 and the chassis side connector terminal No.C21-4.
Is there a continuity?
8
Check to see if continuity between chassis side connector
terminal No. C16-1 and chassis side relay terminal No.X16-1.
Is there a continuity?
Chart “B” Condenser Fan Does Not Stop
Step
1
Action
1. Disconnect the triple pressure connector.
Does condenser fan stop?
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–31
Air Conditioning System
Individual Inspection
General Repair Procedure
Triple Pressure Switch (V6, A/T)
Precautions For Replacement or Repair of
Air Conditioning Parts
1. Disconnect the connector and check for continuity
between pressure switch side connector terminals (1)
and (2).
2. Reconnect the connector to activate the A/C switch,
and check to see if there is continuity between the
chassis side connector terminals (3) and (4) and the
fan operates.
875RY00010
Condenser Fan
1. Disconnect the condenser fan connector.
2. Connect the battery positive terminal to the
condenser fan side connector terminal No.C-16-1
and negative to the No.C-16-2.
3. Check that condenser fan is rotating correctly.
875R200002
There are certain procedures, practices and precautions
that should be followed when servicing air conditioning
systems:
B Keep your work area clean.
B Always wear safety goggles and protective gloves
when working on refrigerant systems.
B Beware of the danger of carbon monoxide fumes
caused by running the engine.
B Beware of discharged refrigerant in enclosed or
improperly ventilated garages.
B Always disconnect the negative battery cable and
discharge and recover the refrigerant whenever
repairing the air conditioning system.
B When discharging and recovering the refrigerant, do
not allow refrigerant to discharge too fast; it will draw
compressor oil out of the system.
B Keep moisture and contaminants out of the system.
When disconnecting or removing any lines or parts,
use plugs or caps to close the fittings immediately.
Never remove the caps or plugs until the lines or parts
are reconnected or installed.
B When disconnecting or reconnecting the lines, use
two wrenches to support the line fitting, to prevent
from twisting or other damage.
B Always install new O-rings whenever a connection is
disassembled.
B Before connecting any hoses or lines, apply new
specified compressor oil to the O-rings.
B When removing and replacing any parts which
require discharging the refrigerant circuit, the
operations described in this section must be
performed in the following sequence:
1. Use the J-39500 (ACR4: HFC-134a Refrigerant
Recovery / Recycling / Recharging / System) or
equivalent to thoroughly discharge and recover the
refrigerant.
2. Remove and replace the defective part.
3. After evacuation, charge the air conditioning
system and check for leaks.
1A–32 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Repair Of Refrigerant Leaks
Refrigerant Line Connections
Install new O-rings, if required. When disconnecting or
connecting lines, use two wrenches to prevent the
connecting portion from twisting or becoming damaged.
O-rings (2) must be fitted in the groove (1) of refrigerant
line.
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.
852R200001
When connecting the refrigerant line at a block joint,
securely insert the projecting portion of the joint portion
into the connecting hole on the unit side and secure with a
bolt. Apply the specified compressor oil to the O-rings
prior to connecting.
CAUTION: Compressor (PAG) oil to be used varies
according to the compressor model. Be sure to apply
oil specified for the model of compressor.
850RW004
850RW002
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–33
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 air–conditioner to see if there
occurs any refrigerant leak along the flow of refrigerant.
NOTE:
B To avoid refrigerant leak detection error, avoid
refrigerant vapor and cigarette smoke presence when
performing the inspection. Also, select a location that
is not susceptible to wind, in case refrigerant vapor is
found it will not be blown off.
B Inspection should be conducted chiefly on the pipe
connections and sections where a marked oil
contamination is found. When refrigerant is leaking,
oil inside is also leaking at the same time.
B It is possible to visually check the leak from inside the
cooling unit. Follow the method below when
performing the inspection. Remove the drain hose or
resistor of the cooling unit, and insert a leak detector
to see if there are signs of leakage.
High Pressure Side
1. Discharger section of compressor.
2. Inlet/outlet section of condenser.
3. Inlet/outlet section of receiver driver.
4. Inlet section of cooling unit.
Low Pressure Side
1. Outlet section of cooling unit.
2. Intake section of compressor.
Major Checking Points of Refrigerant Leak
Compressor
B Pipe connection
B Sealing section of shaft
B Mating section or cylinder
Condenser
B Pipe connection
B Welds of condenser body
Yes
No
Repair refrigerant
system.
Go to Step 2
Repair refrigerant
system.
Compressor
operation to be
confirmed.
Receiver driver
B Pipe connection
B Attaching section of pressure switch
B Section around the sight glass
Evaporator unit (cooling unit)
B Pipe connections
B Connections of expansion valve
B Brazed sections of evaporator
NOTE:
B The evaporator and expansion valve are contained in
the case. Remove the drain hose or the resistor of the
cooling unit and insert a leak detector when checking
for any leak.
Flexible hose
B Pipe connection
B Caulking section of the hose
B Hose (cracks, pinholes, flaws)
Pipe
B Pipe connection
B Pipe (cracks, flaws)
Charge valve
NOTE:
B The charge valve, which is used to connect the gauge
manifold, is normally provided with a resin cap. When
the valve inside gets deteriorated, refrigerant will leak
out.
Leak at Refrigerant Line Connections
1. Check the torque on the refrigerant line fitting and, if
too loose, tighten to the specified torque.
B Use two wrenches to prevent twisting and damage
to the line.
B Do not over tighten.
2. Perform a leak test on the refrigerant line fitting.
1A–34 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
3. If the leak is still present, discharge and recover the
refrigerant from the system.
4. Replace the O-rings.
B O-rings cannot be reused. Always replace with new
ones.
B Be sure to apply the specified compressor oil to the
new O-rings.
5. Retighten the refrigerant line fitting to the specified
torque.
B Use two wrenches to prevent twisting and damage
to the line.
6. Evacuate, charge and retest the system.
WARNING:
B SHOULD HFC-134A CONTACT YOUR EYE(S),
CONSULT A DOCTOR IMMEDIATELY.
B DO NOT RUB THE AFFECTED EYE(S). INSTEAD,
SPLASH QUANTITIES OF FRESH COLD WATER
OVER THE AFFECTED AREA TO GRADUALLY
RAISE
THE
TEMPERATURE
OF
THE
REFRIGERANT ABOVE THE FREEZING POINT.
B OBTAIN PROPER MEDICAL TREATMENT AS
SOON AS POSSIBLE. SHOULD THE HFC-134A
TOUCH THE SKIN, THE INJURY MUST BE
TREATED THE SAME AS SKIN WHICH HAS BEEN
FROSTBITTEN OR FROZEN.
Leaks In The Hose
Refrigerant Recovery
If the compressor inlet or outlet hose is leaking, the entire
hose must be replaced. The refrigerant hose must not be
cut or spliced for repair.
1. Locate the leak.
2. Discharge and recover the refrigerant.
3. Remove the hose assembly.
B Cap the open connections at once.
4. Connect the new hose assembly.
B Use two wrenches to prevent twisting or damage to
the hose fitting.
The refrigerant must be discharged and recovered by
using the J-39500 (ACR4:HFC-134a Refrigerant
Recovery/Recycling/Recharging/System) or equivalent
before removing or mounting air conditioning parts.
1. Connect the high and low charging hoses of the
ACR4(or equivalent) as shown below.
B Tighten the hose fitting to the specified torque.
5. Evacuate, charge and test the system.
Compressor Leaks
If leaks are located around the compressor shaft seal or
shell, replace or repair the compressor.
Recovery, Recycling, Evacuation and
Charging of HFC-134a
Air conditioning systems contain HFC-134a. This is a
chemical mixture which requires special handling
procedures to avoid personal injury.
B Always wear safety goggles and protective gloves.
B Always work in a well-ventilated area. Do not weld or
steam clean on or near any vehicle-installed air
conditioning lines or components.
B If HFC-134a should come in contact with any part of
the body, flush the exposed area with cold water and
immediately seek medical help.
B If it is necessary to transport or carry any container of
HFC-134a in a vehicle, do not carry it in the
passenger compartment.
B If it is necessary to fill a small HFC-134a container
from a large one, never fill the container completely.
Space should always be allowed above the liquid for
expansion.
B HFC-134a and R-12 should never be mixed as their
compositions are not the same.
B HFC-134a PAG oil tends to absorb moisture more
quickly than R-12 mineral oil and, therefore, should
be handled more carefully.
B Keep HFC-134a containers stored below 40°C
(104°F).
901R100022
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.
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–35
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.
Evacuation of The Refrigerant System
8. If no leaks are found, again operate the vacuum pump
for 20 minutes or more. After confirming that the
gauge manifold pressure is at 750 mmHg (30 inHg),
close both hand valves.
9. Close positive shutoff valve. Stop the vacuum pump
and disconnect the center hose from the vacuum
pump.
Charging The Refrigerant System
There are various methods of charging refrigerant into the
air conditioning system.
These include using J-39500 (ACR4:HFC-134a
Refrigerant Recovery/Recycling/Recharging/System) or
equivalent and direct charging with a weight scale
charging station.
Charging Procedure
B ACR4(or equivalent) Method
For the charging of refrigerant recovered by ACR4(or
equivalent), follow the manufacturer’s instruction.
901R100023
Legend
(1) Low Side
(2) High Side
NOTE: Explained below is a method using a vacuum
pump. Refer to the ACR4(or equivalent) manufacturer’s
instructions when evacuating the system with a ACR4(or
equivalent).
Air and moisture in the refrigerant will cause problems in
the air conditioning system. Therefore, before charging
the refrigerant, be sure to evacuate air and moisture thoroughly from the system.
1. Connect the gauge manifold.
B High-pressure valve (HI) — Discharge-side.
B Low-pressure valve (LOW) — Suction-side.
2. Discharge and recover the refrigerant.
3. Connect the center hose of the gauge manifold set to
the vacuum pump inlet.
4. Operate the vacuum pump, open shutoff valve and
then open both hand valves.
5. When
the
low-pressure
gauge
indicates
approximately 750 mmHg (30 inHg), continue the
evacuation for 5 minutes or more.
6. Close both hand valves and stop the vacuum pump.
7. Check to ensure that the pressure does not change
after 10 minutes or more.
B If the pressure changes, check the system for
leaks.
B If leaks occur, retighten the refrigerant line
connections and repeat the evacuation steps.
901R100022
Legend
(1) Low Side
(2) High Side
B Direct charging with a weight scale charging
station method
1. Make sure the evacuation process is correctly
completed.
2. Connect the center hose of the manifold gauge to the
weight scale.
1A–36 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
3. Connect the low pressure charging hose of the
manifold gauge to the low pressure side service valve
of the vehicle.
4. Connect the high pressure charging hose of the
manifold gauge to the high pressure side service
valve of the vehicle.
901RS144
6. Perform a system leak test:
B Charge the system with approximately 200 g
(0.44 lbs) of HFC-134a.
B Make sure the high pressure valve of the manifold
gauge is closed.
B Check to ensure that the degree of pressure does
not change.
B Check for refrigerant leaks by using a HFC-134a
leak detector.
B If a leak occurs, recover the refrigerant. Repair the
leak and start all over again from the first step of
evacuation.
901R100021
Legend
(1) Low Side
(2) High Side
(3) Refrigerant Container
(4) Weight Scale
5. Place the refrigerant container(3) up right on a weight
scale(4).
Note the total weight before charging the refrigerant.
a. Open the refrigerant container valve.
b. Open the low side vale on the manifold gauge set.
Refer to the manufacturer’s instructions for a
weight scale charging station.
7. If no leaks are found, continue charging refrigerant to
the air conditioning system.
B Charge the refrigerant until the scale reading
decreases by the amount of the charge specified.
Specified amount: 700 g (1.54 lbs)
B If charging the system becomes difficult:
1. Run the engine at idle and close all the vehicle
doors.
2. Turn A/C switch “ON”.
3. Set the fan switch to its highest position.
4. Set the air source selector lever to “CIRC”.
5. Slowly open the low side valve on the manifold
gauge set.
WARNING: BE ABSOLUTELY SURE NOT TO OPEN
THE HIGH PRESSURE VALVE OF THE MANIFOLD
GAUGE. SHOULD THE HIGH PRESSURE VALVE BE
OPENED, THE HIGH PRESSURE REFRIGERANT
WOULD FLOW BACKWARD, AND THIS MAY CAUSE
THE REFRIGERANT CONTAINER TO BURST.
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–37
8. When finished with the refrigerant charging, close the
low pressure valve of the manifold gauge and
container valve.
9. Check for refrigerant leaks.
Checking The A/C System
1. Run the engine and close all the vehicle doors.
2. Turn A/C switch “ON”, set the fan switch to its highest
position.
3. Set the air source switch to “CIRC”, set the
temperature switch to the full cool position.
4. Check the high and low pressure of the manifold
gauge.
B Immediately after charging refrigerant, both high
and low pressures might be slightly high, but they
settle down to the pressure guidelines shown
below:
B The ambient temperature should be between
25–30°C (77–86°F).
B The pressure guideline for the high-pressure side is
approximately 1372.9–1863.3 kPa (199.1–270.2
psi).
B The pressure guideline for the low-pressure side is
approximately 147.1–294.2 kPa (21.3–42.7 psi).
B If an abnormal pressure is found, refer to Checking
The Refrigerant System With Manifold Gauge in
this section.
5. Put your hand in front of the air outlet and move the
temperature switch of the control panel to different
positions. Check if the outlet temperature changes as
selected by the control switch.
1A–38 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Compressor Assembly
Compressor Assembly and Associated Parts (6VE1)
852R100002
Legend
(1) Compressor Bracket
(2) Magnetic Clutch Harness Connector
(3) Compressor
(4) O-ring
Removal
1. Disconnect the battery ground cable.
2. Discharge and recover refrigerant
B Refer to Refrigerant Recovery in this section.
3. Disconnect magnetic clutch harness connector.
(5)
(6)
(7)
(8)
(9)
To Evaporator
Suction Line (Low-Pressure Hose)
Discharge Line (High-Pressure Hose)
To Condenser
Serpentine Belt
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–39
4. Remove serpentine belt.
B Move serpentine belt tensioner to loose side using
wrench then remove serpentine belt.
4. Connect magnetic clutch harness connector.
New Compressor Installation
The new compressor is filled with 150cc (5.0fl.oz.)of
compressor oil and nitrogen gas. When mounting the
compressor on the vehicle, perform the following steps;
1. Gently release nitrogen gas from the new
compressor.
B Take care not to let the compressor oil flow out.
B Inspect O-rings and replace if necessary.
850RY00005
Legend
(1) Auto Tensioner
(2) Idle Pulley
(3) Cooling Fan Pulley
(4) Serpentine Belt
(5) Power Steering Oil Pump
(6) Air Conditioner Compressor
(7) Crankshaft Pulley
(8) Generator
5. Disconnect refrigerant line connector.
B When removing the line connector, the connecting
part should immediately be plugged or capped to
prevent foreign matter from being mixed into the
line.
6. Remove compressor.
871RX033
2. Turn the compressor several times by hand and
release the compressor oil in the rotor.
3. When installing on a new system, the compressor
should installed as it is. When installing on a used
system, the compressor should be installed after
adjusting the amount of compressor oil. (Refer to
Compressor in this section)
Installation
1. Install compressor.
B Tighten the compressor fixing bolts to the specified
torque.
Torque: 19 N•m (14 lb•ft)
2. Connect refrigerant line connector.
B Tighten the refrigerant line connector fixing bolts to
the specified torque.
Torque: 15 N•m (11 lb•ft)
B O-rings cannot be reused. Always replace with new
ones.
B Be sure to apply new compressor oil to the O-rings
when connecting refrigerant lines.
3. Install serpentine belt.
B Move serpentine belt tensioner to loose side using
wrench, then install serpentine belt to normal
position.
871RX035
1A–40 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Condenser Assembly
Condenser Assembly and Associated Parts
875R200022
Legend
(1) Refrigerant Line
(2) Pressure Switch Connector
(3) Condenser & Receiver Tank Assembly
(4) Condenser Air Guide
(5) Front Bumper Assembly
Removal
1. Disconnect the battery ground cable.
2. Discharge and recover refrigerant.
B Refer to Refrigerant Recovery in this section.
3. Remove front bumper assembly.
B Refer to the Front Bumper in Body Structure
section.
(6) Engine Hood Front End W/Engine Hood Lock
& Bumper Stay
(7) Front Center Bumper Retainer
(8) Front Side Bumper Retainer (RH)
(9) Head Light (R/LH)
(10) Front Side Turn Signal Light (R/LH)
(11) Horn (R/LH)
4. Remove front center bumper retainer.
5. Remove front side bumper retainer (RH).
6. Remove condenser air guide.
7. Remove engine hood front end with engine hood lock
& bumper stay.
B Apply setting mark to the engine hood lock fixing
position before removing it.
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–41
8. Remove horn (R/LH).
9. Remove front side turn signal light (R/LH).
10. Remove head light (R/LH).
11. Disconnect pressure switch, ambient sensor and
condenser fan connector.
12. Disconnect refrigerant line.
B When removing the line connector, the connecting
part should immediately be plugged or capped to
prevent foreign matter from being mixed into the
line.
13. Remove condenser & receiver tank assembly.
B Handle with care to prevent damaging the
condenser or radiator fin.
Installation
1. Install condenser & reciver tank assembly.
B If installing a new condenser, be sure to add 30cc
(1.0 fl. oz.) of new compressor oil to a new one.
B Tighten the condenser fixing bolts to the specified
torque.
Torque: 6 N•m (52 lb in)
2. Connect refrigerant line.
B Tighten the inlet line connector fixing bolt to the
specified torque.
Torque: 15 N•m (11 lb ft)
B Tighten the outlet line connector fixing bolt to the
specified torque.
Torque: 6 N•m (52 lb in)
B O-rings cannot be reused. Always replace with new
ones.
B Be sure to apply new compressor oil to the O-rings
when connecting the refrigerant line.
3. Connect pressure switch, ambient sensor and
condenser fan connector.
4. Install head light (R/LH).
5. Install front side turn signal light (R/LH).
6. Install horn (R/LH).
7. Install engine hood front end with engine hood lock &
bumper stay.
B Align the setting mark when installing.
8. Install condenser air guide.
9. Install front side bumper retainer (RH).
10. Install front center bumper retainer.
11. Install front bumper assembly.
1A–42 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Condenser Fan Motor
Condenser Fan Motor and Associated Parts
875R200016
Legend
(1) Condenser Fan Assembly
(2) Condenser Air Guide
(3) Front Bumper Assembly
Removal
1. Disconnect the battery ground cable.
2. Remove the front bumper assembly.
B Refer to the Front Bumper in Body Structure
section.
3. Remove the condenser air guide.
4. Remove the horn (RH).
5. Remove the condenser fan assembly.
B Disconnect the fan motor connector and remove
the 3 fixing bolts.
6. Remove the shroud.
B Remove the 3 fixing nuts.
B Loosen the condenser fixing nut and disconnect the
fan motor connector from bracket.
7. Remove the fan.
B Remove the fan fixing C-ring and plate.
8. Remove the condenser fan motor.
(4)
(5)
(6)
(7)
Condenser Fan Motor
Shroud
Fan
Horn (RH)
Installation
To install, follow the removal steps in the reverse order,
noting the following point.
1. Route the fan motor harness in its previous position,
and fix it securely with clip and bracket.
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–43
Receiver / Drier
Receiver / Drier and Associated Parts
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
1. If installing a new receiver/drier, be sure to add 30cc
(1.0 fl. oz.) of new compressor oil to a new one.
2. Put the receiver/drier in the bracket and connect with
the refrigerant line. Check that no excessive force is
imposed on the line. Fasten the bracket bolt to the
receiver/drier.
3. Tighten the refrigerant line to the specified torque.
Torque: 6 N•m (52 lb in)
4. O-rings cannot be reused. Always replace with new
ones.
5. Be sure to apply new compressor oil to the O-rings
when connecting the refrigerant line.
875R200019
Legend
(1) Front Side Turn Signal Light (LH)
(2) Refrigerant Line
(3) Head Light (LH)
(4) Front Bumper Assembly
(5) Receiver / Drier
(6) Pressure Switch Connector
Removal
1. Disconnect the battery ground cable.
2. Discharge and recover refrigerant.
B Refer to Refrigerant Recovery in this section.
3. Remove front bumper assembly.
B Refer to the Front Bumper in Body Structure
section.
4. Remove front side turn signal light (LH).
5. Remove head light (LH).
6. Disconnect pressure switch connector.
7. Disconnect refrigerant line.
B When removing the line connected part, the
connecting part should immediately be plugged or
capped to prevent foreign matter from being mixed
into the line.
8. Remove receiver/drier.
B Loosen the bolt, then, using care not to touch or
bend the refrigerant line, carefully pull out the
receiver/drier.
1A–44 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Pressure Switch
Pressure Switch and Associated Parts
Installation
To install, follow the removal steps in the reverse order,
noting the following point:
1. O-ring cannot be reused. Always replace with a new
one.
2. Be sure to apply new compressor oil to the O-ring
when connecting pressure switch.
3. Tighten the pressure switch to the specified torque.
Torque: 13 N•m (113 lb in)
875R200021
Legend
(1) Pressure Switch Connector
(2) Front Side Turn Signal Light (LH)
(3) Head Light (LH)
(4) Front Bumper Assembly
(5) Pressure Switch
Removal
1. Disconnect the battery ground cable.
2. Discharge and recover refrigerant.
B Refer to “Refrigerant Recovery in this section.
3. Remove the front bumper assembly.
B Refer to the Front Bumper in Body Structure
section.
4. Remove the front side turn signal light (LH).
5. Remove the head light (LH).
6. Disconnect pressure switch connector.
7. Disconnect pressure switch.
B When removing the switch connected part, the
connecting part should immediately be plugged or
capped to prevent foreign matter from being mixed
into the line.
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–45
Evaporator Assembly
Evaporator Assembly and Associated Parts
874R200015
Legend
(1) Refrigerant Line
(2) Drain Hose
(3) Dash Side Trim Panel
(4) Power Transistor and Duct Sensor Connector
(5)
(6)
(7)
(8)
Passenger Lower Bracket
Sill Plate
Evaporator Assembly
Glove Box
Removal
1. Disconnect the battery ground cable.
2. Discharge and recover refrigerant.
B Refer to Refrigerant Recovery in this section.
3. Remove glove box.
4. Disconnect power transistor (2) and duct sensor
connector (1).
5. Remove sill plate.
6. Remove dash side trim panel.
7. Remove passenger lower bracket.
8. Disconnect drain hose.
874R200005
1A–46 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
9. Disconnect drain hose.
10. Disconnect refrigerant line.
B Use a back-up wrench when disconnecting and
reconnecting the refrigerant lines.
B When removing the refrigerant line connected part,
the connecting part should immediately be plugged
or capped to prevent foreign matter from being
mixed into the line.
11. Remove evaporator assembly.
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
1. To install a new evaporator assembly, add 50cc
(1.7 fl. oz.) of new compressor oil to the new core.
2. Tighten the refrigerant outlet line to the specified
torque.
Torque: 25 N•m (18 lb ft)
3. Tighten the refrigerant inlet line to the specified
torque.
Torque: 15 N•m (11 lb ft)
4. O-rings cannot be reused. Always replace with new
ones.
5. Be sure to apply new compressor oil to the O-rings
when connecting lines.
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–47
Duct Sensor, Evaporator Core and/or Expansion Valve
Disassembled View
874R200012
Legend
(1) Lining
(2) Expansion Valve
(3) O-ring
(4) Evaporator Assembly
(5) Lower Case
(6)
(7)
(8)
(9)
(10)
Clip
Attaching Screw
Evaporator Core
Duct Sensor
Upper Case
Removal
1. Disconnect the battery ground cable.
2. Discharge and recover refrigerant.
B Refer to Refrigerant Recovery in this section.
3. Remove evaporator assembly.
B Refer to Evaporator Assembly in this section.
4. Remove the duct sensor fixing clip.
Pull the sensor from the evaporator assembly.
5. Remove clip.
6. Remove attaching screw.
7. Remove upper case.
8. Remove lower case.
B Slit the case parting face with a knife since the lining
is separated when removing the evaporator.
874RS006
1A–48 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
B Lift to remove the upper case.
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
1. The sensor is installed on the core with the clip.
2. The sensor must not interfere with the evaporator
core.
3. When installing the new evaporator core, install the
duct sensor (2) to the evaporator core (1) specified
position with the clip in the illustration.
874R200007
9. Remove evaporator core.
874RY00016
874R200008
10. Remove expansion valve.
B Tear off the insulator carefully.
B Remove the sensor fixing clip.
B Use a back-up wrench when disconnecting all
refrigerant pipes.
4. O-rings cannot be reused. Always replace with new
ones.
5. Be sure to apply new compressor oil to the O-rings
when connecting lines.
6. Be sure to install the sensor and the insulator on the
place where they were before.
7. To install a new evaporator core, add 50cc (1.7 fl. oz.)
of new compressor oil to the new core.
8. Tighten the refrigerant lines to the specified torque.
Refer to Main Data and Specifications for Torque
Specifications in this section.
9. Apply an adhesive to the parting face of the lining
when assembling the evaporator assembly.
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–49
Refrigerant Line
Refrigerant Line and Associated Parts
852R200007
Legend
(1) Clip and Clamp
(2) Liquid Line (High-Pressure Pipe)
(3) Discharge Line (High-Pressure Hose)
(4) Condenser Air Guide
Removal
1. Disconnect the battery ground cable.
2. Discharge and recover refrigerant.
B Refer to Refrigerant Recovery in this section.
3. Remove the front bumper assembly.
B Refer to the Front Bumper in Body Structure
section.
4. Remove the condenser air guide.
(5)
(6)
(7)
(8)
Front Bumper Assembly
Front Side Turn Signal Light (LH)
Head Light (LH)
Suction Line (Low-Pressure Pipe)
5. Remove the front side turn signal light (LH).
6. Remove the head light (LH).
7. Remove clip and clamp.
8. Disconnect liquid line (High-pressure pipe).
9. Disconnect suction line (Low-pressure pipe) using a
back-up wrench.
10. Disconnect suction line (Low-pressure hose) using a
back-up wrench.
1A–50 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
11. Disconnect discharge line (High-pressure hose)
using a back-up wrench.
B Use a backup wrench when disconnecting and
reconnecting the refrigerant lines.
B When removing the refrigerant line connecting part,
the connecting part should immediately be plugged
or capped to prevent foreign matter from being
mixed into the line.
Installation
To install, follow the removal steps in the reverse order,
noting the following point:
1. O-rings cannot be reused. Always replace with new
ones.
2. Be sure to apply new compressor oil to the O-rings
when connecting lines.
3. Tighten the refrigerant line to the specified torque.
Refer to Main Data and Specifications for Torque
Specifications in this section.
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–51
Main Data And Specifications
General Specifications
Heater Unit
Temperature control
Reheat air mix system
Capacity
4.3 kw (3700 Kcal./hr.)
Air flow
280 m#/h
HEATER CORE
Type
Plate and corrugate fin
Element dimension
167 mm (6.6 in.) × 151 mm (5.9 in.) × 35 mm (1.4 in.)
Radiating area
Approx. 2.4 [email protected]
EVAPORATOR ASSEMBLY
Capacity
4.8 kw (4100 Kcal./hr.)
Air flow
430 m#/hr
EVAPORATOR CORE
Type
Al-laminate louver fin type
Element dimension
235 mm (9.3 in.) × 224 mm (8.8 in.) × 60 mm (2.4 in.)
EXPANSION VALVE
Type
Internal pressure equalizer type
CONDENSER
Type
Parallel flow type
Radiation performance
14.8 kw (12,700 Kcal./hr.)
CONDENSER FAN
Air flow
850 m3/h
Fan size
W261
RECEIVER/DRIER
Type
Assembly includes triple pressure switch
Internal volume
300 cc (10 fl.oz.)
PRESSURE SWITCH
Type
Triple pressure switch
Low pressure control
ON: 206.0±30.0 kPa (29.8±4.3 psi)
OFF: 176.5±19.6 kPa (25.6±2.8 psi)
Medium pressure control
ON: 1471.0±98.1 kPa (213.3±14.2 psi)
OFF: 1078.7±117.7 kPa (156.4±17.7 psi)
High pressure control
ON: 2353.6±196.1 kPa (341.3±28.4 psi)
OFF: 2942.0±196.1 kPa (426.6±28.4 psi)
REFRIGERANT
Type
HFC-134a
Specified amount
700 g (1.54 lbs.)
1A–52 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Torque Specifications
852R200009
874R200013
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–53
Compressor
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT LOCATION VIEW IN ORDER TO
DETERMINE WHETHER YOU ARE PERFORMING
SERVICE ON OR NEAR THE SRS COMPONENTS OR
THE SRS WIRING. WHEN YOU ARE PERFORMING
SERVICE ON OR NEAR THE SRS COMPONENTS OR
THE SRS WIRING, REFER TO THE SRS ON-VEHICLE
SERVICE INFORMATION. FAILURE TO FOLLOW
CAUTIONS COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT,
PERSONAL
INJURY,
OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
General Description
When servicing the compressor, keep dirt or foreign
material from getting on or into the compressor parts and
system. Clean tools and a clean work area are important
for proper service. The compressor connections and the
outside of the compressor should be cleaned before any
”On–Vehicle” repair, or before removal of the
compressor. The parts must be kept clean at all times and
any parts to be reassembled should be cleaned with
Trichloroethane, naphtha, kerosene, or equivalent
solvent, and dried with dry air. Use only lint free cloths to
wipe parts.
The operations described below are based on bench
overhaul with compressor removed from the vehicle,
except as noted. They have been prepared in order of
accessibility of the components. When the compressor is
removed from the vehicle for servicing, the oil remaining
in the compressor should be discarded and new
compressor oil added to the compressor.
Compressor malfunction will appear in one of four ways:
noise, seizure, leakage or low discharge pressure.
Resonant compressor noises are not cause for alarm;
however, irregular noise or rattles may indicate broken
parts or excessive clearances due to wear. To check
seizure, de–energize the magnetic clutch and check to
see if the drive plate can be rotated. If rotation is
impossible, the compressor is seized. Low discharge
pressure may be due to a faulty internal seal of the
compressor, or a restriction in the compressor. Low
discharge pressure may also be due to an insufficient
refrigerant charge or a restriction elsewhere in the
system. These possibilities should be checked prior to
servicing the compressor.
If the compressor is
inoperative, but is not seized, check to see if current is
being supplied to the magnetic clutch coil terminals.
The compressor oil used in the HFC–134a system
compressor differs from that used in R–12 systems.
Also, compressor oil to be used varies according to the
compressor model. Be sure to avoid mixing two or more
different types of oil.
If the wrong oil is used, lubrication will be poor and the
compressor will seize or malfunction.
DKV-14G Type Compressor
DKV–14G is equipped with five–vane rotary compressor.
These vanes are built into a rotor which is mounted on a
shaft.
When the shaft rotates, the vanes built into the cylinder
block assembly are operated by centrifugal force.
This changes the volume of the spare formed by the rotor
and cylinder, resulting in the intake and compression of
the refrigerant gas. The discharge valve and the valve
stopper, which protects the discharge valve, are built into
the cylinder block assembly. There is no suction valve but
a shaft seal is installed between the shaft and head; a
trigger valve, which applies back pressure to the vanes, is
installed in the cylinder block and a refrigerant gas
temperature sensor is installed in the front head.
The specified quantity of compressor oil is contained in
the compressor to lubricate the various parts using the
refrigerant gas discharge pressure.
871RX002
1A–54 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Diagnosis
Condition
Noise from compression
Noise from magnetic clutch
Insufficient cooling
Not rotating
Possible cause
Defective rotor/piston
Replace compressor/cylinder and
shaft assembly
Defective shaft
Replace compressor/cylinder and
shaft assembly
Defective bearing
Replace magnetic clutch
Defective clutch
Replace magnetic clutch
Clearance between drive plate and
pulley not standard
Adjust the clearance or replace
magnetic clutch
Defective gasket
Replace compressor/gasket
Defective rotor/reed valve
Replace compressor/valve plate
Defective trigger valve/suction valve
Replace compressor/suction valve
Defective rotor/piston
Replace compressor/cylinder and
shaft assembly
Defective shaft
Replace compressor/cylinder and
shaft assembly
Rotating parts
insufficient oil
Oil and/or gas leakage
Correction
seized
due
to
Replace compressor
Defective seal
Replace compressor/shaft seal
Defective O-ring
Replace
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–55
Magnetic Clutch Assembly (DKV-14G Type)
Parts Location View
871RX025
(4)
(5)
(6)
(7)
Legend
(1) Drive Plate bolt
(2) Drive Plate
(3) Snap Ring
Pulley Assembly
Field Coil
Shim (s)
Lead Wire
2. Remove drive plate by using drive plate puller
J-33944-A (2) and forcing screw J-33944-4 (1).
Removal
1. Using drive plate holder J-33939 (1) to prevent the
drive plate from rotating, then remove the drive plate
bolt.
871RX023
3. Remove shim (s).
871RX029
1A–56 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
4. Remove snap ring (1) by using snap ring pliers.
6. Loosen screw and disconnect the field coil wire
connector.
871RY00029
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).
871RY00030
7. Loosen three screws and remove the field coil.
871RY00034
871RY00033
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–57
3. Install pulley assembly by using pulley installer
J-33940-A (2) and drive handle J-8092 (1).
Inspection and Repair
Drive Plate
If the frictional surface shows signs of damage due to
excessive heat, the drive plate and pulley should be
replaced.
Pulley Assembly
Check the appearance of the pulley assembly. If the
frictional surface of the pulley shows signs of excessive
grooving due to slippage, both the pulley and drive plate
should be replaced. The frictional surfaces of the pulley
assembly should be cleaned with a suitable solvent
before reinstallation.
Coil
Check coil for loose connector or cracked insulation.
Installation
1. Install field coil.
B Align the located portion (1) of the field coil and
compressor.
871RY00032
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.
871RY00035
B Tighten the mounting screw to the specified torque.
Torque: 5N·m (44 lb in)
2. Connect the lead wire connector with the rubber hold
and tighten the screw.
871RY00031
1A–58 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
7. Install drive plate bolt by using drive plate holder
J-33939 (1) to prevent the drive plate from rotating.
B Check to be sure that the clutch clearance is
between 0.3-0.6 mm (0.01-0.02 in.)
871RX029
B Tighten the drive plate bolt to the specified torque.
Torque: 13 N·m (113 lb in)
B After tightening the drive plate bolt, check to be sure
the pulley rotates smoothly.
871RY00028
Legend
(1) Dial Gauge
(2) Pulley Assembly
(3) Field Coil Wire Connector
B If necessary, install adjusting shim(s).
B Adjusting shims are available in the following
thickness.
Thickness
B 0.1 mm (0.0039 in.)
B 0.3 mm (0.0118 in.)
B 0.5 mm (0.0197 in.)
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–59
Compressor Oil
Oil Specification
B The HFC-134a system requires a synthetic (PAG)
compressor oil whereas the R-12 system requires a
mineral compressor oil. The two oils must never be
mixed.
B Compressor (PAG) oil varies according to
compressor model. Be sure to use oil specified for the
model of compressor.
B Always use HFC-134a Vane Rotary Type
Compressor Oil (AIPDN Part No.2-90188-301-0)
Handling of Oil
B The oil should be free from moisture, dust, metal
powder, etc.
B Do not mix with other oil.
B The water content in the oil increases when exposed
to the air. After use, seal oil from air immediately.
(HFC-134a Vane Rotary Compressor Oil absorbs
moisture very easily.)
B The compressor oil must be stored in steel
containers, not in plastic containers.
Compressor Oil Check
The oil used to lubricate the compressor is circulating with
the refrigerant.
Whenever replacing any component of the system or a
large amount of gas leakage occurs, add oil to maintain
the original amount of oil.
Oil Capacity
Capacity total in system: 150cc (5.0 fl.oz)
Compressor (Service parts) charging amount:
150 cc (5.0 fl.oz)
Checking and Adjusting Oil Quantity
for Used Compressor
1. Perform oil return operation. Refer to Oil Return
Operation in this section.
2. Discharge and recover refrigerant and remove the
compressor.
3. Drain the compressor oil and measure the extracted
oil with a measuring cylinder.
4. If the amount of oil drained is much less than 90 cc
(3.0 fl. oz.), some refrigerant may have leaked out.
Conduct a leak tests on the connections of each
system, and if necessary, repair or replace faulty
parts.
5. Check the compressor oil contamination. (Refer to
Contamination of Compressor Oil in this section.)
6. Adjust the oil level following the next procedure
below.
(Charging Amount)
(Collected Amount)
more than 90cc (3.0
fl.oz)
same as collected
amount
less than 90 cc (3.0 fl.oz)
90cc (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 cc (3.0 fl. oz.) of oil is extracted from
the compressor, supply the same amount of oil to the
compressor to be installed.
5. If the amount of oil extracted is less than 90 cc (3.0 fl.
oz.), recheck the compressor oil in the following
order.
6. Supply 90 cc (3.0 fl. oz.) of oil to the compressor and
install it onto the vehicle.
7. Evacuate and recharge with the proper amount of
refrigerant.
8. Perform the oil return operation.
9. Remove the compressor and recheck the amount of
oil.
10. Adjust the compressor oil, if necessary.
(Collected Amount)
(Charging Amount)
more than 90 cc (3.0
fl.oz)
same as collected
amount
less than 90 cc (3.0 fl.oz)
90 cc (3.0 fl.oz)
1A–60 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Checking and Adjusting for
Compressor Replacement
150 cc (5.0 fl.oz.) of oil is charged in compressor (service
parts). So it is necessary to drain the proper amount of oil
from the new compressor.
1. Perform oil return operation.
2. Discharge and recover the refrigerant and remove the
compressor.
3. Drain the compressor oil and measure the extracted
oil.
4. Check the compressor oil for contamination.
5. Adjust the oil level as required.
(Amount of oil drained
from used compressor)
(Draining amount of oil
from new compressor)
less than 90 cc (3.0 fl.oz)
Same as drained
amount
more than 90 cc (3.0
fl.oz)
90 cc (3.0 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:
B The capacity of the oil has increased.
B The oil has changed to red.
B Foreign substances, metal powder, etc., are present
in the oil.
If any of these conditions exists, the compressor oil
is
contaminated.
Whenever
contaminated
compressor oil is discovered, the receiver/drier must
be replaced.
Oil Return Operation
There is close affinity between the oil and the refrigerant.
During normal operation, part of the oil recirculates with
the refrigerant in the system. When checking the amount
of oil in the system, or replacing any component of the
system, the compressor must be run in advance for oil
return operation. The procedure is as follows:
1. Open all the doors and the engine hood.
2. Start the engine and air conditioning switch to “ON”
and set the fan control knob at its highest position.
3. Run the compressor for more than 20 minutes
between 800 and 1,000 rpm in order to operate the
system.
4. Stop the engine.
Replacement of Component Parts
When replacing the system component parts, supply the
following amount of oil to the component parts to be
installed.
(Component parts to be
installed)
(Amount of Oil)
Evaporator
50 cc (1.7 fl. oz.)
Condenser
30 cc (1.0 fl. oz.)
Receiver/dryer
30 cc (1.0 fl. oz.)
Refrigerant line (one
piece)
10 cc (0.3 fl. oz.)
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–61
Main Data and Specifications
General Specifications
COMPRESSOR
Model
DKV-14G
Type
Vane rotary type
Number of vanes
Rotor diameter
5
64 mm (2.52 in.)
Stroke
8.75 mm (0.34 in.)
Displacement
140 cc (47.3 fl.oz.)
Maximum speed
7,000 rpm (up to 8,400 rpm)
Direction of rotation
Clockwise (Front-side view)
Lubrication system
Pressure differential type
Lubricant
R-134a Vane Rotary Type Compressor Oil
(AIPDN Part No.2-90188-301-0)
150 cc (5.0 fl.oz.)
Refrigerant
Refrigerant-134a (R-134a), 700 g (1.54 lbs.)
Shaft seal
Lip type
Weight
3.5 kg
MAGNETIC CLUTCH
Type
Rated voltage
Current consumption
Starting torque
Direction of rotation
Weight
Electromagnetic single-plate dry clutch
12 Volts D.C.
3.7 A
49 N·m (36 lb·ft)
Clockwise (Front-side view)
3.0 kg (6.6 lbs.)
1A–62 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Torque Specifications
871RX028
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–63
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION
TOOL NO.
TOOL NAME
J-33939
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
1A–64 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Automatic Air Conditioning System
General Description
Using a variety of sensors, this automatic air conditioner
accurately senses outside air temperature, solar
radiation quantity, evaporator’s blowing temperature, and
interior temperature, then enters these data to the
automatic air conditioner control unit (equipped with the
built-in micro-computer). The data provided to the control
unit enables to automatically control blow temperature
and blow air quantity, turn on or off the compressor and
switch the blow port as well as switching between the
fresh air intake and interior air circulation.
Resetting the automatic function allows you to switch to
the manual control mode.
The self-diagnoisis function of the automatic air
conditioner control unit (with the built-in micro-computer)
allows the unit to access and diagnose a failed part easier
and quicker.
Automatic Air Conditioner Parts Configuration
865R200050
Legend
(1) In Car Sensor
(2) Sun Sensor
(3) Ambient Sensor
(4) Intake Actuator
(5) Blower Unit
(6) Max – High Relay
(7) Display
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Audio & Switch Assembly
Evaporator Assembly
Duct Sensor
Mix Actuator
Heater Unit
Automatic Air Conditioner Control Unit
Mode Actuator
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–65
Circuit Diagram
D01R200010
1A–66 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
D01R200011
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–67
D01R200003
1A–68 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
D01R200004
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–69
D01R200009
1A–70 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Functions and Features
Automatic air conditioning control unit
The control unit features a prominent control and display
panel that clearly shows air conditioner operational
settings (delivered air volume, air outlet location,
inside/outside air circulation, and set temperature).
Desired temperature can be set in –17°C (1°F)
increments. The current setting appears on the digital
display.
Automatic temperature control
Vehicle interior temperature is maintained at the set level.
It is unaffected by changes in vehicle speed, outside air
temperature, and number of passengers.
Maximum cooling and heating
Moving the switch to the 18°C (65°F) position provides
maximum cooling. Moving the switch to the 32°C (90°F)
position provides maximum heating.
Automatic air flow control
Air flow is automatically and precisely regulated in
response to set temperature change and/or changes in
heater unit mixing door aperture.
Automatic air outlet selection
Appropriate air outlets (VENT, BE-LEVEL, FOOT, or
DEF) are selected in response to changes in outlet
temperatures. The mode switch permits manual selection
of the desired air outlet.
Air source (Fresh air intake from outside the
vehicle or recirculation of the air inside the vehicle)
selection
Automatic switching between outside air (FRESH),
recirculated inside air (RECIRC), or a combination of the
two (MIX) occurs in response to changes in outlet
temperatures.The intake switch permits manual
selection of the air source (FRESH or RECIRC). Mixing
of the two sources is not possible during manual
operation. When the defrost mode switch (DEF) is
pressed, the system automatically switches to outside air
intake.
Cooler start-up control
When the vehicle is parked in a hot area for an extended
period of time, the evaporator becomes hot. When the
cooler is turned on, hot air is blown into the vehicle until
the evaporator cools down. The cooler start-up control
prevents blower operation until the evaporator is able to
provide cool air.
Heater start-up control
When the vehicle is parked in a cold area for an extended
period of time, the heater core becomes cold. When the
heater is turned on, cold air is blown into the vehicle until
the heater core heats up. The heater start-up control
prevents blower operation to the air outlets until the
heater core is able to provide warm air. Air is delivered
through the defrost outlets.
Solar radiation offset
The sun sensor uses a photodiode to precisely determine
the amount of solar radiation affecting the vehicle. The
cooler operates in response to this radiation to quickly
correct the vehicle interior temperature.
Switch position memory
Current switch positions are stored in memory when the
ignition switch is turned off. When the ignition switch is
turned on again, the switches automatically return to the
position they were in when the ignition switch was turned
off. This simplifies the restarting procedure.
Self-diagnosis function
The self-diagnosis switches on the control panel permit
easy system troubleshooting. Refer to “Self-Diagnosis”
later in this Section.
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–71
Automatic Air Conditioner Block Diagram
F01R200004
1A–72 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Control Panel Layout
865R200006
Legend
(1) Temperature Control Switch
(2) Auto Switch
(3) DEF Mode Switch
(4) Rr DEF Mode Switch
(5)
(6)
(7)
(8)
(9)
Intake Switch
Mode Switch
Air Conditioning Switch
Fan Switch
Off Switch
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–73
Air Control Functions
C01R200013
Legend
(1) DEF Door
(2) Air Mix Door
(3) Evaporator Core
(4) Fresh Air Intake
(5) Interior Air Intake
(6) Blower Unit
(7)
(8)
(9)
(10)
(11)
(12)
Evaporator Unit
Heater Core
Heater Unit
Sub Air Mix Door
FOOT Door
VENT Door
1A–74 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Control Panel Switch Operation
Switch Name
A
u
t
o
S
w
i
t
c
h
O
f
f
S
w
i
t
c
h
F
a
n
Y
·
B
S
w
i
t
c
h
M
o
d
e
S
w
i
t
c
h
Panel Display
Switch Operation
During manual outside air intake (FRESH), pressing the AUTO
switch cancels manual outside air intake. The display panel shows
the current set temperature, the current air outlet(s), and the blower
speed. The intake switch LED shows the current air source. The
A/C switch LED is on.
Air volume, air outlet operation, and air source are controlled
automatically. The compressor is on.
During manual inside air recirculation (REC), pressing the AUTO
switch does not cancel inside air recirculation. The intake switch
LED is on.
When the OFF switch is pressed, the display panel clears except
for the air outlet indication. Blower and compressor operation stop.
The air source switches from automatic to outside air.
During manual inside air recirculation (REC), pressing the OFF
switch does not cancel inside air recirculation. The intake switch
LED is on.
When the fan switch is pressed, air outlet volume (fan speed) can
be manually controlled. Other control switches are unaffected. The
display panel clears AUTO indication.
1. FAN switch is pressed during automatic fan control (AUTO)
Fan control (AUTO)→Press Y fan switch→Fan speed increases
from automatic set speed to HI
Fan control (AUTO)→Press B fan switch→Fan speed decreases
from automatic set speed to LO
2. Fan switch is pressed when the fan is off.
Fan (OFF)→Press Y fan switch→The fan operates at LO speed
Fan (OFF)→Press B fan switch→The fan operates at LO speed
3. Fan switch is pressed when the fan is in manual operation.
Manual (LO)→Press Y fan switch→Manual operation
(LO)→ (M1)→(M2)→(M3)→(HI)
Manual (HI)→Press B fan switch→Manual operation
(HI)→(M3)→(M2)→(M1)→(LO)
Press the mode switch to manually select the air outlet(s). Each
time the switch is pressed, the air outlets change in the progression
shown below.
Mode switch (Automatic control of air
outlets)→VENT→BI-LEVEL→FOOT→DEF/FOOT
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–75
A
/
C
·
S
w
i
t
c
h
When the A/C switch is pressed, the LED light goes out and the
compressor turns off. If the switch is pressed again, the LED light
turns on and the compressor begins to operate.
The air conditioner will not operate if the fan switch is off.
During manual DEF or D/F operation, the A/C LED will turn on or off
in response to switch operation. However, the compressor remains
on regardless of switch position.
D
E
F
When the defrost switch (DEF) is pressed, air flows from the defroster outlets. The compressor is on and blower speed is automatically controlled. Air intake is from outside the vehicle (FRESH). The
defroster symbol appears on the display.
When the defrost switch (DEF) is pressed again, the unit returns to
the settings in use before the defroster was turned on.
M
o
d
e
S
w
i
t
c
h
1A–76 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Pressing the intake switch permits manual control of air intake and/
or recirculation.
I
n
t
a
k
e
S
w
i
t
c
h
If the intake switch is pressed during manual DEF or D/F, the intake
switch LED briefly turns on. However, outside air intake (FRESH)
continues.
T
e
m
p
e
r
a
t
u
r
e
C
o
n
t
r
o
l
S
w
i
t
c
h
The display panel temperature setting can be set from 18°C (65°F)
to 32°C (90°F).
Pressing and immediately releasing the Y switch increases the
temperature setting in -17°C (1°F) increments. If the switch is
pressed and held, the temperature setting increases rapidly.
Pressing and immediately releasing the B switch decreases the
temperature setting in -17°C (1°F) decrements. If the switch is
pressed and held, the temperature setting decreases rapidly.
When the temperature setting is at 32°C (90°F), the unit is set to
maximum heat mode.
When the temperature setting is at 18°C (65°F), the unit is set to
maximum cooling mode.
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–77
Overview of Construction, Movement
and Control of Major Parts of
Automatic Air Conditioner System
Automatic Air Conditioner Control Unit
Equipped with the built-in micro-computer, this control
unit operates on signals from sensors and input signals
from switches to offer total control of the blower fan, and
actuators used for the mode door, intake door and air mix
door.
Its self-diagnosis function enables quicker access to a
failed part and its more accurate troubleshooting.
In Car Sensor
It is a sensor used for detecting room temperature of a
vehicle. This sensor converts a given room temperature
into a resistance value before entering the data to the
automatic air conditioner control unit.
This in car sensor unites the power driven aspirator and
the motor fan so that a small amount of room air may be
constantly fed to the sensor.
This sensor is provided on the right side of meter cluster.
875R200017
Legend
(1) Ambient Sensor
(2) Condenser Assembly
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.
865R200001
Legend
(1) Meter Cluster
(2) In Car Sensor
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.
874R200001
Legend
(1) Sensor Part
(2) Duct Sensor Assembly
(3) Evaporator Assembly
1A–78 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Sun Sensor
Power Transistor
It is a photodiode used for detecting quantity of solar
radiation.
This sensor converts the offset signal
generated by changes in the interior temperature (which
results from fluctuations in solar radiation) into
photoelectric current to enter into the automatic air
conditioner control unit.
This sensor is provided at top of the center cluster upper.
Receiving base current from the automatic air conditioner
control unit, the power transistor implements stage-less
speed change of the blower fan motor. This transistor is
provided on the evaporator.
874R200009
865R200002
Legend
(1) Sun Sensor
(2) Center Cluster Upper
Legend
(1) Evaporator Assembly
(2) Power Transistor
Max Hi Relay
This relay turned on or off by the signal from the automatic
air conditioner control unit. As the Max Hi relay is turned
on, supply voltage is directly fed to the blower fan motor to
select the Max Hi mode.
873RY00005
Legend
(1) Blower Unit
(2) Max High Relay
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–79
Actuator
The actuators are power driven type containing a small
motor. Receiving output current from the automatic air
conditioner control unit, actuators drive the heater and
blower unit mode doors.
Actuators consist of the mode actuator used for switching
the mode (blow port selection), the mix actuator used for
changing aperture of the air mix door, the intake actuator
used for switching the intake mode(fresh air/interior air)
actuator.
860RW026
Legend
(1) Output Axis
(2) Motor
(3) Printed Circuit Board
(4) Sliding Contact
860R200004
Legend
(1) Mix Actuator
(2) Intake Actuator
(3) Blower Unit
(4) Mode Actuator
(5) Heater Unit
The mode and mix actuators are common actuators with
the built-in potentiometer. For the intake actuator, the
contact switch type is selected.
The potentiometer is a register assembled to the printed
circuit board of the mix and mode actuators. It detects the
air mix door position specified by rotation of the output
axis as a ratio of the variable terminal (VM) voltage
against the reference voltage (VDD: 5V), then signals the
value to the automatic air conditioner control unit.
The actuator changes the motor speed using the gear
and drives each door rotating the output axis united with
the sliding contact.
C01RX016
1A–80 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Movement of Mix Actuator
Movement of Mode 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.
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.
C-43
Rotation
direction
Remarks
(+) side
(-) side
8
6
Clockwise
Full heat side
6
8
Counter
clockwise
Full cool side
Conduction pin
Rotation
direction
Remarks
(+) side
(-) side
5
1
Clockwise
VENT to DEF
direction
1
5
Counter
clockwise
DEF to VENT
direction
C01RX005
C01RX017
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–81
Movement of Intake Actuator
The controller on the automatic heater/air conditioner
control unit selects an intake mode to be used.
As the Terminal No.5 C-33 is grounded via the sliding
contact on the terminal plate, the transistor on the driver is
activated, thus turning on the motor rotation. Then,
accompanying move of the motor, the sliding contact
rotates until grounding of the Terminal No.5 C-33 is
removed, thus stopping the motor.
Grounding
terminal
Rotation
direction
Remarks
No.5 C-33
Clockwise
RE-CIRCULATI
ON→MIX→
FRESH
C01RX006
Overview of Automatic Control of
Automatic Air Conditioner
The automatic air conditioner on this vehicle has the
following features:
Interior temperature control.
Air flow control.
Mode (blow port) control.
Intake (switching between fresh air and interior air)
control.
Heater start timing control.
Cooler start timing control.
Evaporator anti-freeze control.
1A–82 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Automatic Air Conditioning System
System Overview (Chart)
Conditions both inside and outside the vehicle are
detected by sensors (in-car temperature sensor, ambient
temperature sensor, duct sensor, sun sensor, speed
sensor, and water temperature sensor). These sensors
send signals to the control unit.
Potentiometer position sensors send data to the control
unit. Signals related to control panel settings are also sent
to the control unit.
In response to the signals received, the control unit
automatically adjusts air-mix door aperture (outlet air
temperature), fan speed (forced air volume), and air
intake (outside air, recirculated inside air, or a mixture of
the two).
F01R200003
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–83
Interior Temperature Control
Air Flow Control
When the temperature control switch is set to a specific
temperature, a signal is sent to the A/C control unit. Other
signals are sent to the control unit from the various
sensors. This data is analyzed by the control unit which
creates a composite data signal that is compared with the
signal received from the potentiometer. The result
determines the direction of mix actuator rotation.
The mix actuator reacts to the composite air mix door
opening angle signal. Opening angle is increased or
decreased to maintain the temperature at the selected
level.
When the compressor is off, the air mix door moves
toward the COOL side. When the compressor turns on,
the temperature of the air being discharged from the
outlet vents is regulated.
When the temperature control is set to 18°C (65°F), the
air mix door moves to the FULL COOL position. When the
control is set to 32°C (90°F), the door moves to the FULL
HOT position.
In the VENT position, the air mix door moves from FULL
COOL to a 60% aperture. This prevents hot air from being
discharged into the vehicle.
In the Auto Mode
Automatic operation
When the AUTO switch or the DEF switch is pressed, a
signal indicating the forced air volume is sent to the A/C
auto-control unit. Other signals are sent to the control
unit from the various sensors. This data is analyzed by
the control unit which creates a composite data signal.
Based on this signal, the base voltage of the power
transistor is varied to change the blower voltage. This
results in a non-stepped change in blower motor
speed.
When the temperature control switch is set to either
18°C (65°F) or 32°C (90°F), blower motor speed is in
the MAX-HI mode.
In the Manual Mode
Manual operation
When the fan switch is manually set to a specified air
volume, a signal is sent to the A/C auto-control-unit. In
response to this signal, the auto-control unit controls
the blower voltage.
When the fan switch is set to HI, the max-hi relay
operates to increase blower motor speed to the
MAX-HI mode.
C01R200005
C01R200001
1A–84 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Mode (Blow Port) Control
The A/C control unit receives temperature setting data as
well as temperature and solar radiation level data from the
various sensors. Based on this data, the control unit
compiles a composite TMO signal. The TMO signal
allows the outlet positions to be changed in a set pattern
(VENT→BI-LEVEL→FOOT→DEFROST/FOOT).
The mode actuator acts in response to mode position. It
compares data signals received from the target mode, the
door position, and mode door position to determine the
direction of rotation.
If the temperature is set to 18°C (65°F), cool air is
discharged from the head outlets. If t he temperature is
set to 32°C (90°F), warm air is discharged from the foot
outlets.
In manual mode, existing air outlet settings remain
unchanged when the temperature is set to 18°C (65°F) or
32°C (90°F).
<Mode switch operation>
Press the mode switch to change to the outlet mode.
Blower operation (outlet mode position) can now be
switched between the VENT, BI-LEVEL, FOOT, and DEF
positions.
<Defroster switch operation>
The DEF position can be selected from the outlet mode.
Intake (Fresh air/interior air switching)
Control
During automatic operation, the A/C control unit responds
to the temperature setting signal together with signals
from the various sensors to generate a general signal that
controls operation in a prescribed pattern.
If either or both the fan and the cooler are off, air intake is
from outside the vehicle.
If the temperature control switch is set to either 18°C
(65°F) or 32°C (90°F), the air inside the vehicle is
recirculated.
1. Manual switch operation
Press the intake switch to change between outside air
intake and recirculated inside air.
2. Defrost switch operation
Air intake is from outside the vehicle.
3. Mode switch operation
During automatic operation, outside air intake or
recirculated inside air is selected as appropriate.
During manual operation or when the DEF mode is
selected, air intake is from outside the vehicle.
C01R200004
C01R200003
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–85
Compressor Control
Cooler Start-up Control
In the automatic control mode, the automatic air
conditioner control unit turns on or off the compressor
with the evaporator anti-freeze mechanism using the
evaporation sensor. And, when outside air is detected to
be low through the outside air temperature sensor signal,
the control unit turns off the compressor using the
compressor control function.
Manual Control
When cooler operation is started with the air discharge
mode is in the VENT or B/L position and the in-car
temperature higher than 26°C (78°F) (detected by the
in-car sensor), cooler start-up control occurs.
For the first 7 seconds of cooler operation, the fan
remains OFF. It then switches to AUTO LO. Air discharge
volume then increases in linear increments to the pre-set
level.
Cooler start-up control occurs the first time the engine is
started or the cooler switch is moved from OFF to AUTO.
It will not occur during subsequent switch movements.
In the automatic control mode, pressing the A/C (air
conditioning) switch turns off the compressor.
Pressing the DEF mode switch automatically turns on
the compressor.
C06R200001
C01R200002
Heater Start-up Control
Heater start-up control occurs when the air discharge
mode is in the BI=LEVEL, FOOT, or DEF/FOOT position
and the heater core temperature is less than 14°C (58°F).
Air discharge volume remains in the AUTO LO mode until
the engine coolant temperature rises above 14°C (58°F).
The volume then increases in linear increments to the
pre-set level.
840R200010
1A–86 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Troubleshooting
Troubleshooting, Its Overview and
Procedures
The automatic air conditioner equips with the
“Self-Diagnosis Function” to check its major components.
This function makes access to the sensors, actuators and
blower fan motor system easier when checking them up
and, when a failed part is located, this function restores its
original performance.
When
implementing
the
troubleshooting,
this
self-diagnosis function narrows the range to be searched
at the first step, then check relevant parts one by one
according to the “Checking Procedures by Failed
Location”. As for a location this function is unappreciable,
the system accurately determines characteristics of a
given trouble and checks relevant parts according to the
“Checking Procedures by Failed Location”.
The following illustrates basic troubleshooting flow.
Basic Troubleshooting Flow
F01RX009
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–87
Auto Air Conditioner Control Unit Power Supply Diagnosis
This check is required because a trouble on the auto
amplifier (control unit) power supply circuit or grounding
circuit prevents accurate troubleshooting.
D08R200034
Condition
Power source does not supply to
auto air conditioner control unit.
Possible cause
—
Correction
Refer to Chart A
1A–88 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Chart “A”: Check of Auto Amplifier Power Supply System
Step
1
2
3
Action
5
6
Go to Step 2
Replace the
fuse
—
Go to Step 3
Replace the
fuse
Approx. 12V
Go to Step 5
Go to Step 4
Is the action complete?
—
Go to Step 4
—
Is there continuity between the harness side connector
terminal No.I19–16 and the ground?
—
Go to Step 7
Go to Step 6
—
Go to Step 5
—
Approx. 12V
Go to Step 9
Go to Step 8
—
Go to Step 7
—
Approx. 12V
—
Go to Step 10
—
Verify repair
—
Is the fuse F–7 normal?
Disconnect the auto A/C control unit connector I–19.
Repair an open circuit between the fuse C–5 and
terminal No.I19–8.
Repair an open circuit between terminal No.I19–16 and
the ground No.B–9.
Turn the lighting switch on.
Is the battery voltage applied between the harness side
connector terminal No.I19–12 and the ground?
8
Repair an open circuit between the lighting switch and
terminal No.I19–12.
Is the action complete?
9
Turn the starter switch on.
Is the battery voltage applied between the harness side
connector terminal No.I19–7 and the ground?
10
No
—
Is the action complete?
7
Yes
Is the fuse C–5 normal?
Is the battery voltage applied between the harness side
connector terminal No.I32–8 and the ground?
4
Value(s)
Repair an open circuit between the fuse F–7 and
terminal No.I19–7.
Is the action complete?
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–89
Performance and Movement
checklist for Automatic Air
Conditioner Related Parts
Start the engine, and when the engine coolant reached
50°C (122°F) check performance and movement of the
related parts according the following checklist.
Performance Check Using the Manual Switch
No
No.
1
Item
Procedure
Condition
Air discharge
temperature
(Ai
(Air–mix
i door
d
operation)
Auto–switch ON
Air discharge
volume (Fan
operation)
Fan switch ON
2
Criteria
Set temperature to
18°C (65°F).
Cold air discharge.
Set temperature to
32°C (90°F).
Hot air discharge.
1. Set temperature to
25°C (77°F).
2. Press the OFF
switch.
Fan does not operate. There is no
air discharge.
1. Set temperature to
25°C (77°F).
2. Press the fan Y
switch.
Fan operates. Fan speed increases
each time the switch is pressed (LO
to HI in 5 increments).
Air discharge
temperature
(Mode door
operation)
Fan in manual
5–speed operation
1. Set temperature to
25°C (77°F).
2. Press the mode
switch.
3. Move through the 5
modes
(VENT→BI–LEVEL
→FOOT→DEF/FO
OT→DEF).
B Panel display lights for each
mode.
B Air discharge outlet position
changes for each mode.
Inside/outside air
mode (Intake door
operation)
Auto–switch ON
1. Set temperature to
25°C (77°F).
2. Press the intake
switch.
3. Press the fan Y
switch.
4. Set the fan to the
highest speed.
5. Press the intake
switch.
B Intake switch LED turns from on
to off.
B Air discharge sound changes.
Compressor
Outside air
temperature above
0°C (32°F) and
vehicle interior at
normal temperature
1. Set temperature to
25°C (77°F).
2. Press the OFF
switch.
3. Press the
auto–switch.
4. Press the air
conditioner switch.
B When the auto–switch is
pressed, the LED in the air
conditioner switch turns on and
the compressor begins
operation.
B When the air conditioner switch
is pressed, the LED in the air
conditioner switch turns off and
the compressor stops operation.
3
4
5
Operation
1A–90 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Check of Auto Function
No
No.
Item
Procedure
Condition
Criteria
Operation
AUTO display highlighted on
display panel.
Cold air discharge.
Set temperature to
18°C
18
C (65
(65°F)
F).
1
Automatic operation
Auto-switch ON
Gradually increase
the temperature
setting from 18°C
(65°F) to 31.5°C
(89°F).
VENT mode.
Intake switch LED on.
Fan speed bar graph display at
MAX6dash;HI
A/C switch LED on.
Temperature of air discharge
increases with increase in setting
temperature.
Air discharge volume changes.
Panel display shows VENT,
BI–LEVEL, FOOT, or DEF/FOOT.
Hot air discharge.
A/C bar graph display disappears.
Set temperature to
32°C (90°F).
(90°F)
Foot mode.
Intake LED switch off.
Fan speed bar graph display at
MAX-HI
A/C switch LED on.
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–91
Troubleshooting With Self-Diagnosis Function
Overview of Self-Diagnosis Function
Sensors (input) and actuators (output) are used to check
circuit function and provide essential data on these
circuits. For more detailed information, refer to the
[Inspection and Repair] Sections for the applicable
system or component.
The Table below shows how to turn the self-diagnosis
function on and off.
Self-Diagnosis Operation Procedure
865R200033
1A–92 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Step
1
Action
Value(s)
Yes
No
1. Allow the engine to idle until it completely warms up.
2. Turn the starter switch to the OFF position.
3. Place a 60–watt lamp approximately 15 cm from the
sun sensor.
NOTE: This procedure is best performed at night or in
a dark, unlit area.
Is the action complete?
2
—
Go to Step 3
Replace
display unit
—
Go to Step 4
Replace
audio unit
—
Go to Step 6
Go to Step 5
—
Go to Step 1
—
—
Go to Step 8
Go to Step 7
—
Go to Step 1
—
—
Go to Step 10
Go to Step 9
—
Go to Step 1
—
—
Go to Step 12
Go to Step 11
NOTE: A ’1’ should appear in the set temperature
segment of the display.
Does ’0’ appear in the outside air segment of the
display?
5
—
Press the COMPUTER MODE key.
Does DIAG AIRCON appear on the display?
4
Go to Step 2
Simultaneously press and hold the RESET key and the
CLOCK key (display unit).
Move the starter switch to start the engine.
Does DIAG appear on the display?
3
—
Repair or replace damaged parts.
NOTE: Refer to Step 1 Trouble Code Table.
Is the action complete?
6
Press and release the Y fan switch (one time only).
NOTE: A ’2’ should appear in the set temperature
segment of the display.
Does ’0’ appear in the outside air segment of the
display?
7
Repair or replace damaged parts.
NOTE: Refer to Step 2 Trouble Code Table.
Is the action complete?
8
Press and release the Y fan switch (one time only).
NOTE:
B
B
Refer to Step 3 Sensor Output Check for a sample
output value.
A ’3’ should appear in the set temperature
segment of the display.
Does the correct sensor output value appear in the
outside air segment of the display?
9
Repair or replace damaged parts.
NOTE: Refer to Trouble Spot Inspection.
Is the action complete?
10
Press and release the Y fan switch one time only.
NOTE: Refer to Step 4 (Operation Check) for display
readings and inspection steps.
Are all parts operating normally?
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–93
Step
11
Action
Value(s)
Yes
No
Repair or replace damaged parts.
NOTE: Refer to Trouble Spot Inspection.
Is the action complete?
12
—
Go to Step 1
—
—
Go to Step 15
Go to Step 13
—
Go to Step 14
—
—
Go to Step 15
Replace
display unit
—
—
—
1. Press and release the fan switch (one time only).
2. Press the DEF switch several times.
NOTE: A ’3’ should appear in the set temperature
segment of the display.
Does the correct sequence pattern (1, 2, 1, 2) appear in
the outside air segment of the display?
13
Perform diagnosis for DEF switch, intake actuator, and
AUTO A/C control unit.
Have the diagnosis procedures been completed.
14
1. Press and release the fan switch (one time only).
2. Press the DEF switch several times.
Are all parts operating normally?
15
Turn the starter switch OFF.
Is the action complete?
1A–94 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
STEP 1: Trouble Code Table
Trouble
Code
Defective Part
Trouble
Code
Defective Part
1
In Car Sensor Open Circuit
–1
In Car Sensor Short Circuit
2
Ambient Sensor Open Circuit
–2
Ambient Sensor Short Circuit
3
Sun Sensor Open Circuit
–3
Sun Sensor Short Circuit
4
Duct Sensor Open Circuit
–4
Duct Sensor Short Circuit
5
Mix Potentiometer Open Circuit
–5
Mix Potentiometer Short Circuit
6
Mode Encoder Open Circuit
7
Intake Encoder Open Circuit
0
No Defective Part
STEP 2: Trouble Code Table
Trouble
Code
Defective Part
Trouble
Code
Defective Part
1
In Car Sensor Open Circuit
–1
In Car Sensor Short Circuit
2
Ambient Sensor Open Circuit
–2
Ambient Sensor Short Circuit
3
Not Used
–3
Sun Sensor Short Circuit
4
Duct Sensor Open Circuit
–4
Duct Sensor Short Circuit
5
Mix Potentiometer Open Circuit
–5
Mix Potentiometer Short Circuit
6
Mode Encoder Open Circuit
7
Intake Encoder Open Circuit
0
No Defective Part
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–95
STEP 3: Sensor Output Check
865R200035
1A–96 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
STEP 4: Operation Check
865R200032
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–97
Inspection By Failed Location
Inspection of the Sensors
When the self-diagnosis function has determined that
trouble is present on the sensors, check them according
to the following flow chart.
F01RY00005
1A–98 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Chart 1: In Car Sensor
D08R200029
Step
1
2
3
4
5
Action
Yes
No
Disconnect the in car sensor connector. (No.I-17)
Is performance of the sensor normal? (Refer to the
later section on “Individual Inspection”)
—
Go to Step 2
Replace the
in car sensor
Is there continuity between the harness side connector
No.I20–1 and No.I17–3?
—
Go to Step 4
Go to Step 3
Is the action complete?
—
Go to Step 2
—
Is there continuity between the harness side connector
No.I20–11 and No.I17–4?
—
Go to Step 6
Go to Step 5
—
Go to Step 4
—
—
Verify repair
—
Repair an open circuit between terminal No.I20–1 and
No.I17–3.
Repair an open circuit between terminal No.I20–11 and
No.I17–4.
Is the action complete?
6
Value(s)
Replace the auto air conditioner control unit.
Is the action complete?
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–99
Chart 2: Ambient Sensor
D08R200030
Step
1
Action
3
No
Go to Step 2
Replace the
ambient
sensor
Go to Step 4
Go to Step 3
—
Verify repair
—
—
Verify repair
—
—
Connect the ambient sensor connector.
Refer to the
later
section
Is resistance between the harness side connector
on
“Individual
No.I20–2 and No.I20–11 normal?
inspection”
Repair an open circuit between terminal No.I20–2 and
No.C19–1 or No.I20–11 and No.C19–2.
Is the action complete?
4
Yes
Disconnect ambient sensor connector. (No.C–19)
Is performance of the ambient sensor normal? (Refer
to the later section on “Individual inspection”)
2
Value(s)
Replace the auto air conditioner control unit.
Is the action complete?
1A–100 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Chart 3: Sun Sensor
D08R200059
Step
1
2
3
4
5
Action
Yes
No
Disconnect the sun sensor connector. (No.I–15)
Is performance of the sun sensor normal? (Refer to the
later section on individual inspection)
—
Go to Step 2
Replace the
sun sensor.
Is there continuity between the harness side connector
terminal No.I20–3 and No.I15–2?
—
Go to Step 4
Go to Step 4
Is the action complete?
—
Go to Step 2
—
Is there continuity between the harness side connector
terminal No.I20–11 and No.I15–1?
—
Go to Step 6
Go to Step 5
—
Go to Step 4
—
—
Verify repair
—
Repair an open circuit between terminal No.I20–3 and
No.I15–2.
Repair an open circuit between terminal No.I20–11 and
I15–1.
Is the action complete?
6
Value(s)
Replace the auto air conditioner control unit.
Is the action complete?
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–101
Inspection of the Intake Actuator System
D08R200060
1A–102 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Condition
Possible cause
Correction
Does not work at all
—
Refer to Chart A
Control failure
—
Refer to Chart B
Chart A: Does Not Work At All
Step
1
2
3
4
Action
7
8
9
Go to Step 2
Replace the
fuse
—
Go to Step 3
Replace the
fuse
—
Go to Step 4
Replace the
relay
Approx 12V
Go to Step 6
Go to Step 5
—
Go to Step 4
—
Approx 12V
Go to Step 8
Go to Step 7
Is the action complete?
—
Go to Step 6
—
Is there continuity between the harness side connector
terminal No.I19–11 and No.C33–4?
—
Go to Step 10
Go to Step 9
—
Verify repair
—
—
Verify repair
—
Is the fuse F–7 normal?
Is the relay X–1 normal?
Turn on the ignition switch. (the engine is run.)
Repair an open circuit between terminal No.C33–3 and
No.X1–1.
Is the battery voltage applied between the harness side
connector terminal No.C33–4 and ground?
Replace the intake actuator motor.
Repair an open circuit between No.I19–11 and C33–4.
Is the action complete?
10
No
—
Is the action complete?
6
Yes
Is the fuse FL–1 normal?
Is the battery voltage applied between the harness side
connector terminal No.C33–3 and ground?
5
Value(s)
Replace the auto air conditioner control unit.
Is the action complete?
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–103
Chart B: Failure on the Intake Control
Step
1
2
3
Action
5
6
7
8
9
10
11
12
14
Go to Step 2
Replace the
fuse
—
Go to Step 3
Replace the
relay
—
Go to Step 5
Go to Step 4
Is the action complete?
—
Verify repair
—
Is there continuity between the harness side connector
terminal No.C33–5 and No.I20–11?
—
Go to Step 7
Go to Step 6
Is the action complete?
—
Go to Step 5
—
Is there continuity between the harness side connector
terminal No.C33–6 and No.I20–12?
—
Go to Step 9
Go to Step 8
Is the action complete?
—
Go to Step 7
—
Is there continuity between the harness side connector
terminal No.C33–1 and No.I20–13?
—
Go to Step 11
Go to Step 10
Is the action complete?
—
Go to Step 9
—
Is there continuity between the harness side connector
terminal No.C33–2 and No.I20–14?
—
Go to Step 13
Go to Step 12
—
Go to Step 11
—
—
Go to Step 14
Go to Step 15
—
Verify repair
—
—
Verify repair
—
Is the relay No.X–1 normal?
Turn on the ignition switch. (the engine is run.)
Replace or repair the auto air conditioner control unit.
Repair an open circuit between terminal No.C33–5 and
No.I20–11.
Repair an open circuit between terminal No.C33–6 and
No.I20–12.
Repair an open circuit between terminal No.C33–1 and
I20-13.
Repair an open circuit between harness No.C33–2 and
No.I20–14.
1. Disconnect the intake actuator connector No.C33.
2. Is the battery voltage applied between harness side
connector terminal
No.C33–6 and ground?
No.C33–2 and ground?
No.C33–1 and ground?
Replace or repair the intake actuator.
Is the action complete?
15
No
—
Is the action complete?
13
Yes
Is the fuse No.F–7 normal?
Is the intake actuator stopped?
4
Value(s)
Replace or repair the air conditioner control unit.
Is the action complete?
1A–104 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Inspection of the Mix Actuator System
D08R200032
Condition
Possible cause
Correction
Does not work at all
—
Refer to Chart A
Control failure
—
Refer to Chart B
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–105
Chart A: Does Not work At All
Step
1
Action
3
5
6
No
—
Go to Step 3
Go to Step 2
—
Varify repair
—
—
Go to Step 5
Go to Step 4
—
Verify repair
—
—
Go to Step 7
Go to Step 6
Is the action complete?
—
Go to Step 5
—
Is there continuity between the harness side connector
terminal No.I19–5 and No.C43–8?
—
Go to Step 9
Go to Step 8
—
Verify repair
—
—
Verify repair
—
Replace the auto air conditioner control unit.
Using the temperature control switch, select 32°C
(90°F) for the temperature.
Is the battery voltage applied on a regular interval basis
between the harness side connector terminal
No.C43–6 (+) and No.C43–8 (-)?
4
Yes
1. Turn on the ignition switch (the engine is run).
2. Disconnect the mix actuator connector (C–43).
3. Short-circuit the chassis harness side connector
terminal No.C43–3 and No.C43–7.
4. Using the temperature control switch, select 18°C
(65°F) for the temperature.
Is the battery voltage applied on a regular interval basis
between the harness side connector terminal
No.C43–6 (-) and No.C43–8 (+)?
2
Value(s)
Replace the auto air conditioner control unit.
Is there continuity between the harness side connector
terminal No.I19–6 and No.C43–6?
Repair an open circuit between terminal No.I19–6 and
No.C43–6.
7
8
Repair an open circuit between terminal No.I19–5 and
No.C43–8.
Is the action complete?
9
Replace the mix actuator.
Is the action complete?
1A–106 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Chart B: Mix Actuator Control Failure
Step
1
Action
3
4
5
6
8
9
10
Go to Step 3
Go to Step 2
Is the action complete?
—
Varify repair
—
Is there continuity between the harness side connector
terminal No.C43–3 and No.I20–11?
—
Go to Step 5
Go to Step 4
Is the action complete?
—
Go to Step 3
—
Is there continuity between harness side connector
terminal No.C43–7 and No.I20–5?
—
Go to Step 7
Go to Step 6
—
Go to Step 5
—
—
Go to Step 9
Go to Step 8
Is the action complete?
—
Go to Step 7
—
Is sum of the voltage between the following chassis
harness side connector terminals approximately 5V?
No.I20–15 and No.I20–5, No.I20–5 and No.I20–11
—
Go to Step 11
Go to Step 10
—
Verify repair
—
—
Verify repair
—
Repair or replace the air mix door or the link unit.
Repair an open circuit between terminal No.C43–3 and
No.I20–11.
Repair an open circuit between terminal No.C43–7 and
No.I20–5.
Is there continuity between the harness side connector
terminal No.C43–2 and No.I20–15?
Repair an open circuit between terminal No.C43–2 and
No.I20–15.
Replace the actuator.
Is the action complete?
11
No
—
Is the action complete?
7
Yes
Turn the ignition switch (the engine is run).
Dose the mix actuator fully stroke when 32°C (90°F)
and 18°C (65°F) of the temperature control switch?
2
Value(s)
Replace the auto air conditioner control unit.
Is the action complete?
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–107
Inspection of the Mode Actuator System
D08R200035
Condition
Possible cause
Correction
Does not work at all
—
Refer to Chart A
Control failure
—
Refer to Chart B
1A–108 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Chart A: Does Not Work At All
Step
1
Action
Go to Step 3
Go to Step 2
—
Varify repair
—
—
Go to Step 5
Go to Step 4
—
Varify repair
—
—
Go to Step 7
Go to Step 6
Is the action complete?
—
Go to Step 5
—
Is there continuity between the harness side connector
terminal No.C42–5 and No.I19–3?
—
Go to Step 9
Go to Step 8
—
Verify repair
—
—
Verify repair
—
Replace the auto air conditioner control unit.
Turn on the DEF mode switch.
Is the battery voltage provided on a regular interval
between the chassis side connector terminal
No.C42–5 (+) and No.C42–1 (-)?
4
5
6
7
8
Replace the auto air conditioner control unit.
Is there continuity between the harness side connector
terminal No.C42–1 and No.I19–4?
Repair an open circuit between terminal No.C42–1 and
No.I19–4.
Repair an open circuit between terminal No.C42–5 and
No.I19–3.
Is the action complete?
9
No
—
Is the action complete?
3
Yes
1. Turn on the ignition switch (the engine is run).
2. Disconnect the mode actuator connector (C–42)
3. Select VENT pressing the mode actuator.
Is the battery voltage provided on a regular interval
between the harness side connector terminal
No.C42–1 (+) and No.C42–5 (-)?
2
Value(s)
Replace the mode actuator.
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–109
Chart B: Mode Actuator Control Failure
Step
1
Action
3
4
5
6
7
8
9
10
11
12
No
—
Go to Step 3
Go to Step 2
Is the action complete?
—
Go to Step 1
—
Is there continuity between the harness side connector
terminal No.C42–9 and No.I20–11?
—
Go to Step 5
Go to Step 4
Is the action complete?
—
Go to Step 3
—
Is there continuity between the harness side connector
terminal No.C42–3 and No.I20–10?
—
Go to Step 7
Go to Step 6
Is the action complete?
—
Go to Step 5
—
Is there continuity between harness side connector
terminal No.C42–4 and No.I20–8?
—
Go to Step 9
Go to Step 8
Is the action complete?
—
Go to Step 7
—
Is sum of the voltage between the following harness
side connector terminal approximately 5V? Voltage
between No.I20–8 and No.I20–10 plus voltage
between No.I20–8 and No.I20–11
5V
Go to Step 11
Go to Step 10
Is the action complete?
—
Verify repair
—
Dose the mode actuator work normally through manual
operation?
—
Go to Step 13
Go to Step 12
—
Verify repair
—
—
Verify repair
—
Repair or replace the mode door or the link unit.
Repair an open circuit between terminal No.C42–9 and
No.I20–11.
Repair an open circuit between terminal No.C42–3 and
No.I20–10.
Repair an open circuit between terminal No.C42–4 and
No.I20–8.
Replace the actuator.
Replace the sensor.
Is the action complete?
13
Yes
Turn on the ignition switch (the engine is run).
Dose the mode actuator fully stroke when the defrost
mode and the vent mode are selected?
2
Value(s)
Replace the auto air conditioner control unit.
Is the action complete?
1A–110 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Inspection of the Fan Motor System
D08R200058
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–111
Condition
Possible cause
Correction
The fan dose not rotate at all
—
Refer to Chart A
The fan dose not rotate in the
MAX–HI mode
—
Refer to Chart B
The fan dose not rotate in any mode
other than MAX–HI
—
Refer to Chart C
The fan dose not stop
—
Refer to Chart D
Chart A: Fan Does Not Rotate At All
Step
1
2
3
Action
5
6
7
8
No
—
Go to Step 2
Replace the
fuse
—
Go to Step 3
Replace the
relay
—
Go to Step 5
Go to Step 4
Is the action complete?
—
Go to Step 3
—
Is there continuity between the harness side connector
terminal No.C36–2 and ground (No.C–10)?
—
Go to Step 7
Go to Step 6
Is the action complete?
—
—
—
Is the battery voltage applied between the harness side
connector terminal No.C36–2 and No.C36–1?
—
Go to Step 8
Go to Step 9
—
Verify repair
—
—
Verify repair
—
Are the relay No.X–1 and No.C–35 normal?
Turn on the ignition switch (the engine is run).
Repair an open circuit between terminal No.C36–1 and
No.F–5 and F–6 fuse.
Repair an open circuit between terminal No.C36–2 and
ground.
Replace the blower motor.
Is the action complete?
9
Yes
Are the fuse No.F–5, F–6 and No.F–7 normal?
Is the battery voltage applied between the harness side
connector terminal No.C36–1 and ground?
4
Value(s)
Refer to chart B and C.
Is the action complete?
1A–112 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Chart B: Fan Does Not Rotate in MAX HI Mode
Step
1
2
Action
4
5
6
7
8
9
No
—
Go to Step 2
Replace the
relay
—
Go to Step 4
Go to Step 3
Is the action complete?
—
Go to Step 3
—
Is there continuity between the harness side connector
terminal No.C35–1 and ground (No.C–10)?
—
Go to Step 6
Go to Step 5
Is the action complete?
—
Go to Step 4
—
Is the battery voltage applied between the harness side
connector terminal No.C35–2 and ground?
—
Go to Step 8
Go to Step 7
Is the action complete?
—
Go to Step 6
—
Is the battery voltage applied between the harness side
connector terminal No.I19–2 and ground?
—
Go to Step 10
Go to Step 9
—
Verify repair
—
—
Verify repair
—
1. Turn on the ignition switch (the engine is run).
2. Set the fan switch to the MAX-HI.
Repair an open circuit between terminal No.C36–2 and
No.C35–5.
Repair an open circuit between terminal No.C35–1 and
ground (No.C–10).
Repair an open circuit between terminal No.C35–2 and
No.F–7 fuse.
Repair an open circuit between terminal No.C35–4 and
No.I19–2.
Is the action complete?
10
Yes
Is the MAX-HI relay (C–35) normal?
Is there continuity between the harness side connector
terminal No.C36–2 and No.C35–5?
3
Value(s)
Replace the auto air conditioner control unit.
Is the action complete?
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–113
Chart C: Fan Does Not Rotate In Any Mode Other Than MAX HI
Step
1
2
3
4
5
6
7
Action
Yes
Is the power transistor performance normal? (Refer to
the later section on “individual inspection”)
No
—
Go to Step 2
Replace the
power
transistor
—
Go to Step 4
Go to Step 3
—
Go to Step 2
—
—
Go to Step 6
Go to Step 5
Is the action complete?
—
Go to Step 4
—
Is there continuity between the harness side connector
terminal No.C34–2 and No.I20–19?
—
Go to Step 8
Go to Step 7
—
Go to Step 6
—
—
Verify repair
—
Is there continuity between the harness side connector
terminal No.C36–2 and No.C34–1, No.C36–2 and
No.I20–17?
Repair an open circuit between terminal.
No.C36–2 and C34–1
No.C36–2 and I20–17
Is there continuity between the harness side connector
terminal No.C34–3 and ground (No.C–10)?
Repair an open circuit between terminal No.C34–3 and
ground.
Repair an open circuit between terminal No.C34–2 and
No.I20–19.
Is the action complete?
8
Value(s)
Replace the auto air conditioner control unit.
Is the action complete?
1A–114 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Chart D: Fan Does Not Stop
Step
1
Action
3
4
Go to Step 3
Go to Step 2
Is the action complete?
—
Verify repair
—
Is the max high relay normal? (Refer to the later section
on “individual inspection”.)
—
Go to Step 4
Replace the
relay
—
Go to Step 6
Go to Step 5
—
Go to Step 4
—
—
Go to Step 7
Replace the
power
transistor
—
Replace the
auto A/C
control unit
—
Repair a short circuit between connector No.C36–2
and No.C35–5, No.C36–2 and No.C34–1, or
No.C36–2 and I20–17.
Reinstall the max high relay.
Repair a short circuit between connector No.C35–4
and No.I19–2.
Is the action complete?
6
7
No
—
Does the blower motor start operating?
5
Yes
1. Disconnect the max high relay, the power transistor
connector C–34 and the auto A/C control unit
connector I–20.
2. Turn on the ignition switch.
Does the blower motor stop?
2
Value(s)
Is the power transistor normal? (Refer to the later
section on “individual inspection”.)
Reinstall the power transistor.
Does the blower motor start operating?
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–115
Inspection of the Magnetic Clutch System
6VE1 Engine
D08R200037
1A–116 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Condition
Possible cause
Magnetic clutch does not work
Correction
Refer to Chart A
—
Chart A: Magnetic Clutch Does Not work
Step
1
2
3
4
5
Action
7
8
9
10
11
12
13
14
15
16
Yes
Is the fuse No.F–7 normal?
No
—
Go to Step 2
Replace the
fuse
Is the relay No.X–2 (compressor relay) No.X–8 (A/C
thermo relay) and No.X–1 (heater relay) normal?
—
Go to Step 3
Replace the
relay
Is there continuity between the pressure switch side
connector terminal No.C21–1 and No.C21–2?
—
Go to Step 5
Go to Step 4
Pressure switch defective or refrigerant pressure
improper.
Pressure switch replaced or refrigerant pressure
adjusted?
—
Go to Step 3
—
—
Go to Step 7
Go to Step 6
Magnetic clutch replaced or earth replaced?
—
Go to Step 5
—
Is there continuity between the harness side connector
terminal No.X2–1 and No.E2–1?
—
Go to Step 9
Go to Step 8
Is the action complete?
—
Go to Step 7
—
Is the battery voltage applied between the harness side
connector terminal No.X2–5 and ground, No.X2–2 and
ground?
—
Go to Step 11
Go to Step 10
Is the action complete?
—
Go to Step 9
—
Is the battery voltage applied between the harness side
connector terminal No.I20–18 and ground?
—
Go to Step 13
Go to Step 12
Is the action complete?
—
Go to Step 11
—
Is the battery voltage applied between the harness side
connector terminal No.C21–2 and ground?
—
Go to Step 15
Go to Step 14
Is the action complete?
—
Go to Step 13
—
Is the battery voltage applied between the harness side
connector terminal No.X8–5 and ground, No.X8–2 and
ground?
—
Go to Step 17
Go to Step 16
—
Go to Step 15
—
1. Turn the ignition switch on. (the engine is run.)
2. Turn the air conditioner switch on.
Is the battery voltage applied between the harness side
connector terminal No.E2–1 and the ground?
6
Value(s)
Magnetic clutch defective or earth defective.
Repair an open circuit between terminal No.X2–1 and
No.E2–1.
Repair an open circuit between terminal No.X2–5 and
fuse No.F–7, No.X2–2 and fuse No.F–7.
Repair an open circuit between terminal No.I20–18 and
No.X2–4.
Repair an open circuit between terminal No.C21–2 and
fuse No.F–7.
Repair an open circuit between terminal No.X8–5 and
No.C21–1, No.X8–2 and fuse No.F–7.
Is the action complete?
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–117
Chart A: Magnetic Clutch Does Not work (Cont’d)
Step
Action
Value(s)
17
Is the battery voltage applied between the harness side
connector terminal No.I19–14 and ground?
—
Go to Step 19
Go to Step 18
Is the action complete?
—
Go to Step 17
—
Is there continuity between the harness side connector
terminal No.X8–1 and PCM (F45)?
—
Go to Step 21
Go to Step 20
Is the action complete?
—
Go to Step 19
—
Is there continuity between the harness side connector
terminal No.X2–4 and PCM (F4)?
—
Go to Step 23
Go to Step 22
Is the action complete?
—
Go to Step 21
—
Is there continuity between the harness side connector
terminal No.I20–4 and ground?
—
Go to Step 25
Go to Step 24
—
Go to Step 23
—
—
Replace the
auto air
conditioner
control unit
Replace the
PCM
18
19
20
21
22
23
24
No
Repair an open circuit between terminal No.X8–3 and
I19–14.
Repair an open circuit between terminal No.X8–1 and
PCM (F45).
Repair on open circuit between terminal No.X2–4 and
PCM (F4).
Repair an open circuit between terminal No.I20–4 and
PCM (S47).
Is the action complete?
25
Yes
1. Connect the connector of PCM.
2. Connect the connector terminal No.I19–14 which is
on the harness side on the auto air conditioner
control unit.
Magnetic clutch works?
CAUTION: There are conditions which air
conditioner system dose not operate except trouble
as follows.
1. The throttle is griater than 90%.
2. The ignition voltage is below 10.5 volts.
3. The engine speed greater than 4500 RPM for 5
seconds or 5400 RPM.
4. The engine coolant temperature (ECT) is greater
than 125°C (257°F).
5. The intake air temperature (IAT) is less than 5°C
(41°F).
6. The power steering pressure switch signals a
high pressure condition.
1A–118 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Sun Sensor
Individual Inspection
In Car Sensor
1. Disconnect the in car sensor connector (I–17).
2. Measure resistance between the in car sensor side
terminal No.I17–3 and No.I17–4.
1. Disconnect the sun sensor connector (I–15).
2. Measure the current value on the sun sensor when
placed it approximately 15 cm away from 60W
incandescent lamp.
D06R200001
Ambient Sensor
1. Disconnect the connector (C–19) on the ambient
sensor.
2. Measure resistance between the ambient sensor side
terminals.
C01R200015
C01R200014
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–119
Power Transistor
In Car Sensor
1. Remove the power transistor connector (C–34) from
the evaporator assembly.
2. Check the conduction between the power transistor
side terminals.
1. Turn on the ignition switch (the engine is started).
Start the air conditioner in “Auto”.
2. Make sure that the in car sensor suctions cigarette
smokes and such.
In Car Sensor
1. Dismount the in car sensor from the automatic
heater/air conditioner control unit. Connect (+) end
and (–) end of the battery to the aspirator motor side
terminals No.I17–1 and No.I17–2, respectively, then
check if the motor runs normally.
C01R200006
MAX HI Relay
1. Remove the MAX – HI relay connector (C–35) from
the blower assembly.
2. Check the conduction between the MAX – HI relay
side terminals.
C01R200010
C01R200011
1A–120 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Heater (X–1) And Compressor (X–2) Relay
1. Disconnect relays and check for continuity and
resistance between relay terminals.
B For handling of these relays, refer to Heater Relay
in this section.
Triple Pressure Switch
1. Disconnect the connector and check for continuity
between pressure switch side connector terminals (1)
and (2).
2. Reconnect the connector to activate the A/C switch,
and check to see if there is continuity between the
chassis side connector terminal (3) and (4) and the
fan operates.
C01R200011
Thermostat (X–8) Relay
1. Disconnect relays and check for continuity and
resistance between relay terminals.
B For handling of these relays, refer to Heater Relay
in this section.
C01R200012
875R200020
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–121
On-Vehicle Service
Power Transistor
Automatic Heater/Air
Control Unit
Conditioner
874R200014
Legend
(1) Glove Box
(2) MAX HI Relay
(3) Power Transistor Connector
(4) Power Transistor
Removal
1. Remove the glove box.
2. Remove the MAX–HI relay.
3. Disconnect the power transistor connector.
4. Remove the power transistor.
Installation
To install, follow the removal step in the reverse order.
865R200007
Legend
(1) Display
(2) Audio & Switch Assembly
(3) Automatic Air Conditioner Control Unit
(4) Knee Pad (RH)
(5) Center Cluster
(6) Center Cluster Upper
(7) Knee Pad (LH)
Removal
1. Disconnect the battery ground cable.
2. Remove the knee pad (R/LH).
3. Remove the center cluster upper.
4. Remove the center cluster.
B Refer to Instrument Panel Assembly in Body
Stractur section.
5. Disconnnect the six connectors.
6. Remove the automatic air conditioner control unit.
Installation
To install, follow the removal step in the reverse order.
1A–122 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
In Car Sensor
Ambient Sensor
865R200001
Legend
(1) Meter Cluster
(2) In Car Sensor
Removal
1. Disconnect the battery ground cable.
2. Remove the meter cluster.
B Refer to Instrument Panel Assembly in Body
Structure section.
3. Remove the in car sensor.
875R200018
Legend
(1) Ambient Sensor
(2) Ambient Sensor Connector
(3) Horn (LH)
Removal
1. Disconnect the battery ground cable.
2. Remove the horn (LH).
3. Disconnect the ambient sensor connector.
4. Remove the ambient sensor.
Installation
Installation
To install, follow the removal step in the reverse order.
To install, follow the removal step in the reverse order.
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–123
Sun Sensor
Duct Sensor
865R200002
Legend
(1) Sun Sensor
(2) Center Cluster Upper
Removal
1. Disconnect the battery ground cable.
2. Remove the center cluster upper.
3. Disconnect the sun sensor connector.
4. Remove the sun sensor.
Installation
To install, follow the removal step in the reverse order.
874R200010
Legend
(1) Sensor Part
(2) Evaporator Core
(3) Duct Sensor Assembly
(4) Evaporator Assembly
Removal
1. Disconnect the battery ground cable.
2. Remove the evaporator assembly.
B Refer to evaporator assembly in this section.
3. Remove the duct sensor assembly.
Installation
To install, follow the removal step in the reverse order.
1A–124 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Mode Actuator
Mix Actuator
840R200005
Legend
(1) Driver Knee Bolster Assembly
(2) Instrument Panel Driver Lower Cover
Assembly
(3) Actuator Rod
(4) Mode Actuator
Removal
1. Disconnect the battery ground cable.
2. Remove the instrument panel driver lower cover
assembly.
3. Remove the driver knee bolster assembly.
B Refer to the Instrument Panel Assembly in Body
Structure section.
4. Remove the actuator rod.
5. Remove the mode actuator.
Installation
To install, follow the remove step in the reverse order.
840R200006
Legend
(1) Center Cluster Upper
(2) Center Cluster
(3) Knee Pad (RH)
(4) Actuator Rod
(5) Mix Actuator
(6) Knee Pad (LH)
(7) Audio & Switch Assembly
Removal
1. Disconnect the battery ground cable.
2. Remove the knee pad (R/RH).
3. Remove the center cluster upper.
4. Remove the center cluster.
B Refer to the Instrument Panel Assembly in Body
Structure section.
5. Disconnect the six connectors.
6. Remove the Audio & Switch Assembly.
7. Remove the actuator rod.
8. Remove the mix actuator.
Installation
To install, follow the remove step in the reverse order.
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–125
Intake Actuator
873R200003
Legend
(1) Evaporator Assembly
(2) Intake Actuator
(3) Intake Actuator Connector
Removal
1. Disconnect the battery ground cable.
2. Discharge and recover refrigerant.
B Refer to Refrigerant Recovery in this section.
3. Remove the evaporator assembly.
B Refer to Evaporator Assembly section.
4. Disconnect the intake actuator connector.
5. Remove the intake actuator.
Installation
To install, follow the remove step in the reverse order.
SECTION
POWER–ASSISTED STEERING SYSTEM
2A–1
AXIOM
STEERING
POWER-ASSISTED STEERING SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Description . . . . . . . . . . . . . . . . . . . . .
Power Steering System Test . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bleeding The Power Steering System . . . . . .
Bleeding Procedure . . . . . . . . . . . . . . . . . . . . .
Flushing The Power Steering System . . . . . .
Steering Wheel Free Play Inspection . . . . . .
Front End Alignment Inspection and
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Steering Unit . . . . . . . . . . . . . . . . . . . . .
Power Steering Unit and Associated Parts
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation (4×2 Model) . . . . . . . . . . . . . . . .
Installation (4×4 Model) . . . . . . . . . . . . . . . .
Power Steering Unit Disassembled View . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Steering Pump . . . . . . . . . . . . . . . . . . . .
Power Steering Pump and Associated Parts
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Steering Pump Disassembled View
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications . . . . . . . . . . .
Transfer Gear Assembly . . . . . . . . . . . . . . . . .
Transfer Gear Assembly and Associated
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2A–2
2A–2
2A–8
2A–10
2A–11
2A–11
2A–11
2A–11
2A–11
2A–12
2A–12
2A–16
2A–17
2A–18
2A–18
2A–18
2A–19
2A–19
2A–20
2A–21
2A–21
2A–21
2A–22
2A–22
2A–23
2A–23
2A–23
2A–23
2A–24
2A–24
2A–25
2A–25
2A–27
2A–28
2A–28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supplemental Restraint System Steering
Wheel & Column . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution . . . . . . . . . . . . . . . . . . . .
SRS Connectors . . . . . . . . . . . . . . . . . . . . . .
Inflator Module . . . . . . . . . . . . . . . . . . . . . . . . . .
Inflator Module and Associated Parts . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Wheel and Associated Parts . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Combination Switch . . . . . . . . . . . . . . . . . . . . .
Combination Switch and Associated Parts
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lock Cylinder and Associated Parts . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Inspection . . . . . . . . . . . . . . . . . . . . .
Steering Column . . . . . . . . . . . . . . . . . . . . . . . .
Steering Column and Associated Parts . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Inspection . . . . . . . . . . . . . . . . . . . . .
Supplemental Restraint System Steering
Wheel & Column and Associated Parts . . . .
Main Data and Specifications . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . .
2A–28
2A–28
2A–28
2A–29
2A–29
2A–29
2A–31
2A–31
2A–31
2A–32
2A–32
2A–33
2A–33
2A–33
2A–35
2A–36
2A–36
2A–36
2A–38
2A–40
2A–40
2A–40
2A–42
2A–43
2A–44
2A–44
2A–44
2A–46
2A–48
2A–49
2A–50
2A–50
2A–50
2A–2 POWER–ASSISTED STEERING SYSTEM
Service Precaution
Diagnosis
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.
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.
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 Diagnosis
Condition
Vehicle Pulls
Possible cause
Mismatched or uneven tires.
Replace tire.
Tires not adequately inflated.
Adjust tire pressure.
Broken or sagging springs.
Replace spring.
Radial tire lateral force.
Replace tire.
Improper wheel alignment.
Adjust wheel alignment.
Brake dragging in one wheel.
Repair brake.
Loose, bent or broken front or rear
suspension parts.
Tighten or replace the appropriate
suspension part(s).
Faulty shock absorbers.
Replace shock absorber.
Parts in power
defective.
Abnormal or Excessive Tire Wear
Correction
steering
valve
Replace power steering unit.
Sagging or broken spring.
Replace spring.
Tire out of balance.
Balance or replace tire.
Improper wheel alignment.
Check front end alignment.
Faulty shock absorber.
Replace shock absorber.
Hard driving.
Replace tire.
Overloaded vehicle.
Replace tire and reduce load.
Tires not rotated periodically.
Replace or rotate tire.
Worn or loose road wheel bearings.
Replace wheel bearing.
Wobbly wheel or tires.
Replace wheel or tire.
Tires not adequately inflated.
Adjust the pressure.
POWER–ASSISTED STEERING SYSTEM
Condition
Wheel Hop
Shimmy, Shake or Vibration
Hard Steering
Too Much Play In Steering
Possible cause
Correction
Blister or bump on tire.
Replace tire.
Improper shock absorber operation.
Replace shock absorber.
Tire or wheel out of balance.
Balance wheels or replace tire/or
wheel.
Loose wheel bearings.
Replace wheel bearing.
Worn steering linkage ball joints.
Replace ball joints.
Worn upper or lower end ball joints.
Replace ball joints.
Excessive wheel run–out.
Repair or replace wheel and/or tire.
Blister or bump on tire.
Replace tire.
Excessive loaded radial run–out of
tire/wheel assembly.
Replace tire or wheel.
Improper wheel alignment.
Check wheel alignment.
Loose or worn steering linkage.
Tighten or replace steering linkage.
Loose steering unit.
Tighten steering unit.
Tires not adequately inflated.
Adjust tire pressure.
Loose, bent or broken front or rear
suspension parts.
Tighten or replace the appropriate
suspension parts.
Faulty shock absorber.
Replace shock absorber.
Hub bearing preload misadjustment.
Adjust preload.
Parts in power
defective.
Replace power steering unit.
steering
valve
Bind in steering linkage ball studs,
upper or lower end ball joint.
Replace ball joint.
Improper wheel alignment.
Check wheel alignment.
Tire not adequately inflated.
Inflate tires to proper pressure.
Bind in steering column or shaft.
Repair or replace.
Improper power steering system
operation.
Repair or replace.
Refer to Power steering system
diagnosis
Wheel bearings worn.
Replace wheel bearings.
Loose steering unit or linkage.
Retighten or repair.
Worn or loose
universal joint.
Poor Steering Wheel Returnability
2A–3
steering
shaft
Retighten or replace steering shaft.
Worn steering linkage ball joints.
Replace ball joints.
Worn upper or lower end ball joints.
Replace ball joints.
Bind in steering linkage ball joints.
Replace ball joints.
Bind in upper or lower end ball joints.
Replace ball joints.
Bind in steering column and shaft.
Repair or replace.
Bind in steering gear.
Check and repair steering gear.
Improper wheel alignment.
Adjust wheel alignment.
Tires not adequately inflated.
Adjust tire pressure.
Loose steering wheel nut.
Retighten.
Worn wheel bearing.
Replace.
2A–4 POWER–ASSISTED STEERING SYSTEM
Condition
Abnormal Noise
Possible cause
Correction
Worn, sticky or loose upper or lower
ball joint, steering linkage ball joints
or drive axle joints.
Replace.
Faulty shock absorbers.
Replace.
Worn upper or lower control arm
bushing.
Replace.
Loose stabilizer bar.
Retighten bolts or replace bushings.
Loose wheel nuts.
Tighten nuts. Check for elongated
wheel nut holes.
Replace wheel if required.
Wandering or Poor Steering Stability
Erratic Steering When Braking
Loose suspension bolts or nuts.
Retighten suspension bolts or nuts.
Broken or otherwise damaged wheel
bearings.
Replace wheel bearing.
Broken suspension springs.
Replace spring.
Loose steering unit.
Retighten mounting bolt.
Faulty steering unit.
Replace steering unit.
Mismatched or unevenly worn tires.
Replace tire or inflate tires to proper
pressure.
Loose steering linkage ball joints.
Replace ball joints.
Faulty shock absorbers.
Replace shock absorber.
Loose stabilizer bar.
Tighten or replace stabilizer bar or
bushings.
Broken or sagging springs.
Replace spring (pairs).
Improper wheel alignment.
Adjust wheel alignment.
Worn wheel bearings.
Replace wheel bearings.
Broken or sagging springs.
Replace spring (pairs).
Leaking caliper.
Repair or replace caliper.
Warped discs.
Replace brake disc.
Badly worn brake pads.
Replace brake pads.
Tires are inflated unequally.
Inflate tires to proper pressure.
POWER–ASSISTED STEERING SYSTEM
2A–5
Power Steering System
There is some noise in all power steering systems. One
of the most common is a hissing sound when the steering
wheel is fully turned and the car is not moving. This noise
will be most evident when the steering wheel is operated
while the brakes are applied. There is no relationship
Condition
Rattle or Chucking Noise
Poor Return of Steering Wheel to
Center
between this noise and steering performance. Do not
replace the valve unless the “hissing” noise is extremely
objectionable. A replacement valve will also have a slight
noise, and is not always a cure for the condition.
Possible cause
Correction
Pressure hose touching other parts
of vehicle.
Adjust hose position. Do not bend
tubing by hand.
Tie rod ends loose.
Tighten or replace tie rod end.
Loose steering unit mounting.
Tighten steering unit mounting.
Improper front wheel alignment.
Adjust front wheel alignment.
Wheel bearing worn.
Replace front wheel bearing.
Tie rod end binding.
Replace tie rod end.
Ball joint binding.
Replace ball joint.
Tight or
bearing.
frozen
steering
shaft
Replace steering assembly.
Sticky or plugged steering unit valve.
Flush or replace steering unit.
Entry of air in the power steering
system.
Bleed the system.
Momentary Increase In Effort When
Turning Wheel Fast To Right or Left
High internal leakage.
Repair steering gear.
Power steering fluid level low.
Replenish fluid.
Steering Wheel Surges or Jerks
When Turning Especially During
Parking
Insufficient pump pressure.
Repair pump assembly.
Sticky steering unit valve.
Flush or replace steering unit.
Power steering fluid level low.
Replenish fluid.
Air in system.
Bleed hydraulic system.
Tie rod end loose.
Tighten tie rod end.
Wheel bearing worn.
Replace wheel bearing.
Sticky steering unit valve.
Flush or replace steering unit.
Insufficient pump pressure.
Repair pump assembly.
Excessive internal pump leakage.
Repair pump assembly.
Excessive internal steering gear
leakage.
Repair steering gear.
Power steering fluid level low.
Replenish fluid.
Pressure switch of the power
steering pump or its harness is faulty.
Repair or replace.
Excessive Wheel Kick Back or Loose
Steering
Hard Steering or Lack or Power
Assist
Unstable Engine Idling or Stalling
When Turning
2A–6 POWER–ASSISTED STEERING SYSTEM
Power Steering Pump
Foaming milky power steering fluid, low fluid level, and
possible low pressure can be caused by air in the fluid, or
loss of fluid due to internal pump leakage. Check for leak
and correct.
Bleed the system. Extremely cold
temperatures will cause air bubbles in the system if the
fluid level is low. If the fluid level is correct and the pump
still foams, remove the pump from the vehicle and check
housing for cracks. If the housing is cracked, replace the
pump housing.
Condition
Possible cause
Low Pressure Due to Steering Pump
Relief valve sticking or inoperative.
Replace relief valve.
Side plate not flat against cam ring.
Replace side plate.
Extreme wear of cam ring.
Replace cam ring.
Scored side plate or rotor.
Replace side plate or rotor.
Vanes sticking in rotor slots.
Repair or replace vanes and rotor.
Cracked or broken side plate.
Replace side plate.
High internal leakage.
Repair internal leakage.
Low Pressure Due to Steering Gear
Scored housing bore.
Replace housing.
Growling Noise In Steering Pump
Excessive back pressure in hoses or
steering unit caused by restriction.
Repair steering unit or pump.
Scored side plate or rotor.
Replace side plate or rotor.
Worn cam ring.
Replace cam ring.
Air in the fluid.
Bleed hydraulic system.
Low fluid level.
Replenish fluid.
Pump mounting loose.
Tighten mounting bolt.
Vanes sticking in rotor slots.
Repair or replace vanes and rotor.
Vane improperly installed.
Repair rotor and vane.
Swishing Noise In Steering Pump
Damaged relief valve.
Replace relief valve.
Whining Noise In Steering Pump
Scored side plate and vanes.
Replace side plate and vanes.
Groaning Noise In Steering Pump
Rattling Noise In Steering Pump
Correction
Steering Column Lock System
Condition
Possible cause
Will Not Unlock
Will Not Lock
Key Cannot
“OFF LOCK”
“OFF-LOCK”
be
Removed
in
Correction
Damaged lock cylinder.
Replace lock cylinder.
Damaged park lock cable.
Replace park lock cable.
Lock spring broken or worn.
Replace lock cylinder.
Damaged lock cylinder.
Replace lock cylinder.
Ignition switch stuck.
Repair or replace ignition switch.
Park lock cable damaged.
Replace park lock cable.
Ignition switch is not set correctly.
Correct ignition switch.
Damaged lock cylinder.
Replace lock cylinder.
Faulty shift lock mechanism.
Repair or replace the shift lock
mechanism.
Column
Condition
Noise in Column
Possible cause
Correction
Universal joint loose.
Tighten joint.
Shaft lock snap ring not seated.
Place snap ring in proper position.
POWER–ASSISTED STEERING SYSTEM
2A–7
Turn Signal Switch
This diagnosis covers mechanical problems only. Refer
to Turn Signal Switch in Electrical section for electrical
diagnosis.
Condition
Possible cause
Turn Signal Will Not Stay In Turn
Position
Foreign material or loose parts
preventing movement of yoke.
Repair or replace signal switch.
Broken or missing
canceling spring.
Replace signal switch.
Turn Signal Will Not Cancel
detent
Correction
or
Loose switch mounting screws.
Tighten mounting screws.
Switch or anchor bosses broken.
Replace turn signal switch.
Broken, missing or out of position
detent, return or canceling spring.
Replace turn signal switch.
Worn canceling cam.
Replace turn signal switch.
Turn signal switch arm loose.
Tighten arm screw.
Broken or distorted yoke.
Replace turn signal switch.
Loose or misplaced springs.
Replace turn signal switch.
Foreign parts and/or material.
Repair turn signal switch.
Loose turn signal switch mounting
screws.
Tighten mounting screws.
Broken lane change pressure pad or
spring hanger.
Replace turn signal switch.
Broken, missing or misplaced lane
change spring.
Replace turn signal switch.
Base of wire damaged.
Replace turn signal switch.
Hazard Switch Cannot Be Turned Off
Foreign material between hazard
switch to turn signal switch body.
Repair or replace hazard switch.
No Turn Signal Lights
Electrical failure in chassis harness.
Refer to Electrical section.
Inoperative turn signal flasher unit.
Replace flasher unit.
Loose chassis harness connector.
Repair loose connector.
Burned-out or damaged turn signal
bulb.
Replace bulb.
High resistance connection
ground at bulb socket.
Repair bulb socket.
Turn Signal Difficult To Operate
Turn Signal Will Not Indicate Lane
Change
Front or Rear Turn Signal Lights Not
Flashing
Loose chassis harness connector.
to
Repair loose connector.
2A–8 POWER–ASSISTED STEERING SYSTEM
General Description
The hydraulic power steering system consists of a pump,
an oil reservoir, a steering unit, a pressure hose and a
return hose.
Power Steering Unit
A02RW001
The power steering unit is rack and pinion type.
The toe–in angle can be adjusted by turning the rod on
each side.
The steering housing cannot be disassembled.
Hydraulic Pump
A02RX002
POWER–ASSISTED STEERING SYSTEM
The hydraulic pump is vane-type design. The submerged
pump has housing and internal parts that are inside the
reservoir and operate submerged in oil. There are two
bore openings at the rear of the pump housing. The larger
opening contains the cam ring, pressure plate, thrust
plate, rotor and vane assembly, and end plate. The
smaller opening contains the pressure line union, flow
control valve and spring.
The flow control orifice is part of the pressure line union.
The pressure relief valve inside the flow control valve
limits the pump pressure.
2A–9
Pressure Switch
When hydraulic pressure reaches 3430 kPa (500 psi), the
pressure switch of the power steering pump closes
causing the Powertrain Control Module (PCM) to actuate
the throttle valve, which increases the engine rpm to
prevent the overload-induced engine speed slow down.
The switch opens when hydraulic pressure drops to 2940
kPa (430 psi).
Steering Column
431RY00009
WARNING: TO AVOID DEPLOYMENT WHEN
TROUBLE-SHOOTING THE SRS SYSTEM, DO NOT
USE ELECTRICAL TEST EQUIPMENT, SUCH AS
BATTERY-POWERED
OR
A/C-POWERED
VOLT-METER, OHMMETER, ETC., OR ANY TYPE OF
ELECTRICAL
EQUIPMENT
OTHER
THAN
SPECIFIED IN THIS MANUAL. DO NOT USE A
NON-POWERED PROBE-TYPE TESTER.
INSTRUCTION IN THIS MANUAL MUST BE
FOLLOWED CAREFULLY, OTHERWISE PERSONAL
INJURY MAY RESULT.
When servicing a vehicle equipped with Supplemental
Restraint System, pay close attention to all WARNINGS
and CAUTIONS.
For detailed explanation about SRS, refer to Restraints
section.
2A–10 POWER–ASSISTED STEERING SYSTEM
The steering column has three important features in
addition to the steering function:
1. The column is energy absorbing, designed to
compress in a front-end collision to minimize the
possibility of injury to the driver of the vehicle.
2. The ignition switch and lock are mounted
conveniently on the column.
3. With the column mounted lock, the ignition and
steering operation can be locked to prevent theft of
the vehicle.
The column can be disassembled and reassembled.
However, to insure the energy absorbing action, use only
the specified screws, bolts and nuts as designated, and
tighten them to the specified torque.
Handle the column with care when it is removed from the
vehicle. A sharp blow on the end of steering shaft or shift
lever, or dropping the assembly could shear or loosen the
fasteners that maintain column rigidity.
Power Steering System Test
Test Procedure
C02RW001
Legend
(1) Fluid Reservoir
Test of fluid pressure in the power steering system is
performed to determine whether or not the oil pump and
power steering unit are functioning normally.
The power steering system test is used to identify and
isolate hydraulic circuit difficulties. Prior to performing
this test, the following inspections and corrections, if
necessary, must be made.
B Inspect pump reservoir for proper fluid level.
B Inspect pump belt for proper tension.
B Inspect pump driver pulley condition.
(2) Power Steering Unit
(3) Power Steering Pump
1. Place a container under the pump to catch the fluid
when disconnecting or connecting the hoses.
2. With the engine NOT running, disconnect the
pressure hose at the power steering pump and install
power steering tester J-29877-A. The gage must be
between the shutoff valve and pump. Open the
shutoff valve.
3. Check the fluid level. Fill the reservoir with power
steering fluid, to the “Full” mark. Start the engine,
then turn the steering wheel and momentarily hold it
against a stop (right or left). Turn the engine off and
check the connections at tester for leakage.
POWER–ASSISTED STEERING SYSTEM
4. Bleed the system. Refer to Bleeding the Power
Steering System in this section.
5. Start the engine and check the fluid level. Add power
steering fluid if required. When the engine is at
normal operating temperature, increase engine
speed to 1500 rpm.
CAUTION: Do not leave shutoff valve fully closed
for more than 5 seconds, as the pump could become
damaged internally.
6. Fully close the shutoff valve. Record the highest
pressures.
B If the pressure recorded is within 9300–9800 kPa
(1350–1420 psi), the pump is functioning within its
specifications.
B If the pressure recorded is higher than 9800 kPa
(1420 psi), the valve in the pump is defective.
B If the pressure recorded is lower than 9300 kPa
(1350 psi), the valve or the rotating group in the
pump is defective.
7. If the pump pressures are within specifications, leave
the valve open and turn (or have someone else turn)
the steering wheel fully in both directions. Record the
highest pressures and compare with the maximum
pump pressure recorded in step 6. If this pressure
cannot be built in either side of the power steering
unit, the power steering unit is leaking internally and
must be replaced.
8. Shut the engine off, remove the testing gauge.
9. Reconnect the pressure hose, check the fluid level
and make the needed repairs.
10. If the problem still exists, the steering and front
suspension must be thoroughly examined.
Maintenance
The hydraulic system should be kept clean and fluid level
in the reservoir should be checked at regular intervals and
fluid added when required. Refer to Recommended
Fluids and Lubricants in General Information section for
the type of fluid to be used and the intervals for filling.
If the system contains some dirt, flush it as described in
this section. If it is exceptionally dirty, the pump must be
completely disassembled before further usage. (The
steering unit cannot be disassembled.)
All tubes, hoses, and fittings should be inspected for
leakage at regular intervals. Fittings must be tight. Make
sure the clips, clamps and supporting tubes and hoses
are in place and properly secured.
Power steering hoses and lines must not be twisted,
kinked or tightly bent. Air in the system will cause spongy
action and noisy operation. When a hose is disconnected
or when fluid is lost, for any reason, the system must be
bled after refilling. Refer to Bleeding the Power Steering
System in this section.
B Inspect belt for tightness.
B Inspect pulley for looseness or damage. The pulley
should not wobble with the engine running.
B Inspect hoses so they are not touching any other
parts of the vehicle.
B Inspect fluid level and fill to the proper level.
2A–11
Fluid Level
1. Run the engine until the power steering fluid reaches
normal operating temperature, about 55°C (130°F),
then shut the engine off.
2. Check the level of fluid in the reservoir.
3. If the fluid level is low, add power steering fluid as
specified in General Information to the proper level
and install the receiver cap.
4. When checking the fluid level after the steering
system has been serviced, air must be bled from the
system. Refer to Bleeding the Power Steering
System in this section.
Bleeding The Power Steering System
When a power steering pump or unit has been installed,
or an oil line has been disconnected, the air that has
entered the system must be bled out before the vehicle is
operated. If air is allowed to remain in the power steering
fluid system, noisy and unsatisfactory operation of the
system may result.
Bleeding Procedure
When bleeding the system, and any time fluid is added to
the power steering system, be sure to use only power
steering fluid as specified in General Information.
1. Fill the pump fluid reservoir to the proper level and let
the fluid settle for at least two minutes.
2. Start the engine and let it run for a few seconds. Do
not turn the steering wheel. Then turn the engine off.
3. Add fluid if necessary.
4. Repeat the above procedure until the fluid level
remains constant after running the engine.
5. Raise and support the front end of the vehicle so that
the wheels are off the ground.
6. Start the engine. Slowly turn the steering wheel right
and left, lightly contacting the wheel stops.
7. Add power steering fluid if necessary.
8. Lower the vehicle, set the steering wheel at the
straight forward position after turning it to its full steer
positions 2 or 3 times, and stop the engine.
9. Check the fluid level and refill as required.
10. If the fluid is extremely foamy, allow the vehicle to set
a few minutes, then repeat the above procedure.
Flushing The Power Steering System
1. Raise and support the front end of the vehicle off the
ground until the wheels are free to turn.
2. Remove the fluid return line at the pump inlet
connector and plug the connector port on the pump.
Position the line toward a large container to catch the
draining fluid.
3. While running the engine at idle, fill the reservoir with
new power steering fluid. Turn the steering wheel in
both directions. Do not contact or hold the steering
wheel to the wheel stops. This will cause the pump to
go to pressure relief mode, which may cause a
sudden fluid overflow at the reservoir.
2A–12 POWER–ASSISTED STEERING SYSTEM
4. Install all the lines and hoses. Fill the system with new
power steering fluid and bleed the system as
described in Bleeding The Power Steering System.
Operate the engine for about 15 minutes.
Remove the pump return line at the pump inlet and
plug the connection on the pump. While refilling the
reservoir, check the draining fluid for contamination.
If foreign material is still evident, replace all lines,
disassemble and clean or replace the power steering
system components. Do not re-use any drained
power steering fluid.
Camber:
This illustration shows view from the front of the vehicle.
Steering Wheel Free Play Inspection
480RS004
430R200001
1. With the tires in the straight-ahead position, check the
amount of steering wheel play by turning the wheel in
both directions until the tires begin to move.
Camber is the vertical tilting inward or outward of the front
wheels. When the wheels tilt outward at the top, the
camber is positive (+). When the wheels tilt inward at the
top, the camber is negative (-). The amount of tilt
measured in degrees from the vertical is called the
camber angle (1). If camber is extreme or unequal
between the wheels, improper steering and excessive tire
wear will result. Negative camber causes wear on the
inside of the tire, while positive camber causes wear to the
outside.
Caster:
This illustration shows view from the side of the vehicle.
NOTE: The wheel free play should be checked with the
engine running.
Free play: 0 – 30 mm (0 – 1.18 in)
2. Also check the steering wheel for play and looseness
in the mount by moving it back and forth and
sideways. When test driving, check for hard steering,
steering shimmy and tendency to pull to one side.
Front End Alignment Inspection and
Adjustment
General Description
“Front End Alignment” refers to the angular relationship
between the front wheels, the front suspension attaching
parts and the ground.
Proper front end alignment must be maintained in order to
insure efficient steering, good directional stability and to
prevent abnormal tire wear.
The most important factors of front end alignment are
wheel toe-in, wheel camber and axle caster.
480RS005
POWER–ASSISTED STEERING SYSTEM
Caster (1) is the vertical tilting of the wheel axis either
forward or backward (when viewed from the side of the
vehicle). A backward tilt is positive (+) and a forward tilt is
negative (-). On the short and long arm type suspension
you cannot see a caster angle without a special
instrument, but if you look straight down from the top of
the upper control arm to the ground, the ball joints do not
line up (fore and aft) when a caster angle other than 0
degree is present. With a positive angle, the lower ball
joint would be slightly ahead (toward the front of the
vehicle) of the upper ball joint center line.
Toe-in:
This illustration shows view from the top of the vehicle.
2A–13
6. Inspect the wheel and tires for run-out. Refer to
Wheel Replacement in Wheel and Tire System
section.
7. Inspect the trim height. If not within specifications, the
correction must be made before adjusting caster.
8. Inspect the steering unit for looseness at the frame.
9. Inspect shock absorbers for leaks or any noticeable
noise. Refer to Shock Absorber in Suspension
section.
10. Inspect the control arms or stabilizer bar attachment
for looseness. Refer to Suspension section.
11. Inspect the front end alignment using alignment
equipment. Follow the manufacturer’s instructions.
12. Park the vehicle on a level surface.
Trim Height Adjustment
Adjust the trim height (1) by means of the adjusting bolt on
the height control arms.
CAUTION: When adjusting front end alignment, be
sure to begin with trim height first, as it may change
other adjusted alignments.
480RS003
Toe-in is the measured amount the front wheels are
turned in. The actual amount of toe-in is normally a
fraction of a degree. Toe-in is measured from the center
of the tire treads or from the inside of the tires. The
purpose of toe-in is to insure parallel rolling of the front
wheels and to offset any small deflections of the wheel
support system which occurs when the vehicle is rolling
forward. Incorrect toe-in results in excessive toe-in and
unstable steering. Toe-in is the last alignment to be set in
the front end alignment procedure.
450RS003
Inspection
Before making any adjustments affecting caster, camber
or toe-in, the following front end inspection should be
made.
1. Inspect the tires for proper inflation pressure. Refer to
Main Data and Specifications in Wheel and Tire
System section.
2. Make sure that the vehicle is unladen condition (With
no passenger or loading).
3. Make sure that the spare tire is installed at the normal
position.
4. Inspect the front wheel bearings for proper
adjustment. Refer to Front Hub and Disc Overhaul in
Suspension section.
5. Inspect the ball joints and tie rod ends. If excessive
looseness is noted, correct before adjusting. Refer to
Steering Linkage in this section.
410RS001
2A–14 POWER–ASSISTED STEERING SYSTEM
1. Check and adjust the tire inflation pressures.
2. Park the vehicle on a level ground and move the front
of the vehicle up and down several times to settle the
suspension.
3. Make necessary adjustment with the adjusting bolt on
the height control arms.
Trim height: 119 ± 5 mm (4.69 ± 0.2 in)
NOTE: Difference of the caster shim front/rear thickness
should be 3.6 mm (0.142 in) or less. Overall thickness of
caster shim and camber shim should be 10.8 mm
(0.425 in) or less.
Tighten the fulcrum pin bolt to the specified torque.
Torque: 152 N·m 112 ( lb ft)
Camber Adjustment
Caster Adjustment
The caster angle can be adjusted by means of the caster
shims (1) installed between the chassis frame (2) and
fulcrum pins.
Caster angle: 2°30’ ± 1°
The camber angle can be adjusted by means of the
camber shims (2) installed in position between the
chassis frame (1) and fulcrum pins
Camber angle: 0° ± 30’
King pin inclination: 12°30’ ± 30’
CAUTION: Left and right side must be equal within
30’.
CAUTION: Left and right side must be equal within
30’.
450RW007
450RW006
450RS005
450RS002
POWER–ASSISTED STEERING SYSTEM
2A–15
NOTE: Overall thickness of caster shim and camber
shim should be 10.8 mm (0.425 in) or less.
Tighten the fulcrum pin bolt to the specified torque.
Torque: 152 N·m (112 lb ft)
Position of shims
Caster shim
Camber angle
Caster angle
When removed
Decreases
Decreases
When removed
When added
Increases
Increases
—
When removed
Unchanged
Decreases
—
When added
Unchanged
Increases
When added
Decreases
Unchanged
When removed
Increases
Unchanged
Front side
Rear side
When added
Camber shim
Toe-in Adjustment
1. To adjust the toe-in angle, loosen the lock nuts (2) on
the tie rod (1) and turn the tie rod. Turn both rods the
same amount, to keep the steering wheel centered .
Toe-in: 0 to +2 mm (0 to +0.08 in)
433RW003
2. Tighten the lock nut to the specified torque.
Torque: 98 N·m (72 lb ft)
2A–16 POWER–ASSISTED STEERING SYSTEM
Main Data and Specifications
General Specification
2°30’ ± 1°
Caster
0° ± 30’
Camber
12°30’ ± 30’
King pin inclination
Toe-in
Max. steering angle
0 to +2 mm (0 to +0.08 in)
inside
outside
32.6° (+0°30’ to –2°30’ )
31.8°
Torque Specification
E02RX001
POWER–ASSISTED STEERING SYSTEM
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
J–29877–A
Tester;
Power steering
J–39213
Adapter;
Power steering tester
2A–17
2A–18 POWER–ASSISTED STEERING SYSTEM
Power Steering Unit
Power Steering Unit and Associated Parts
440R100001
Legend
(1) Bracket
(2) Transfer Gear Assembly
(3) Universal Joint Assembly
(4) Power Steering Unit Assembly
(5) Crossmember
Removal
1. Remove the stone guard.
2. Remove the transfer gear assembly and universal
joint assembly.
Make a setting mark across the coupling flange and
transfer gear assembly to ensure reassembly of the
parts in the original position.
3. Drain power steering fluid.
4. Remove the tie rod end assembly from knuckle.
Use tie rod end remover J–29107.
433RW002
2A–19
POWER–ASSISTED STEERING SYSTEM
5. Disconnect the feed line and return line from steering
unit.
Remove the clips on the crossmember and frame.
Wire the power steering line to frame.
NOTE: Take care to prevent foreign matter from entry
when disconnect the power steering line.
6. Remove the power steering unit.
4×2 model:
1. Remove the
crossmember.
power
steering
unit
from
the
Installation (4×2 Model)
1. Install power steering unit to crossmember.
Tighten fixing bolt to specified torque.
Torque: 116 N·m (85 lb ft)
2. Connect the feed line and return line.
Torque: 25 N·m (18 lb ft)
3. Install tie–rod end assembly to knuckle.
Torque: 118 N·m (87 lb ft)
4.
a. Align the setting marks made at removal.
Install the universal joint assembly to the transfer
gear assembly.
Temporary tighten the universal joint bolt.
b. Install the universal joint assembly to the power
steering unit assembly.
Temporary tighten the universal joint bolt.
435RW001
4×4 model:
1. Remove the torsion bar. Refer to Front Suspension in
Suspension section.
2. Remove the lower control arm bolt (Frame side).
Refer to Front Suspension in Suspension section.
3. Apply a setting mark across the crossmember and
frame so parts can be reassembled in their original
position.
c. Install the transfer gear assembly with the shim to
frame.
Torque: 54 N·m (40 lb ft)
d. Tighten the universal joint bolt to the specified
torque.
Torque: 31 N·m (23 lb ft)
5. Install the stone guard.
6. Bleed the system.
Refer to Bleeding the Power Steering System in this
section.
Installation (4×4 Model)
1. Install power steering unit to crossmember.
Tighten fixing bolt to specified torque.
Torque: 116 N·m (85 lb ft)
2. Install power steering unit with crossmember to frame
by aligning the setting marks made when removing.
Tighten crossmember mounting bolt to specified
torque.
Torque: 173 N·m (128 lb ft)
3. Install lower control arm bolt.
Refer to Front Suspension in Suspension section.
4. Install torsion bar.
Refer to Front Suspension in Suspension section.
431RX013
4. Remove the crossmember fixing bolt.
5. Remove the power steering unit
crossmember.
with
the
5. Connect the feed line and return line.
Torque: 25 N·m (18 lb ft)
6. Install tie–rod end assembly to knuckle.
Torque: 118 N·m (87 lb ft)
2A–20 POWER–ASSISTED STEERING SYSTEM
7.
a. Align the setting marks made at removal.
Install the universal joint assembly to the transfer
gear assembly.
Temporary tighten the universal joint bolt.
8. Install the stone guard.
9. Bleed the system.
Refer to Bleeding the Power Steering System in this
section.
b. Install the universal joint assembly to the power
steering unit assembly.
Temporary tighten the universal joint bolt.
c. Install the transfer gear assembly with the shim to
frame.
Torque: 54 N·m (40 lb ft)
d. Tighten the universal joint bolt to the specified
torque.
Torque: 31 N·m (23 lb ft)
Power Steering Unit Disassembled View
440R100002
Legend
(1) Tie-rod End
(2) Lock Nut
(3) Clip
(4) Bellows
(5) Band
(6)
(7)
(8)
(9)
(10)
(11)
Tie-rod Assembly
Tab Washer
Oil Line
Valve Housing Assembly
Mounting Rubber
Dust Cover
POWER–ASSISTED STEERING SYSTEM
Disassembly
2A–21
Reassembly
NOTE: The valve housing is made of aluminum and care
should be exercised when clamping in a vise, etc. to
prevent distortion or damage.
1. Install mounting rubber and dust cover (If removed).
2. Install oil line.
1. Loosen lock nut and remove tie–rod end.
2. Remove clip (3) and band (5), then remove bellows
(4).
3. Remove tie-rod assembly.
To remove, move the boot toward the tie-rod end,
then remove tab washer.
3. Install tie-rod assembly with tab washer.
Apply grease to ball joint, install tie-rod and tab
washer, then tighten to specified torque.
4. Remove oil line, mounting rubber and dust cover.
Inspection and Repair
Inspect the following parts for wear, damage or any
abnormal conditions.
Tie-rod End
If looseness or play is found when checked by moving the
end of ball joint at tie-rod end, replace tie-rod end.
Tie-rod Assembly
If the resistance is insufficient or play is felt when checked
by moving the ball on the tie-rod, replace the tie-rod
assembly.
Rubber Parts
If wear or damage is found through inspection, replace
with new ones.
Torque: 13 N· m (113 lb in)
Torque: 83 N·m (61 lb ft)
After tightening, bend tab washer against width
across flat of inner ball joint.
4. Apply a thin coat of grease to the shaft for smooth
installation. Then install bellows.
5. Install band and clip.
6. Install tie-rod end and tighten lock nut.
Torque: 98 N·m (72 lb ft)
2A–22 POWER–ASSISTED STEERING SYSTEM
Main Data and Specifications
General Specifications
Power Steering unit
Type
Rack and pinion
Rack stroke
152 mm (5.98 in)
Lock to lock
3.64
Torque Specifications
440R100003
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
J–29107
Tie rod end remover
POWER–ASSISTED STEERING SYSTEM
2A–23
Power Steering Pump
Power Steering Pump and Associated Parts
436RX001
Legend
(1) Pump Assembly
(2) Hose, Suction
Removal
1. Remove the drive belt.
2. Place a drain pan below the pump.
3. Disconnect the suction hose.
4. Disconnect the flexible hose.
5. Remove the power steering fixing bolt and remove
the pump assembly.
(3) Hose, Flexible
(4) Bolt
Installation
1. Install the pump assembly to the pump braket, tighten
the fixing bolt to the specified torque.
Torque: 46 N·m (34 lb ft)
2. Install the flexible hose.
Tighten the eye bolt to specified torque.
Torque: 54 N·m (40 lb ft)
3. Install the drive belt.
4. Connect the suction hose, then fill and bleed system.
Refer to Bleeding the Power Steering System in this
section.
2A–24 POWER–ASSISTED STEERING SYSTEM
Power Steering Pump Disassembled View
442RX001
Legend
(1) Bolt
(2) Suction Pipe
(3) O-ring
(4) Shaft Assembly
(5) Oil Seal
(6) Front Housing
(7) O-ring
(8) O-ring
(9) Side Plate
(10) Rotor and Vane
(11) Pin
Disassembly
1. Clean the oil pump with solvent (plug the discharge
and suction ports to prevent the entry of solvent).
Be careful not to expose the oil seal of shaft assembly
to solvent.
2. Remove the bolt, suction pipe and O-ring.
3. Remove the connector, O-ring, relief valve and
spring.
4. Remove the pressure switch assembly.
5. Remove the bolt, rear housing and O-ring.
6. Remove the snap ring.
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
Cam
Pump Cartridge Assembly
O-ring
Snap Ring
Rear Housing
Bolt
Spring
Relief Valve
O-ring
Connector
Pressure Switch Assembly
7. Remove the shaft assembly.
8. Remove the oil seal.
CAUTION: When removing the oil seal, be careful
not to damage the housing.
9. Remove the pump cartridge assembly from the front
housing.
10. Remove two O-rings.
POWER–ASSISTED STEERING SYSTEM
Inspection and Repair
Make all necessary adjustments, repairs, and part
replacements if wear, damage, or other problems are
discovered during inspection.
Rotor
2A–25
Sliding faces of the vane should be free from wear.
(Particularly the curved face at the tip that contact with the
cam should be free from wear and distortion). When part
replacement becomes necessary, the pump cartridge
should be replaced as a subassembly.
Cam
The inner face of the arm should have a uniform contact
pattern without a sign of step wear. When part
replacement becomes necessary, the pump cartridge
should be replaced as a subassembly.
Side Plate
The sliding faces of parts must be free from step wear
(more than 0.01 mm), which can be felt by the finger nail.
The parts with minor scores may be reused after lapping
the face.
Relief Valve
The sliding face of the valve must be free from burrs and
damage. The parts with minor scores may be reused after
smoothing with emery cloth (#800 or finer).
Shaft
442RS002
Check that the groove in the vane is free from excessive
wear and that the vane slides smoothly. When part
replacement becomes necessary, the pump cartridge
should be replaced as a subassembly.
Vane
Oil seal sliding faces must be free from a step wear which
can be felt by the finger nail. Bushing fitting face must be
free from damage and wear.
O-ring, Oil Seal, Snap Ring
Be sure to discard used parts, and always use new parts
for installation. Prior to installation, lubricate all seals and
rings with power steering fluid.
Pressure Switch
Check the switch operation as follows:
With engine idling and A/C on, turn the steering wheel
fully to the left; compressor should interrupt and engine
idle speed will increase. Shut off A/C and again turn
steering fully to the left; engine idle will increase. If system
fails to function properly, disconnect connector at the
pressure switch and repeat system check while testing
continuity across disconnected SW connector.
Reassembly
1. Install oil seal to front housing. Be sure to discard
used oil seal, and always use new parts for
installation.
442RS003
CAUTION: When installing the oil seal, be careful
not to damage the oil seal contacting surface of the
housing.
2. Install shaft assembly.
2A–26 POWER–ASSISTED STEERING SYSTEM
3. Install the vanes to roter with curved face in contact
with the inner wall of cam.
442RS005
4. Install rotor and vanes to cam.
5. Install pin to front housing.
6. Install two new O-rings to front housing. Be sure to
discard used O-ring.
7. Install side plate.
CAUTION: When installing side plate, be careful not
to damage its inner surface. Damaged side plate may
cause poor pump performance, pump seizure or oil
leakage.
8. Install pump cartridge assembly to front housing.
9. Install snap ring to shaft end.
10. Install rear housing with a new O-ring. Be sure to
discard used O-ring. Then install bolt and tighten it to
specified torque.
Torque: 24 N·m (17 lb ft)
11. Install suction pipe with a new O-ring. Be sure to
discard used O-ring. Then install bolt and tighten it to
specified torque.
Torque: 10 N·m (87 lb in)
12. Install relief valve and spring.
13. Install connector with a new O-ring. Be sure to
discard used O-ring. Tighten the connector to
specified torque.
Torque: 59 N·m (43 lb ft)
14. Install pressure switch assembly and tighten it to
specified torque.
Torque: 18 N·m (13 lb ft)
POWER–ASSISTED STEERING SYSTEM
2A–27
Main Data and Specifications
General Specifications
Oil pump
Type
Operating
fluid
Vane
ATF DEXRON–III
Torque Specifications
E02RX004
2A–28 POWER–ASSISTED STEERING SYSTEM
Transfer Gear Assembly
Transfer Gear Assembly and Associated Parts
441R200001
Legend
(1) Transfer Gear Assembly
(2) Bolt, Universal Joint (Steering Shaft Side)
(3) Fixing Bolt Nut
Removal
1. Apply a setting mark across the universal joint
(steering shaft side) and transfer gear assembly to
reassemble the parts in their original position.
2. Remove universal joint bolt (steering shaft side).
3. Apply a setting mark across the universal joint
assembly and the transfer gear assembly to
reassemble the parts in their original position.
4. Remove universal joint bolts (both of transfer gear
assembly side and power steering unit assembly
side).
5. Loosen fixing bolts and nut and remove transfer gear
assembly with shim.
(4) Shim
(5) Universal Joint Assembly
(6) Bolt, Universal Joint (Steering Unit Side)
Installation
1. Install the transfer gear assembly to the universal
joint (steering shaft side) align the setting marks
made at removal.
Then tighten the universal joint bolt.
2. Install the universal joint assembly to the power
steering unit assembly align the setting marks made
at removal.
Then temporary tighten the universal joint bolt (both
of transfer gear assembly side and power steering
unit assembly side).
3. Install the transfer gear assembly with the shim to
frame.
Torque: 54 N·m (40 lb ft)
Inspection and Repair
The transfer gear assembly cannot be disassembled. If
damage or abnormal condition are found, replace the
entire transfer gear assembly.
4. Tighten the universal joint bolts to the specified
torque.
Torque: 31 N·m (23 lb ft)
POWER–ASSISTED STEERING SYSTEM
2A–29
Supplemental Restraint System Steering Wheel & Column
Service Precaution
This steering wheel and column repair section covers the
Supplemental Restraint System (SRS) steering column.
The following repair procedures are specific to SRS
components. When servicing a vehicle equipped with
Supplemental Restraint System, pay close attention to all
WARNINGS and CAUTIONS.
For detailed explanation about SRS, refer to Restraints
section.
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING, REFER TO
THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
SAFE HANDLING OF INFLATOR MODULES
REQUIRES FOLLOWING THE PROCEDURES
DESCRIBED BELOW FOR BOTH LIVE AND
DEPLOYED MODULES.
SAFETY PRECAUTIONS MUST BE FOLLOWED
WHEN HANDLING A DEPLOYED AIR BAG
ASSEMBLY (AIR BAG). AFTER DEPLOYMENT, THE
AIR BAG ASSEMBLY (AIR BAG) SURFACE MAY
CONTAIN A SMALL AMOUNT OF SODIUM
HYDROXIDE,
A
BY-PRODUCT
OF
THE
DEPLOYMENT REACTION, THAT IS IRRITATING TO
THE SKIN AND EYES. MOST OF THE POWDER ON
THE AIR BAG ASSEMBLY (AIR BAG) IS HARMLESS.
AS A PRECAUTION, WEAR GLOVES AND SAFETY
GLASSES WHEN HANDLING A DEPLOYED AIR BAG
ASSEMBLY, AND WASH YOUR HANDS WITH MILD
SOAP AND WATER AFTERWARDS.
WHEN CARRYING A LIVE AIR BAG ASSEMBLY,
MAKE SURE THE BAG AND TRIM COVER ARE
POINTED AWAY FROM YOU. NEVER CARRY AN AIR
BAG ASSEMBLY BY THE WIRES OR CONNECTOR
ON THE UNDERSIDE OF MODULE. IN THE CASE OF
AN ACCIDENTAL DEPLOYMENT, THE BAG WILL
THEN DEPLOY WITH MINIMAL CHANCE OF INJURY.
WHEN PLACING A LIVE AIR BAG ASSEMBLY ON A
BENCH OR OTHER SURFACE, ALWAYS FACE THE
BAG AND TRIM COVER UP, AWAY FROM THE
SURFACE.
NEVER REST A STEERING COLUMN ASSEMBLY ON
THE STEERING WHEEL WITH THE AIR BAG
ASSEMBLY FACE DOWN AND COLUMN VERTICAL.
THIS IS NECESSARY SO THAT A FREE SPACE IS
PROVIDED TO ALLOW THE AIR BAG ASSEMBLY TO
EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL
DEPLOYMENT. OTHERWISE, PERSONAL INJURY
COULD RESULT.
TO
AVOID
DEPLOYMENT
WHEN
TROUBLESHOOTING THE SRS SYSTEM, DO NOT
USE ELECTRICAL TEST EQUIPMENT, SUCH AS
BATTERY-POWERED
OR
A/C-POWERED
VOLT-METER, OHMMETER, ETC., OR ANY TYPE OF
ELECTRICAL
EQUIPMENT
OTHER
THAN
SPECIFIED IN THIS MANUAL. DO NOT USE A
NON-POWERED PROBE-TYPE TESTER.
INSTRUCTIONS IN THIS MANUAL MUST BE
FOLLOWED CAREFULLY, OTHERWISE PERSONAL
INJURY MAY RESULT.
SRS Connectors
CAUTION: The special yellow color connectors are
used for supplemental restraint system-air bag
circuit.
When removing the cable harness disconnect the
connector by unlocking at two places, outside (1)
and inside (2). Do not pull the wires or disconnection
may occur.
When connecting the double lock type SRS connector, insert the connector completely then lock the
connector. Imperfect locking may cause the SRS circuit to malfunction.
2A–30 POWER–ASSISTED STEERING SYSTEM
Removal
Installation
To remove the connector, hold the cover insulator(1) and
pull it. The cover insulator slides and lock will be released.
Do not hold the socket insulator(2).
To install the connector, hold the soket insulator(1) and
insert it. The cover insulator slides and connector will be
locked.
Do not hold the cover insulator(2).
827RW028
827RW027
POWER–ASSISTED STEERING SYSTEM
2A–31
Inflator Module
Inflator Module and Associated Parts
827RW071
Legend
(1) Horn Lead
(2) SRS Connector
(3) Fixing Bolt
(4) Inflator Module
Removal
1. Turn the steering wheel so that the vehicle’s wheels
are pointing straight ahead.
2. Turn the ignition switch to “LOCK”.
3. Disconnect the battery “–” terminal cable, and wait at
least 5 minutes.
4. Disconnect the yellow 2-way SRS connector located
under the steering column.
5. Loosen the inflator module fixing bolt from behind the
steering wheel assembly using a TORX driver or
equivalent until the inflator module can be released
from steering assembly .
827RW070
2A–32 POWER–ASSISTED STEERING SYSTEM
6. Disconnect the yellow 2-way SRS connector and
horn lead located behind the inflator module.
The inflator module consists of a cover, air bag, inflator,
and retainer. Inspect the inflator module mainly for the
following:
B Check for holes, cracks, severe blemishes and
deformation on the cover.
B Check that the retainer is not deformed.
B Check for defects such as damage and breakage in
the lead wire for the igniter.
Replace the inflator module if a defect is found during
inspection.
Installation
1. Install inflator module.
2. Support the module and carefully connect the module
connector and horn lead.
NOTE: Pass the lead wire through the tabs on the plastic
cover (wire protector) of inflator to prevent lead wire from
being pinched.
3. Tighten bolts to specified torque.
827RW073
7. Remove inflator module.
Inspection and Repair
WARNING: THE INFLATOR MODULE SHOULD
ALWAYS BE CARRIED WITH THE TRIM COVER
AWAY FROM YOUR BODY AND SHOULD ALWAYS
BE LAID ON A FLAT SURFACE WITH THE
URETHANE SIDE UP. THIS IS NECESSARY
BECAUSE FREE SPACE IS PROVIDED TO ALLOW
THE AIR CUSHION TO EXPAND IN THE UNLIKELY
EVENT
OF
ACCIDENTAL
DEPLOYMENT.
OTHERWISE, PERSONAL INJURY MAY RESULT .
827RW072
Torque: 9 N·m (78 lb in)
4. Connect the yellow 2-way SRS connector located
under the steering column.
5. Connect the battery “–” terminal cable.
6. Set ignition to “ON” while watching warning light.
Light should flash 7 times and then go off. If lamp
does not operate correctly, refer to Restraints section.
POWER–ASSISTED STEERING SYSTEM
2A–33
Steering Wheel
Steering Wheel and Associated Parts
827RW069
Legend
(1) Horn Lead
(2) SRS Connector
CAUTION: Once the steering column is removed
from the vehicle, the column is extremely
susceptible to damage. Dropping the column
assembly on its end could collapse the steering shaft
or loosen the slide block which maintains column
rigidity. Leaning on the column assembly could
cause the jacket to bend or deform. Any of the above
damage could impair the column’s collapsible
design. If it is necessary to remove the steering
wheel, use only the specified steering wheel puller.
Under no conditions should the end of the shaft be
hammered upon, as hammering could loosen the
slide block which maintains column rigidity.
(3) Steering Wheel
(4) Steering Wheel Fixing Nut
(5) Inflator Module
Removal
1. Turn the steering wheel so that the vehicle’s wheels
are pointing straight ahead.
2. Turn the ignition switch to “LOCK”.
3. Disconnect the battery ground cable, and wait at least
5 minutes.
4. Disconnect the yellow 2-way SRS connector located
under the steering column.
2A–34 POWER–ASSISTED STEERING SYSTEM
5. Loosen the inflator module fixing bolt from behind the
steering wheel assembly using a TORX driver or
equivalent until the inflator module can be released
from steering assembly.
827RW070
6. Disconnect the yellow 2-way SRS connector located
behind the inflator module.
WARNING: THE INFLATOR MODULE SHOULD
ALWAYS BE CARRIED WITH THE TRIM COVER
AWAY FROM YOUR BODY AND SHOULD ALWAYS
BE LAID ON A FLAT SURFACE WITH THE
URETHANE SIDE UP. THIS IS NECESSARY
BECAUSE FREE SPACE IS PROVIDED TO ALLOW
THE AIR CUSHION TO EXPAND IN THE UNLIKELY
EVENT
OF
ACCIDENTAL
DEPLOYMENT.
OTHERWISE, PERSONAL INJURY MAY RESULT.
8. Remove steering wheel fixing nut.
9. Apply a setting mark (1) across the steering wheel
and shaft so parts can be reassembled in their original
position, then remove steering wheel.
430RW021
10. Move the front wheels to the straight ahead position,
then use steering wheel remover J–29752 to remove
the steering wheel.
CAUTION: Never apply force to the steering wheel
shaft using a hammer or other impact tools in an
attempt to remove the steering wheel. The steering
shaft is designed as an energy absorbing unit.
430RX005
827RW073
7. Disconnect horn lead.
POWER–ASSISTED STEERING SYSTEM
Installation
1. Install steering wheel by aligning the setting marks
made when removing.
CAUTION: Never apply force to the steering wheel
shaft using a hammer or other impact tools in an
attempt to remove the steering wheel. The steering
shaft is designed as an energy absorbing unit.
2. Tighten the steering wheel fixing nut to the specified
torque.
Torque: 34 N·m (25 lb ft)
3. Connect horn lead.
4. Support the module and carefully connect the SRS
connector.
NOTE: Pass the lead wire through the tabs on the plastic
cover (wire protector) of inflator to prevent lead wire from
being pinches.
5. Tighten bolts to specified torque.
Torque: 9 N·m (78 lb in)
6. Connect the yellow 2-way SRS connector located
under the steering column.
7. Connect the battery “–” terminal cable.
8. Turn the ignition switch to the “ON” position and
observe the warning lamp. The lamp should flash 7
times. If the lamp does not operate correctly, refer to
Restraints section.
2A–35
2A–36 POWER–ASSISTED STEERING SYSTEM
Combination Switch
Combination Switch and Associated Parts
431R200003
Legend
(1) Steering Column Cover
(2) Steering Wheel
(3) Inflator Module
Removal
1. Turn the steering wheel so that the vehicle’s wheels
are pointing straight ahead.
2. Turn the ignition switch to “LOCK”.
3. Disconnect the battery ground cable, and wait at least
5 minutes.
4. Disconnect the yellow 2-way SRS connector located
under the steering column.
(4) Combination Switch and SRS Coil Assembly
(5) Instrument Panel Lower Cover
(6) Driver Knee Bolster (reinforcement)
CAUTION: The wheels of the vehicle must be
straight ahead and the steering column in the
“LOCK” position before disconnecting the steering
wheel. Failure to do so will cause the coil assembly
to become uncentered which will cause damage to
the coil assembly.
5. Remove the engine hood opening lever, then remove
instrument panel lower cover.
6. Remove the driver knee bolster (reinforcement).
POWER–ASSISTED STEERING SYSTEM
7. Loosen the inflator module fixing bolt from behind the
steering wheel assembly using a TORX driver or
equivalent until the inflator module can be released
from steering assembly. Disconnect the yellow 2-way
SRS connector and horn lead located behind the
inflator module, then remove inflator module.
2A–37
WARNING: THE INFLATOR MODULE SHOULD
ALWAYS BE CARRIED WITH THE TRIM COVER
AWAY FROM YOUR BODY AND SHOULD ALWAYS
BE LAID ON A FLAT SURFACE WITH THE
URETHANE SIDE UP. THIS IS NECESSARY
BECAUSE FREE SPACE IS PROVIDED TO ALLOW
THE AIR CUSHION TO EXPAND IN THE UNLIKELY
EVENT
OF
ACCIDENTAL
DEPLOYMENT.
OTHERWISE, PERSONAL INJURY MAY RESULT.
827RW070
827RW072
8. Apply a setting mark (1) across the steering wheel
and shaft so parts can be reassembled in their original
position. Move the front wheels to the straight ahead
position, then use steering wheel remover J–29752 to
remove the steering wheel.
827RW073
430RW021
2A–38 POWER–ASSISTED STEERING SYSTEM
CAUTION: Never apply force to the steering wheel
shaft using a hammer or other impact tools in an
attempt to remove the steering wheel. The steering
shaft is designed as an energy absorbing unit.
Installation
1. Install combination switch and SRS coil assembly.
After installation of combination switch assembly,
connect the combination switch wiring harness
connector and the SRS 2-way connector located
under the steering column. Then turn the SRS coil
counter clockwise to full, return about 3 turns and
align the neutral mark.
CAUTION: Turn the SRS coil counter clockwise
until some resistance is felt, or damage may occur to
the SRS coil.
430RX005
9. Remove steering column cover.
10. Disconnect the wiring harness connectors located
under the steering column then remove combination
switch and SRS coil assembly.
825RW016
825RW288
POWER–ASSISTED STEERING SYSTEM
2. When installing the steering column cover, be sure to
route each wire harness as illustrated so that the
harnesses do not catch on any moving parts.
825RW017
Legend
(1) Steering Column Cover
(2) Starter Switch Harness
(3) Combination Switch Harness
(4) Inflator Module Harness
3. Align the setting marks made when removing then
install steering wheel.
CAUTION: Never apply force to the steering wheel
shaft using a hammer or other impact tools in an
attempt to remove the steering wheel. The steering
shaft is designed as an energy absorbing unit.
4. Tighten the steering wheel fixing nut to the specified
torque.
Torque: 34 N·m (25 lb ft)
5. Support the inflator module and carefully connect the
SRS connector and horn lead.
NOTE: Pass the lead wire through the tabs on the plastic
cover (wire protector) of inflator to prevent lead wire from
being pinched.
6. Tighten bolts to specified torque.
Torque: 9 N·m (78 lb in)
7. Install driver knee bolster (reinforcement).
8. Install instrument panel lower cover then Install the
engine hood opening lever.
9. Connect the SRS connector.
10. Connect the battery “-” terminal cable.
11. Turn the ignition switch to the “ON” position and
observe the warning lamp. The lamp should flash 7
times. If the lamp does not operate correctly, refer to
Restraints section.
2A–39
2A–40 POWER–ASSISTED STEERING SYSTEM
Lock Cylinder
Lock Cylinder and Associated Parts
431RX005
Legend
(1) Inflator Module
(2) Steering Wheel
(3) Steering Column Cover
(4) Combination Switch and SRS Coil Assembly
(5) Snap Ring
Removal
1. Turn the steering wheel so that the vehicle’s wheels
are pointing straight ahead.
2. Turn the ignition switch to “LOCK”.
3. Disconnect the battery ground cable, and wait at least
5 minutes.
4. Disconnect the yellow 2-way SRS connector located
under the steering column.
(6)
(7)
(8)
(9)
(10)
Cushion Rubber
Lock Cylinder Assembly
Instrument Panel Lower Cover
Driver Knee Bolster (reinforcement)
Shift Lock Cable (for A/T)
CAUTION: The wheels of the vehicle must be
straight ahead and the steering column in the
”LOCK” position before disconnecting the steering
wheel. Failure to do so will cause the coil assembly
to become uncentered which will cause damage to
the coil assembly.
5. Remove the engine hood opening lever and steering
lower cover.
6. Remove driver knee bolster (reinforcement).
POWER–ASSISTED STEERING SYSTEM
7. Loosen the inflator module fixing bolt from behind the
steering wheel assembly using a TORX driver or
equivalent until the inflator module can be released
from steering assembly.
2A–41
9. Apply a setting mark (1) across the steering wheel
and shaft so parts can be reassembled in their original
position.
430RW021
827RW070
8. Disconnect the yellow 2-way SRS connector and
horn lead located behind the inflator module.
10. Move the front wheels to the straight ahead position,
then use steering wheel remover J–29752 to remove
the steering wheel.
CAUTION: Never apply force to the steering wheel
shaft using a hammer or other impact tools in an
attempt to remove the steering wheel. The steering
shaft is designed as an energy absorbing unit.
827RW073
430RX005
2A–42 POWER–ASSISTED STEERING SYSTEM
WARNING: THE INFLATOR MODULE SHOULD
ALWAYS BE CARRIED WITH THE TRIM COVER
AWAY FROM YOUR BODY AND SHOULD ALWAYS
BE LAID ON A FLAT SURFACE WITH THE
URETHANE SIDE UP. THIS IS NECESSARY
BECAUSE FREE SPACE IS PROVIDED TO ALLOW
THE AIR CUSHION TO EXPAND IN THE UNLIKELY
EVENT
OF
ACCIDENTAL
DEPLOYMENT.
OTHERWISE, PERSONAL INJURY MAY RESULT.
14. Remove snap ring.
15. Remove cushion rubber.
16. Remove shift lock cable (for A/T).
17. Disconnect the starter switch harness connector
located under the steering column then remove lock
cylinder assembly.
Installation
1. Install lock cylinder assembly.
2. Install shift lock cable (for A/T).
3. Install cushion rubber.
4. Install snap ring.
5. Install Combination switch and SRS coil assembly.
After installation of combination switch assembly,
connect the combination switch wiring harness
connector and the SRS 2-way connector located
under the steering column.
6. Turn the SRS coil counter clockwise to full, return
about 3 turns and align the neutral mark.
CAUTION: Turn the SRS coil counter clockwise
until some resistance is felt, or damage may occur to
the SRS coil.
827RW072
11. Remove steering column cover.
12. Disconnect the wiring harness connectors located
under the steering column.
13. Remove the combination switch assembly with SRS
coil.
825RW016
825RW288
POWER–ASSISTED STEERING SYSTEM
7. When installing the steering column cover, be sure to
wire (through each harness) as illustrated so that the
harnesses starter switch, combination switch and
SRS coil may not catch wiring.
825RW017
Legend
(1) Steering Column Cover
(2) Starter Switch Harness
(3) Combination Switch Harness
(4) Inflator Module Harness
8. Install steering wheel by aligning the setting marks
made during removal.
CAUTION: Never apply force to the steering wheel
shaft using a hammer or other impact tools in an
attempt to remove the steering wheel. The steering
shaft is designed as an energy absorbing unit.
9. Tighten the steering wheel fixing nut to the specified
torque.
Torque: 34 N·m (25 lb ft)
10. Support inflator module and carefully connect the
SRS connector and horn lead, then install inflator
module.
NOTE: Pass the lead wire through the tabs on the plastic
cover (wire protector) of inflator to prevent lead wire from
being pinched.
11. Tighten fixing bolts to specified torque.
Torque: 9 N·m (78 lb in)
12. Install driver knee bolster (reinforcement).
13. Install instrument panel lower cover, then install the
engine hood opening lever.
14. Connect the yellow 2-way SRS connector located
under the steering column.
15. Connect the battery ground cable.
2A–43
System Inspection
Turn the ignition switch to the “ON” position and observe
the warning lamp. The lamp should flash 7 times. If the
lamp does not operate correctly, refer to Restraints
section.
2A–44 POWER–ASSISTED STEERING SYSTEM
Steering Column
Steering Column and Associated Parts
431R200002
Legend
(1) Inflator Module
(2) Steering Wheel
(3) Steering Column Cover
(4) Combination Switch and SRS Coil Assembly
(5) Snap Ring
(6) Cushion Rubber
Removal
1. Turn the steering wheel so that the vehicle’s wheels
are pointing straight ahead.
2. Turn the ignition switch to “LOCK”.
3. Disconnect the battery ground cable, and wait at least
5 minutes.
(7)
(8)
(9)
(10)
(11)
(12)
Lock Cylinder Assembly
Shift Lock Cable (For A/T)
Steering Column Assembly
Second Steering Shaft
Instrument Panel Lower Cover
Driver Knee Bolster (reinforcement)
4. Disconnect the yellow 2-way SRS connector located
under the steering column.
CAUTION: The wheel of the vehicle must be straight
ahead and the steering column in the “LOCK”
position before disconnecting the steering column
from the steering gear. Failure to do so will cause the
SRS coil assembly to become uncentered which will
cause damage to the SRS coil assembly.
POWER–ASSISTED STEERING SYSTEM
5. Remove the engine hood opening lever, then remove
instrument panel lower cover.
6. Remove driver knee bolster (reinforcement).
7. Loosen the inflator module fixing bolt from behind the
steering wheel assembly using a TORX driver or
equivalent until the inflator module can be released
from steering assembly.
2A–45
10. Apply a setting mark (1) across the steering wheel
and shaft so parts can be reassembled in their original
position. Move the front wheels to the straight ahead
position, then use steering wheel remover J–29752
to remove the steering wheel.
430RW021
827RW070
8. Disconnect the yellow 2-way SRS connector and
horn lead located behind the inflator module.
9. Remove inflator module.
WARNING: THE INFLATOR MODULE SHOULD
ALWAYS BE CARRIED WITH THE TRIM COVER
AWAY FROM YOUR BODY AND SHOULD ALWAYS
BE LAID ON A FLAT SURFACE WITH THE
URETHANE SIDE UP. THIS IS NECESSARY
BECAUSE FREE SPACE IS PROVIDED TO ALLOW
THE AIR CUSHION TO EXPAND IN THE UNLIKELY
EVENT
OF
ACCIDENTAL
DEPLOYMENT.
OTHERWISE, PERSONAL INJURY MAY RESULT.
430RX005
11. Remove steering column cover.
12. Disconnect the wiring harness connectors located
under the steering column.
827RW072
2A–46 POWER–ASSISTED STEERING SYSTEM
13. Remove the combination switch assembly with SRS
coil.
Inspection
If the abnormal conditions are found through inspection,
replace the steering column assembly.
Column Capsule
Check capsules on steering column bracket assembly; all
must be securely seated in bracket slots and checked for
any loose conditions when pushed or pulled by hand.
825RW288
14. Remove snap ring.
15. Remove cushion rubber.
16. Remove shift lock cable (For A/T).
17. Disconnect the starter switch harness connector
located under the steering column, then remove lock
cylinder assembly.
18. Apply a setting mark across the second steering shaft
and transfer gear assembly to reassemble the parts
in their original position, then remove the steering
column assembly and second steering shaft.
431RW030
Check clearance between capsule and bracket. If must
be within 1mm (0.039 in).
NOTE: A setting mark can be easily made if the shaft is
withdrawn a little by loosening the steering shaft universal
joint.
431RW031
431RW009
POWER–ASSISTED STEERING SYSTEM
2A–47
Column Tube
Shaft Length
Check for collapse by measuring the distance as shown in
the figure.
Standard distance: 162.2-165.8 mm (6.386-6.528
in)
Check the shaft length from the upper end of the slide joint
to the end of the shaft. If column length is not in
specifications, steering column should be replaced.
Standard length:
291.7 – 295.7 mm (11.484 – 11.642 in)
431RY00010
431R200001
Column Universal Joint for Tilt Mechanism
Check steering column assembly for any resistance by
rotating the universal joint. If resistance is felt then
replace the steering column assembly.
Shaft Universal Joint (Lower End)
Sheared Injected Plastic Pin
Shaft Bellows Pipe
Check the sheared injected plastic pins for any loose
conditions or damage.
Use a straightedge to inspect the shaft bellows pipe for
straightness. Replace if the clearance is more than the
specifications.
Standard: Less than 1mm (0.039 in)
If the resistance is felt when checked by rotate the joint,
replace the steering column assembly.
431RY00011
431RW035
2A–48 POWER–ASSISTED STEERING SYSTEM
Tilt Mechanism
Tilt mechanism should moves smoothly.
While locked the tilt mechanism, be sure the steering
column latch securely by pushing the steering wheel
upward and downward.
11. Turn the SRS coil counter clockwise to full, return
about 3 turns and align the neutral mark.
CAUTION: Turn the SRS coil counter clockwise
until a resistance is felt or damage to the SRS coil
may occur from over turning.
Installation
1. Pass through the steering column assembly to the
dash panel hole.
Temporary tightening the steering column bolt(cross
beam).
2. Tighten the steering column bolts(dash panel) to the
specified torque.
Torque: 20 N·m (14 lb ft)
3. Tighten the steering column nuts (cross beam) to the
specified torque.
Torque: 17 N·m (12 lb ft)
4. Install the universal joint assembly to the transfer
gear assembly align the setting marks made at
removal.
Then tighten the universal joint bolt.
Torque: 31 N·m (23 lb ft)
5. Install the second steering shaft to the universal joint
assembly, then tighten the universal joint bolt to the
specified torque.
825RW016
12. When installing the steering column cover, be sure to
route each wire harness as illustrated so that the
harnesses do not catch any moving parts.
Torque: 31 N·m (23 lb ft)
6. Install lock cylinder assembly.
7. Install shift lock cable (For A/T).
8. Install cushion rubber.
9. Install snap ring.
10. Install combination switch and SRS coil assembly.
After installation of combination switch assembly,
connect the combination switch wiring harness
connector and the SRS 2-way connector located
under the steering column.
825RW017
Legend
(1) Steering Column Cover
(2) Starter Switch Harness
(3) Combination Switch Harness
(4) Inflator Module Harness
POWER–ASSISTED STEERING SYSTEM
13. Install steering wheel and align the setting marks
made when removing.
CAUTION: Never apply force to the steering wheel
shaft using a hammer or other impact tools in an
attempt to remove the steering wheel. The steering
shaft is designed as an energy absorbing unit.
14. Tighten the steering wheel fixing nut to the specified
torque.
Torque: 34 N·m (25 lb ft)
15. Support the module and carefully connect the module
connector and horn lead, then install inflator module.
NOTE: Pass the lead wire through the tabs on the plastic
cover (wire protector) of inflator to prevent lead wire from
being pinched.
16. Tighten bolts to specified torque.
Torque: 9 N·m (78 lb in)
17. Install driver knee bolster (reinforcement).
18. Install instrument panel lower cover.
19. Install the engine hood opening lever.
20. Connect the yellow 2-way SRS connector and horn
lead located under the steering column.
21. Connect the battery ground cable.
System Inspection
Turn the ignition switch “ON” and observe if the warning
lamp flashes 7 times. If the warning lamp does not
operate correctly, refer to Restraints section.
2A–49
2A–50 POWER–ASSISTED STEERING SYSTEM
Supplemental Restraint System Steering Wheel & Column and
Associated Parts
Main Data and Specifications
Torque Specifications
430RY00002
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
J–29752
Steering wheel remover
SECTION
FRONT SUSPENSION
3C–1
AXIOM
SUSPENSION
CONTENTS
Front Suspension . . . . . . . . . . . . . . . . . . . . . . .
Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . .
Wheel and Tire System . . . . . . . . . . . . . . . . . .
3C–1
3D–1
3E–1
Intelligent Suspension Control . . . . . . . . . . . .
3F–1
FRONT SUSPENSION
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . .
General Description . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . .
Shock Absorber and Associated Parts . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stabilizer Bar and Associated Parts . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torsion Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torsion Bar and Associated Parts . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knuckle and Associated Parts . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3C–1
3C–2
3C–2
3C–5
3C–5
3C–5
3C–5
3C–5
3C–6
3C–6
3C–6
3C–6
3C–6
3C–7
3C–7
3C–7
3C–8
3C–8
3C–10
3C–10
3C–10
3C–11
3C–11
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.
Upper Control Arm . . . . . . . . . . . . . . . . . . . . . .
Upper Control Arm and Associated Parts .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Control Arm . . . . . . . . . . . . . . . . . . . . . .
Lower Control Arm and Associated Parts .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upper Ball Joint . . . . . . . . . . . . . . . . . . . . . . . . .
Upper Ball Joint and Associated Parts . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Ball Joint . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Ball Joint and Associated Parts . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . .
3C–13
3C–13
3C–13
3C–14
3C–14
3C–16
3C–16
3C–16
3C–17
3C–18
3C–19
3C–19
3C–19
3C–20
3C–20
3C–21
3C–21
3C–21
3C–22
3C–22
3C–23
3C–25
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.
3C–2
FRONT SUSPENSION
General Description
The front suspension is designed to allow each wheel to
compensate for changes in the road surface level without
greatly affecting the opposite wheel. Each wheel is
independently connected to the frame by a steering
knuckle, ball joint assemblies, and upper and lower
control arms. The front wheels are held in proper
relationship to each other by two tie-rods which are
connected to steering arms on the knuckles, and to a
steering unit.
All models have a front suspension system consisting of
control arms, stabilizer bar, shock absorber and a torsion
bar. The front end of the torsion bar is attached to the
lower control arm. The rear of the torsion bar is mounted
into a height control arm at the crossmember. Vehicle trim
height is controlled by adjusting this arm.
Shock absorbers are mounted between the brackets on
the frame and the lower control arms. The lower portion of
each shock absorber is attached to the lower control arm.
The upper portion of each shock absorber extends
through a frame bracket and is secured with two rubber
bushings, two retainers and a nut.
Ball joint assemblies are bolted to the outer end of the
upper and lower control arm and are attached to the
steering knuckle.
The inner ends of the upper control arm have pressed in
bushings. Bolts, passing through the bushing, attach the
control arm to the frame. The inner ends of the lower
control arm are attached to the frame by bolts passing
through the bushings.
Side roll of the front suspension is controlled by a spring
steel stabilizer bar. It is mounted in rubber bushings,
which are held to the frame by brackets. The ends of the
stabilizer bar are connected to the lower control arms by
links.
Diagnosis
Condition
Vehicle Pulls
Possible cause
Mismatched or uneven tires.
Replace tire.
Tires not adequately inflated.
Adjust tire pressure.
Broken or sagging springs.
Replace spring.
Radial tire lateral force.
Replace tire.
Improper wheel alignment.
Adjust wheel alignment.
Brake dragging in one wheel.
Repair brake.
Loose, bent or broken front or rear
suspension parts.
Tighten or replace the appropriate
suspension part(s).
Faulty shock absorbers.
Replace shock absorber.
Parts in power
defective.
Abnormal or Excessive Tire Wear
Wheel Hop
Correction
steering
valve
Replace power steering unit.
Sagging or broken spring.
Replace spring.
Tire out of balance.
Balance or replace tire.
Improper wheel alignment.
Check front end alignment.
Faulty shock absorber.
Replace shock absorber.
Hard driving.
Replace tire.
Overloaded vehicle.
Replace tire and reduce load.
Tires not rotated periodically.
Replace or rotate tire.
Worn or loose road wheel bearings.
Replace wheel bearing.
Wobbly wheel or tires.
Replace wheel or tire.
Tires not adequately inflated.
Adjust the pressure.
Blister or bump on tire.
Replace tire.
Improper shock absorber operation.
Replace shock absorber.
FRONT SUSPENSION
Condition
Shimmy, Shake or Vibration
Hard Steering
Too Much Play In Steering
Possible cause
Correction
Tire or wheel out of balance.
Balance wheels or replace tire/or
wheel.
Loose wheel bearings.
Replace wheel bearing.
Worn steering linkage ball joints.
Replace ball joints.
Worn upper or lower end ball joints.
Replace ball joints.
Excessive wheel runout.
Repair or replace wheel and/or tire.
Blister or bump on tire.
Replace tire.
Excessive loaded radial runout of
tire/wheel assembly.
Replace tire or wheel.
Improper wheel alignment.
Check wheel alignment.
Loose or worn steering linkage.
Tighten or replace steering linkage.
Loose steering unit.
Tighten steering unit.
Tires not adequately inflated.
Adjust tire pressure.
Loose, bent or broken front or rear
suspension parts.
Tighten or replace the appropriate
suspension parts.
Faulty shock absorber.
Replace shock absorber.
Hub bearing preload misadjustment.
Adjust preload.
Parts in power
defective.
Replace power steering unit.
steering
valve
Bind in steering linkage ball studs,
upper or lower ball joint.
Replace ball joint.
Improper wheel alignment.
Check wheel alignment.
Tire not adequately inflated.
Inflate tires to proper pressure.
Bind in steering column or shaft.
Repair or replace.
Improper power steering system
operation.
Repair or replace. Refer to Steering
section.
Wheel bearings worn.
Replace wheel bearings.
Loose steering unit or linkage.
Retighten or repair.
Worn or loose
universal joint.
Poor Steering Wheel Returnability
3C–3
steering
shaft
Retighten or replace steering shaft.
Worn steering linkage ball joints.
Replace ball joints.
Worn upper or lower end ball joints.
Replace ball joints.
Bind in steering linkage ball joints.
Replace ball joints.
Bind in upper or lower ball joints.
Replace ball joints.
Bind in steering column and shaft.
Repair or replace.
Bind in steering gear.
Check and repair steering gear.
Improper wheel alignment.
Adjust wheel alignment.
Tires not adequately inflated.
Adjust pressure.
Loose steering wheel nut.
Retighten.
Worn wheel bearing.
Replace.
3C–4
FRONT SUSPENSION
Condition
Abnormal Noise
Wandering or Poor Steering Stability
Erratic Steering When Braking
Low or Uneven Trim Height
Suspension Bottoms
Body Leans
Cupped Tires
Possible cause
Correction
Worn, sticky or loose upper or lower
ball joint, steering linkage ball joints
or drive axle joints.
Replace.
Faulty shock absorbers.
Replace.
Worn upper or lower control arm
bushing.
Replace.
Loose stabilizer bar.
Retighten bolts or replace bushings.
Loose wheel nuts.
Tighten nuts. Check for elongated
wheel nut holes. Replace wheel if
required.
Loose suspension bolts or nuts.
Retighten suspension bolts or nuts.
Broken or otherwise damaged wheel
bearings.
Replace wheel bearing.
Broken suspension springs.
Replace spring.
Loose steering unit.
Retighten mounting bolt.
Faulty steering unit.
Replace steering unit.
Mismatched or unevenly worn tires.
Replace tire or inflate tires to proper
pressure.
Loose steering linkage ball joints.
Replace ball joints.
Faulty shock absorbers.
Replace shock absorber.
Loose stabilizer bar.
Tighten or replace stabilizer bar or
bushings.
Broken or sagging springs.
Replace spring (pairs).
Improper wheel alignment.
Adjust wheel alignment.
Worn wheel bearings.
Replace wheel bearings.
Broken or sagging springs.
Replace spring (pairs).
Leaking caliper.
Repair or replace caliper.
Warped discs.
Replace brake disc.
Badly worn brake pads.
Replace brake pads.
Tires are inflated unequally.
Inflate tires to proper pressure.
Broken or sagging springs.
Replace springs (In pairs).
Vehicle overloaded.
Reduce load.
Incorrect springs.
Adjust or replace torsion bar.
Vehicle overloaded.
Reduce load.
Faulty shock absorber.
Replace shock absorber.
Incorrect, broken or sagging springs.
Replace springs.
Loose stabilizer bar.
Tighten stabilizer bar bolts or replace
bushings.
Faulty shock absorber, struts or
mounting.
Replace shock absorber.
Broken or sagging springs.
Replace springs (In pairs).
Vehicle overloaded.
Reduce load.
Worn wheel bearings.
Replace wheel bearing.
Excessive tire or wheel run out.
Replace tire or wheel.
Worn ball joints.
Replace ball joints.
Tire out of balance.
Adjust tire balance.
FRONT SUSPENSION
3C–5
Shock Absorber
Shock Absorber and Associated Parts
450R200001
Legend
(1) Nut
(2) Rubber Bushing and Washer
(3) Bolt and Nut
(4) Shock Absorber
Removal
1. Raise the vehicle and support it with suitable safety
stands.
2. Remove wheel and tire assembly. Refer to Wheel
Replacement in this section.
3. Remove bolt and nut.
4. Remove ISC Actuator and Bracket. Refer to
Intelligent Suspension.
5. Remove nut.
6. Remove rubber bushing and washer.
7. Remove shock absorber.
8. Remove rubber bushing and washer.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
Check the following parts :
(5)
(6)
(7)
(8)
Rubber Bushing and Washer
Actuator Bracket
Actuator
Screw
B Shock absorber
B Rubber bushing
Installation
1. Install rubber bushing and washer.
2. Install shock absorber.
3. Install rubber bushing and washer.
4. Install nut, then tighten it to the specified torque.
Torque: 20 N·m (14 lb ft)
5. Install ISC Actuator and Bracket. Refer to Intelligent
Suspension.
6. Install bolt and nut, then tighten to the specified
torque.
Torque: 93 N·m (69 lb ft)
3C–6
FRONT SUSPENSION
Stabilizer Bar
Stabilizer Bar and Associated Parts
410R200001
Legend
(1) Rubber Bushing
(2) Bracket and Bolt
(3) Link
Removal
1. Raise the vehicle and support the frame with suitable
safety stands.
2. Remove the stone guard.
3. Remove wheel and tire assembly. Refer to Wheel
Replacement in this section.
4. Remove nut.
CAUTION: Be careful not to break the ball joint boot.
5. Remove link.
6. Remove bracket.
7. Remove stabilizer bar.
8. Remove rubber bushing.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
(4) Nut
(5) Stabilizer Bar
(6) Washer
Check the following parts :
B Stabilizer bar
B Rubber bushing
B Link ball joint
Installation
1. Install rubber bushing.
2. Install stabilizer bar.
3. Install bracket, then tighten it to the specified torque.
Torque: 25 N·m (18 lb ft)
4. Install link and Washer.
5. Install nut, then tighten it to the specified torque.
Torque: 50 N·m (37 lb ft)
FRONT SUSPENSION
3C–7
Torsion Bar
Torsion Bar and Associated Parts
410RS003
Legend
(1) Adjust Bolt, End Piece and Seat
(2) Height Control Arm
(3) Torsion Bar
Removal
1. Raise the vehicle and support the frame with suitable
safety stands.
2. Apply the setting marks(1) to the adjust bolt and end
piece, then remove adjust bolt, end piece and seat.
410RS004
3C–8
FRONT SUSPENSION
3. Apply the setting marks(2) to the height control arm
and torsion bar, then remove height control arm.
Installation
1. Apply grease to the serrated portions, then install
torsion bar. Make sure the bars are on their correct
respective sides and align the setting marks(3).
410RS005
4. Apply the setting marks(3) to the torsion bar and
lower control arm, then remove torsion bar.
410RS007
410RS006
410RS006
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
Check the following parts:
B Torsion bar
B Height control arm
B Adjust bolt
B Rubber seat
FRONT SUSPENSION
2. Apply grease to the portion that fits into the bracket
then install height control arm and align the setting
marks(2).
3C–9
4. Apply grease to the serrated portions.
5. Install adjust bolt and seat, then turn the adjust bolt to
the setting mark(1) applied during disassembly.
NOTE: Adjust the trim height. Refer to Front End
Alignment Inspection and Adjustment in Steering section.
410RS005
3. Apply grease to the bolt portion of the end piece(4).
Apply grease to the portion of the seat(5) that fits into
the bracket.
410RS008
410RS004
3C–10
FRONT SUSPENSION
Knuckle
Knuckle and Associated Parts
410RW006
Legend
(1) Torsion Bar
(2) Lower Ball Joint, Nut and Cotter Pin
(3) Back Plate
(4) Knuckle Assembly
(5) Knuckle
Removal
1. Raise the vehicle and support the frame with suitable
safety stands.
2. Remove wheel and tire assembly. Refer to Wheel in
this section.
3. Remove the brake caliper. Refer to Disc Brakes in
Brake section.
(6)
(7)
(8)
(9)
(10)
Needle Bearing (4WD MODEL)
Thrust Washer (4WD MODEL)
Oil Seal (4WD MODEL)
Upper Ball Joint, Nut and Cotter Pin
Wheel Speed Sensor
4. Remove the hub assembly. Refer to Front Hub and
Disk in this section.
5. Remove tie–rod end from the knuckle. Refer to Power
Steering Unit in Steering section.
6. Remove the speed sensor from the knuckle.
7. Loosen torsion bar by height control arm adjust bolt,
then remove torsion bar. Refer to Torsion Bar in this
section.
8. Remove wheel speed sensor.
FRONT SUSPENSION
9. Remove back plate.
10. Remove lower ball joint by using remover J–29107.
3C–11
15. Remove needle bearing by using remover J–23907
(Except 2WD model).
CAUTION: Be careful not to damage the ball joint
boot.
901RW044
901RW163
11. Remove upper ball joint by using remover J–36831.
CAUTION: Be careful not to damage the ball joint
boot.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
Check the following parts:
B Knuckle
B Knuckle arm
B Needle bearing
B 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 J–36838 and
J–8092 (Except 2WD model).
901RW162
12. Remove knuckle assembly.
13. Remove oil seal (Except 2WD model).
14. Remove washer (Except 2WD model).
901RW045
3C–12
FRONT SUSPENSION
2. Apply multipurpose type grease to the thrust washer,
and install washer with chamfered side facing knuckle
(Except 2WD model).
3. Use a new oil seal, and apply multipurpose type
grease to the area surrounded by the lip (approx. 2 g).
Then use installer J–36837 and J–8092 to install oil
seal. After fitting the oil seal to the installer, drive it to
the knuckle using a hammer or bench press until the
tool front face contacts with the thrust washer (Except
2WD model).
901RW167
4. Install knuckle assembly.
5. Install upper ball joint and tighten the nut to the
specified torque, with just enough additional torque to
align cotter pin holes. Install new cotter pin.
Torque: 98 N·m (72 lb ft)
6. Install lower ball joint and tighten the nut to the
specified torque, with just enough additional torque to
align cotter pin holes. Install new cotter pin.
Torque: 147 N·m (108 lb ft)
7. Install back plate.
8. Install wheel speed sensor.
9. Install torsion bar, refer to Torsion Bar in this section.
NOTE: Adjust the trim height. Refer to Front End
Alignment Inspection and Adjustment in Steering.
FRONT SUSPENSION
3C–13
Upper Control Arm
Upper Control Arm and Associated Parts
450R200004
Legend
(1) Bolt and Plate
(2) Camber Shims
(3) Caster Shims
(4) Nut Assembly
(5) Upper Control Arm Assembly
(6) Fulcrum Pin
Removal
1. Raise the vehicle and support the frame with suitable
safety stands.
2. Remove wheel and tire assembly. Refer to Wheel in
this section.
(7)
(8)
(9)
(10)
(11)
(12)
Bushing
Plate
Nut
Speed Sensor Cable
Nut and Cotter Pin
Upper Ball Joint
3. Remove the brake caliper and disconnect brake pipe.
Refer to Disc Brakes in Brake section.
4. Support lower control arm with a jack.
5. Remove speed sensor cable.
6. Remove nut and cotter pin then use remover
J–36831.
3C–14
FRONT SUSPENSION
CAUTION: Be careful not to damage the ball joint
boot.
901RW160
16. Remove fulcrum pin.
901RW162
7. Remove upper ball joint.
8. Remove bolt and plate.
9. Remove nut assembly.
10. Remove camber shims and note the positions and
number of shims.
11. Remove caster shims and note the positions and
number of shims.
12. Remove upper control arm assembly.
13. Remove nut.
14. Remove plate.
15. Remove bushing by using remover J–29755.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
Check the following parts:
B Upper control arm
B Bushing
B Fulcrum pin
Installation
1. Install fulcrum pin.
2. Install bushing by using installer J–29755 and
J–39376.
901RW161
901RW164
FRONT SUSPENSION
901RW159
3. Install plate.
4. Install nut and tighten fulcrum pin nut finger–tight.
NOTE: Torque fulcrum pin nut after adjusting buffer
clearance.
3C–15
450RS013
Legend
(1) Projection
(2) Outward
6. Install the caster shims(2) between the chassis frame
and fulcrum pin.
7. Install the camber shims(1) between the chassis
frame and fulcrum pin.
Buffer clearance: 15 mm (0.59 in)
Torque: 108 N·m (80 lb ft)
450R200002
5. Install upper control arm assembly with the fulcrum
pin projections turned inward.
450RS014
8. Install nut assembly.
9. Install bolt and plate, then tighten the bolt to the
specified torque.
Torque: 152 N·m (112 lb ft)
10. Install upper ball joint and tighten it to the specified
torque.
Torque: 57 N·m (42 lb ft)
11. Install nut and cotter pin then tighten the nut to the
specified torque, with just enough additional torque to
align cotter pin holes. Install new cotter pin.
Torque: 98 N·m (72 lb ft)
12. Install speed sensor cable.
3C–16
FRONT SUSPENSION
Lower Control Arm
Lower Control Arm and Associated Parts
450R200003
Legend
(1) Nut, Front
(2) Bush, Front
(3) Bolt, Front
(4) Nut, Rear
(5) Bush, Rear
(6) Bolt, Rear
(7) Bolt, Lower Ball Joint
Removal
1. Raise the vehicle and support the frame with suitable
safety stands.
2. Remove wheel and tire assembly. Refer to Wheel in
this section.
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Bolt, Torsion Bar Arm
Torsion Bar Arm Bracket and Nut
Torsion Bar
Lower Control Arm
Lower Ball Joint and Nut
Shock Absorber
Stabilizer Link
3. Remove the tie-rod end from the knuckle. Refer to
Power Steering Unit in Steering section.
4. Remove the retaining ring from the front axle driving
shaft to release the shaft from hub(Except 2WD
model). Refer to Front Hub and Disc in Driveline/Axle
section.
5. Support lower control arm with a jack.
FRONT SUSPENSION
6. Remove front nut.
7. Remove rear nut.
8. Remove torsion bar, refer to Torsion Bar in this
section.
9. Remove torsion bar arm bracket.
10. Disconnect the stabilizer link at the lower control arm.
11. Remove the shock absorber lower end from the lower
control arm.
12. Remove the lower ball joint from the lower control
arm.
13. Remove front bolt.
14. Remove rear bolt.
15. Remove lower control arm.
16. Remove torsion bar arm bolt.
17. Remove lower ball joint bolt.
18. Remove front bushing by using remover J–36833.
3C–17
19. Remove rear bushing by using remover J–36834.
901RW051
901RW154
901RW052
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
Check the following parts:
B Lower control arm
B Bushing
901RW155
3C–18
FRONT SUSPENSION
11. Install torsion bar arm bracket and tighten it to the
specified torque.
Installation
1. Install rear bushing by using installer J–36834.
Torque: 116 N·m (85 lb ft)
12. Install Torsion bar, refer to Torsion Bar in this section.
13. Install rear nut and tighten lower link nut finger–tight.
NOTE: Torque lower control arm nut after adjusting buffer
clearance.
Buffer clearance: 15 mm (0.59 in)
Torque: 235 N·m (174 lb ft)
901RW053
2. Install front bushing by using installer J–36833.
450R200002
14. Install front nut then tighten lower link nut finger-tight.
NOTE: Torque lower control arm nut after adjusting buffer
clearance .
Buffer clearance: 15 mm (0.59 in)
Torque: 186 N·m (137 lb ft)
NOTE: Adjust the trim height. Refer to Front End
Alignment Inspection and Adjustment in Steering section.
901RW156
3. Install lower ball joint bolt.
4. Install torsion bar arm bolt.
5. Install lower control arm.
6. Install rear bolt.
7. Install front bolt.
8. Install lower ball joint and tighten it to the specified
torque.
Torque: 116 N·m (85 lb ft)
9. Install shock absorber and tighten it to the specified
torque.
Torque: 93 N·m (69 lb ft)
10. Install stabilizer link and tighten it to the specified
torque.
Torque: 50 N·m (37 lb ft)
450R200002
FRONT SUSPENSION
3C–19
Upper Ball Joint
Upper Ball Joint and Associated Parts
450RW004
Legend
(1) Bolt and Nut
Removal
1. Raise the vehicle and support the frame with suitable
safety stands.
2. Remove the speed sensor from the knuckle.
(2) Upper Ball Joint
(3) Nut and Cotter Pin
3C–20
FRONT SUSPENSION
3. Remove upper ball joint nut and cotter pin, then use
remover J–36831 to remove the upper ball joint from
the knuckle.
B After moving the ball joint 4 or 5 times, attach nut then
measure the preload.
Starting torque: 0.5 –3.2 N·m (0.4–2.4 lb ft)
CAUTION: Be careful not to damage the ball joint
boot.
450RS024
901RW162
4. Remove bolt and nut.
5. Remove upper ball joint.
If the above limits specified are exceeded, replace the ball
joint assembly.
Installation
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
B Inspect the lower end boot for damage or grease leak.
Move the ball joint as shown in the figure to confirm its
normal movement.
B Inspect screw/taper area of ball for damage.
B If any defects are found by the above inspections,
replace the ball joint assembly with a new one.
450RS023
1. Install upper ball joint.
2. Install bolt and nut, then tighten them to the specified
torque.
Torque: 57 N·m (42 lb ft)
3. Install nut and cotter pin, then tighten the nut to the
specified torque with just enough additional torque to
align cotter pin holes. Install new cotter pin.
Torque: 98 N·m (72 lb ft)
FRONT SUSPENSION
3C–21
Lower Ball Joint
Lower Ball Joint and Associated Parts
450RW011
Legend
(1) Bolt
(2) Lower Ball Joint
(3) Nut
(4) Nut and Cotter Pin
Removal
1. Raise the vehicle and support the frame with suitable
safety stands.
2. Remove wheel and tire assembly. Refer to Wheel in
this section.
3. Remove the tie-rod end from the knuckle. Refer to
Power Steering Unit in Steering section.
4. Remove the retaining ring from the front axle driving
shaft to release the shaft from hub(Except 2WD
model). Refer to Front Hub and Disc in Driveline/Axle
section.
5. Support lower control arm with a jack.
6. Remove lower ball joint nut and cotter pin, then use
remover J–29107 to remove the lower ball joint from
the knuckle.
CAUTION: Be careful not to damage the ball joint
boot.
901RW163
3C–22
FRONT SUSPENSION
7. Remove nut.
8. Remove bolt.
9. Remove lower ball joint.
Installation
1. Install lower ball joint.
2. Install bolt.
3. Install nut and tighten it to the specified torque.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal condition are found
through inspection.
B Inspect the lower end boot for damage or grease leak.
Move the ball joint as shown in the figure to confirm its
normal movement .
B Inspect screw/taper area of ball for damage.
B If any defects are found by the above inspections,
replace the ball joint assembly with a new one.
450RS026
B After moving the ball joint 4 or 5 times, attach nut the
measure the preload.
Starting torque: 0.5–6.4 N·m (0.4–4.7 lb ft)
450RS024
B If the above limits specified are exceeded, replace the
ball joint assembly.
Torque: 116 N·m (85 lb ft)
4. Install ball joint nut, then tighten it to the specified
torque with just enough additional torque to align
cotter pin holes. Install new cotter pin.
Torque: 147 N·m (108 lb ft)
FRONT SUSPENSION
Main Data and Specifications
General Specifications
Front suspension
Type
Torsion bar spring
Length
1142 mm (45.0 in)
Diameter
29.0 mm (1.14 in)
Front shock absorber
Stabilizer bar
Type
Independent wishbone arms,
torsion bar spring with stabilizer bar.
Hydraulic, double acting, telescopic
Piston diameter
30.0 mm (1.18 in)
Stroke
115.0 mm (4.53 in)
Compressed
length
255.0 mm (10.04 in)
Extended length
370.0 mm (14.57 in)
Diameter
25.0 mm (0.98 in)
3C–23
3C–24
FRONT SUSPENSION
Torque Specifications
E03R200003
FRONT SUSPENSION
3C–25
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION
TOOL NO.
TOOL NAME
J–23907
Remover;Needle
bearing
J–36833
Remover and
Installer kit;
Lower arm front bushing
J–36838
Installer; Needle bearing
J–36834
Remover and
Installer kit;
Lower arm rear bushing
J–8092
Grip
J–36831
Ball joint remover
J–36837
Installer; Oil seal
J–29107
Tie-rod end remover
J–39376
Installer; Upper arm
bushing
J–29775
Remover and Installer
Upper arm bushing
SECTION
REAR SUSPENSION
3D–1
AXIOM (Vehicles Produced Before July/31/2001)
SUSPENSION
REAR SUSPENSION
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . .
General Description . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coil Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coil Spring and Associated Parts . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . .
Shock Absorber and Associated Parts . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trailing Link . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trailing Link and Associated Parts . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3D–1
3D–1
3D–2
3D–5
3D–5
3D–5
3D–6
3D–6
3D–7
3D–7
3D–7
3D–7
3D–7
3D–8
3D–8
3D–8
3D–8
3D–9
Upper Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upper Link and Associated Parts . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lateral Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lateral Rod and Associated Parts . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stabilizer Bar and Associated Parts . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . .
3D–10
3D–10
3D–10
3D–10
3D–11
3D–12
3D–12
3D–12
3D–12
3D–13
3D–14
3D–14
3D–14
3D–14
3D–15
3D–16
3D–18
Service Precaution
General Description
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.
The rear suspension is a 5-link, coil spring type
suspension with a stabilizer bar, consisting of two trailing
links, two upper links, lateral rod, shock absorber, and
stabilizer. In this suspension, the links are specially
arranged to enable the rear axle to move freely, thereby
expanding suspension stroke, reducing friction, and
improving lateral rigidity and roll control. All these result in
improved stability, riding comfort, and rough road
maneuverability.
Each link connects the axle housing with the frame
through a runner bushing. The axle housing is supported
by the trailing links and upper links longitudinally and by
the lateral rod latitudinally.
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.
3D–2
REAR SUSPENSION
Diagnosis
Condition
Vehicle Pulls
Possible cause
Mismatched or uneven tires.
Replace tire.
Tires not adequately inflated.
Adjust tire pressure.
Broken or sagging springs.
Replace spring.
Radial tire lateral force.
Replace tire.
Improper wheel alignment.
Adjust wheel alignment.
Brake dragging in one wheel.
Repair brake.
Loose, bent or broken front or rear
suspension parts.
Tighten or replace the appropriate
suspension part(s).
Faulty shock absorbers.
Replace shock absorber.
Parts in power
defective.
Abnormal or Excessive Tire Wear
Wheel Hop
Shimmy, Shake or Vibration
Correction
steering
valve
Replace power steering unit.
Sagging or broken spring.
Replace spring.
Tire out of balance.
Balance or replace tire.
Improper wheel alignment.
Check front end alignment.
Faulty shock absorber.
Replace shock absorber.
Hard driving.
Replace tire.
Overloaded vehicle.
Replace tire and reduce load.
Tires not rotated periodically.
Replace or rotate tire.
Worn or loose road wheel bearings.
Replace wheel bearing.
Wobbly wheel or tires.
Replace wheel or tire.
Tires not adequately inflated.
Adjust the pressure.
Blister or bump on tire.
Replace tire.
Improper shock absorber operation.
Replace shock absorber.
Tire or wheel out of balance.
Balance wheels or replace tire/or
wheel.
Loose wheel bearings.
Replace wheel bearing.
Worn steering linkage ball joints.
Replace ball joints.
Worn upper or lower end ball joints.
Replace ball joints.
Excessive wheel runout.
Repair or replace wheel and/or tire.
Blister or bump on tire.
Replace tire.
Excessive loaded radial runout of
tire/wheel assembly.
Replace tire or wheel.
Improper wheel alignment.
Check wheel alignment.
Loose or worn steering linkage.
Tighten or replace steering linkage.
Loose steering unit.
Tighten steering unit.
Tires not adequately inflated.
Adjust tire pressure.
Loose, bent or broken front or rear
suspension parts.
Tighten or replace the appropriate
suspension parts.
Faulty shock absorber.
Replace shock absorber.
Hub bearing preload misadjustment.
Adjust preload.
Parts in power
defective.
Replace power steering unit.
steering
valve
REAR SUSPENSION
Condition
Hard Steering
Too Much Play In Steering
Possible cause
Abnormal Noise
Wandering or Poor Steering Stability
Correction
Bind in steering linkage ball studs,
upper or lower ball joint.
Replace ball joint.
Improper wheel alignment.
Check wheel alignment.
Tire not adequately inflated.
Inflate tires to proper pressure.
Bind in steering column or shaft.
Repair or replace.
Improper power steering system
operation.
Repair or replace. Refer to Steering
section.
Wheel bearings worn.
Replace wheel bearings.
Loose steering unit or linkage.
Retighten or repair.
Worn or loose
universal joint.
Poor Steering Wheel Returnability
3D–3
steering
shaft
Retighten or replace steering shaft.
Worn steering linkage ball joints.
Replace ball joints.
Worn upper or lower end ball joints.
Replace ball joints.
Bind in steering linkage ball joints.
Replace ball joints.
Bind in upper or lower ball joints.
Replace ball joints.
Bind in steering column and shaft.
Repair or replace.
Bind in steering gear.
Check and repair steering gear.
Improper wheel alignment.
Adjust wheel alignment.
Tires not adequately inflated.
Adjust pressure.
Loose steering wheel nut.
Retighten.
Worn wheel bearing.
Replace.
Worn, sticky or loose upper or lower
ball joint, steering linkage ball joints
or drive axle joints.
Replace.
Faulty shock absorbers.
Replace.
Worn upper or lower control arm
bushing.
Replace.
Loose stabilizer bar.
Retighten bolts or replace bushings.
Loose wheel nuts.
Tighten nuts. Check for elongated
wheel nut holes. Replace wheel if
required.
Loose suspension bolts or nuts.
Retighten suspension bolts or nuts.
Broken or otherwise damaged wheel
bearings.
Replace wheel bearing.
Broken suspension springs.
Replace spring.
Loose steering unit.
Retighten mounting bolt.
Faulty steering unit.
Replace steering unit.
Mismatched or unevenly worn tires.
Replace tire or inflate tires to proper
pressure.
Loose steering linkage ball joints.
Replace ball joints.
Faulty shock absorbers.
Replace shock absorber.
Loose stabilizer bar.
Tighten or replace stabilizer bar or
bushings.
Broken or sagging springs.
Replace spring (pairs).
Improper wheel alignment.
Adjust wheel alignment.
3D–4
REAR SUSPENSION
Condition
Erratic Steering When Braking
Low or Uneven Trim Height
Suspension Bottoms
Body Leans
Cupped Tires
Possible cause
Correction
Worn wheel bearings.
Replace wheel bearings.
Broken or sagging springs.
Replace spring (In pairs).
Leaking caliper.
Repair or replace caliper.
Warped discs.
Replace brake disc.
Badly worn brake pads.
Replace brake pads.
Tires are inflated unequally.
Inflate tires to proper pressure.
Broken or sagging springs.
Replace springs (In pairs).
Vehicle overloaded.
Reduce load.
Incorrect springs.
Adjust or replace torsion bar.
Vehicle overloaded.
Reduce load.
Faulty shock absorber.
Replace shock absorber.
Incorrect, broken or sagging springs.
Replace springs.
Loose stabilizer bar.
Tighten stabilizer bar bolts or replace
bushings.
Faulty shock absorber, struts or
mounting.
Replace shock absorber.
Broken or sagging springs.
Replace springs (In pairs).
Vehicle overloaded.
Reduce load.
Worn wheel bearings.
Replace wheel bearing.
Excessive tire or wheel run out.
Replace tire or wheel.
Worn ball joints.
Replace ball joints.
Tire out of balance.
Adjust tire balance.
REAR SUSPENSION
3D–5
Coil Spring
Coil Spring and Associated Parts
460R200001
Legend
(1) Stabilizer Bar
(2) Upper Link Fixing Bolt and Nut
(3) Rubber Plate
Removal
1. Raise the vehicle and support the frame with suitable
safety stands.
2. Support the rear axle case with a jack.
3. Disconnect brake hose at the crossmember.
4. Remove breather hose.
5. Remove upper link fixing bolt, nut and rubber plate on
the rear axle case (left-side only).
(4)
(5)
(6)
(7)
Coil Spring
Insulator
Shock Absorber
Breather Hose
6. Disconnect the stabilizer bar at the stabilizer link.
7. Remove the shock absorber from the axle case.
8. Remove spring insulator.
9. Remove the insulator and coil spring while lowering
the rear axle case.
CAUTION: Be sure not to let the brake hose, parking
brake cable, and breather hose extend to their full
length.
3D–6
REAR SUSPENSION
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
Check the following parts:
B Coil spring
B Insulator
3. Install the insulator on the coil spring. Jack up the axle
case gently with the top of the coil spring set to the
spring seat on the frame side.
Installation
1. Install coil spring and make sure that the coil spring is
installed in the proper position. Paint mark(1) should
be downward.
460RW013
4. Install shock absorber and make sure that installed in
the proper position. (Refer to Intelligent Suspension)
Tighten the nut lightly, then retighten it to the specified
torque after the vehicle is at curb height.
NOTE: When mounting shock absorber, be sure not to
use grease on bushings or any other nearby part.
Torque: 78 N·m (58 lb ft)
5. Install stabilizer bar.
460RW001
2. Fit the end of the coil spring to the coil spring seat and
mount the coil spring on the rear axle case.
Torque: 31 N·m (23 lb ft)
6. Install upper link with rubber plate and tighten fixing
bolt.
Torque: 137 N·m (101 lb ft)
7. Install breather hose.
8. Connect brake hose and bleed the brake system.
Refer to Bleeding the Brake Hydraulic System in
Brake section.
460RW004
REAR SUSPENSION
3D–7
Shock Absorber
Shock Absorber and Associated Parts
461R200001
Legend
(1) Nut, Bush and Washer
Removal
1. Remove shock absorber fixing nut, bush and washer
(upper side).
2. Remove shock absorber fixing nut and washer (lower
side).
3. Remove shock absorber.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
Check the following parts:
B Shock absorber
B Rubber bushing
NOTE: When mounting rubber bushings, be sure not to
use grease on bushings or any other nearby part.
(2) Shock Absorber
(3) Nut and Washer
Installation
1. Install shock absorber. When mounting shock
absorber, make sure to be installed in the proper
position and not to use grease on bushings or any
other nearby part. (Refer to Intelligent Suspension)
2. Install nut and washer (lower side), then tighten the
nut lightly. Retighten to the bolt and nut specified
torque after the vehicle is at curb height.
Torque: 78 N·m (58 lb ft)
3. Install nut, bush and washer (upper side), then tighten
the nut lightly. Retighten to the nut specified torque
after the vehicle is at curb height.
Torque: 20 N·m (14 lb ft)
3D–8
REAR SUSPENSION
Trailing Link
Trailing Link and Associated Parts
460RW005
Legend
(1) Bolt and Nut (Axle side)
(2) Protector (Left side only)
(3) Bolt (Frame side)
Removal
1. Remove the parking brake cable from the trailing link.
2. Remove the trailing link fixing bolt, nut and protector.
3. Remove trailing link.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
1. Trailing link
2. Rubber bushing
B Remove the rubber bushing by using remover
J–39214.
901RW058
REAR SUSPENSION
B Install the rubber bushing by using installer
J–39214.
NOTE: When mounting rubber bushings, be sure not to
use grease on bushings or any other nearby part.
901RW059
Installation
1. Install trailing link. Make sure that the trailing link is in
its correct position.
NOTE: When mounting trailing link, be sure not to use
grease on bushings or any other nearby part.
460RW011
2. Install bolt, nut and protector. Tighten the bolts and
nuts lightly, then retighten them to the specified
torque after the vehicle is at curb height.
Torque: 137 N·m (101 lb ft)
3. Install parking brake cable.
CAUTION: The parking brake cable should not be
overstrained or slackened.
3D–9
3D–10
REAR SUSPENSION
Upper Link
Upper Link and Associated Parts
460RW006
Legend
(1) Bolt and Nut (Axle side)
(2) Rubber Plate
(3) Upper Link
(4) Protector (Left side only)
(5) Bolt (Frame side)
Removal
1. Remove fuel tank. Refer to Engine Fuel in Engine
section.
2. Remove the speed sensor cable from the upper link.
3. Remove bolt, nut, rubber plate and protector.
4. Remove upper link.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
1. Upper link
2. Rubber bushing
B Remove the rubber bushing by using remover
J–43008.
460RY00006
REAR SUSPENSION
B Install the rubber bushing by using to installer
J–43008.
NOTE: When mounting rubber bushings, be sure not to
use grease on bushings or any other nearby part.
460RY00007
Installation
1. Install upper link. Make sure that the upper link is in its
correct position.
NOTE: When mounting upper link, be sure not to use
grease bushings or any other nearby part.
460RW012
2. Install bolt, nut, rubber plate and protector. Tighten
the bolts and nuts lightly, then retighten them to the
specified torque after the vehicle is at curb height.
Torque: 137 N·m (101 lb ft)
3. Install speed sensor cable.
4. Install fuel tank.
3D–11
3D–12
REAR SUSPENSION
Lateral Rod
Lateral Rod and Associated Parts
460RW007
Legend
(1) Bolt and Nut (Frame side)
(2) Lateral Rod
(3) Nut and Washer (Axle side)
Removal
1. Remove nut and washer.
2. Remove bolt and nut.
3. Remove lateral rod.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
1. Lateral rod
2. Rubber bushing (Frame side)
B Remove the rubber bushing (Frame side) by using
remover J–39215.
901RW060
REAR SUSPENSION
3D–13
B Install the rubber bushing (Frame side) by using
Installer J–39215.
NOTE: When mounting rubber bushings, do not use
grease on bushings or any other nearby parts.
901RW063
Installation
901RW061
3. Rubber bushing (Axle side)
B Remove the rubber bushing (Axle side) by using
remover J–39792.
1. Install lateral rod and make sure that the lateral rod is
in its correct position.
NOTE: When mounting lateral rod, be sure not to use
grease on bushings or any other nearby part.
460RW008
901RW062
B Install the rubber bushing (Axle side) by using
installer J–39792.
Legend
(1) Frame Side
(2) Axle Side
2. Install bolt and nut (Frame side). Tighten the bolt and
nut lightly, then retighten them to the specified torque
after the vehicle is at curb height.
Torque: 137 N·m (101 lb ft)
3. Install nut and washer (Axle side). Tighten the nut
lightly, then retighten the nut to the specified torque
after the vehicle is at curb height.
Torque: 78 N·m (58 lb ft)
3D–14
REAR SUSPENSION
Stabilizer Bar
Stabilizer Bar and Associated Parts
460RW009
Legend
(1) Bracket and Bolt
(2) Link
Removal
1. Raise the vehicle and support the frame with suitable
safety stands.
2. Remove wheel and tire assembly. Refer to Wheel in
this section.
3. Remove bolt and nut.
4. Remove link.
5. Remove bracket.
6. Remove rubber bushing.
(3) Bolt and Nut
(4) Stabilizer Bar
(5) Rubber Bushing
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
Check the following parts:
B Stabilizer bar
B Rubber bushing
B Link
REAR SUSPENSION
Installation
1. Install rubber bushing.
2. Install bracket to axle housing and tighten to the
specified torque.
Torque: 25 N·m (19 lb ft)
3. Install link.
4. Install bolt and nut, then tighten the nut to the
specified torque.
Torque: 31 N·m (27 lb ft)
460RW010
3D–15
3D–16
REAR SUSPENSION
Main Data and Specifications
General Specifications
Rear suspension
Type
Coil spring
Free length
Shock absorber
Stabilizer bar
5–Link, coil spring type with stabilizer bar.
370.5 mm (14.59 in)
Spring diameter
12.4 mm (0.49 in)
Coil diameter
(inner)
105 mm (4.13 in)
Effective No. of
turns
5.21
Total No. of turns
6.71
Type
Hydraulic, double acting, telescopic
Piston diameter
30 mm (1.18 in)
Stroke
159 mm (6.26 in)
Extended length
518 mm (20.39 in)
Compressed
length
359 mm (14.13 in)
Diameter
18 mm (0.71 in)
REAR SUSPENSION
3D–17
Torque Specifications
E03R200002
3D–18
REAR SUSPENSION
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
J–39214
Remover and Installer;
Trailing link bushing
J–43008
Remover and Installer;
Upper link bushing
J–39792
Remover and Installer;
Lateral rod bushing
(Axle side)
J–39215
Remover and Installer;
Lateral rod bushing
(Frame side)
REAR SUSPENSION
3D–19
AXIOM (Vehicles Produced After Aug./1/2001)
REAR SUSPENSION
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . .
General Description . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coil Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coil Spring and Associated Parts . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . .
Shock Absorber and Associated Parts . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trailing Link . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trailing Link and Associated Parts . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3D–19
3D–19
3D–20
3D–23
3D–23
3D–23
3D–24
3D–24
3D–25
3D–25
3D–25
3D–25
3D–25
3D–26
3D–26
3D–26
3D–26
3D–27
Upper Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upper Link and Associated Parts . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lateral Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lateral Rod and Associated Parts . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stabilizer Bar and Associated Parts . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . .
3D–28
3D–28
3D–28
3D–28
3D–29
3D–30
3D–30
3D–30
3D–30
3D–31
3D–32
3D–32
3D–32
3D–32
3D–33
3D–34
3D–36
Service Precaution
General Description
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.
The rear suspension is a 5-link, coil spring type
suspension with a stabilizer bar, consisting of two trailing
links, two upper links, lateral rod, shock absorber, and
stabilizer. In this suspension, the links are specially
arranged to enable the rear axle to move freely, thereby
expanding suspension stroke, reducing friction, and
improving lateral rigidity and roll control. All these result in
improved stability, riding comfort, and rough road
maneuverability.
Each link connects the axle housing with the frame
through a runner bushing. The axle housing is supported
by the trailing links and upper links longitudinally and by
the lateral rod latitudinally.
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.
3D–20
REAR SUSPENSION
Diagnosis
Condition
Vehicle Pulls
Possible cause
Mismatched or uneven tires.
Replace tire.
Tires not adequately inflated.
Adjust tire pressure.
Broken or sagging springs.
Replace spring.
Radial tire lateral force.
Replace tire.
Improper wheel alignment.
Adjust wheel alignment.
Brake dragging in one wheel.
Repair brake.
Loose, bent or broken front or rear
suspension parts.
Tighten or replace the appropriate
suspension part(s).
Faulty shock absorbers.
Replace shock absorber.
Parts in power
defective.
Abnormal or Excessive Tire Wear
Wheel Hop
Shimmy, Shake or Vibration
Correction
steering
valve
Replace power steering unit.
Sagging or broken spring.
Replace spring.
Tire out of balance.
Balance or replace tire.
Improper wheel alignment.
Check front end alignment.
Faulty shock absorber.
Replace shock absorber.
Hard driving.
Replace tire.
Overloaded vehicle.
Replace tire and reduce load.
Tires not rotated periodically.
Replace or rotate tire.
Worn or loose road wheel bearings.
Replace wheel bearing.
Wobbly wheel or tires.
Replace wheel or tire.
Tires not adequately inflated.
Adjust the pressure.
Blister or bump on tire.
Replace tire.
Improper shock absorber operation.
Replace shock absorber.
Tire or wheel out of balance.
Balance wheels or replace tire/or
wheel.
Loose wheel bearings.
Replace wheel bearing.
Worn steering linkage ball joints.
Replace ball joints.
Worn upper or lower end ball joints.
Replace ball joints.
Excessive wheel runout.
Repair or replace wheel and/or tire.
Blister or bump on tire.
Replace tire.
Excessive loaded radial runout of
tire/wheel assembly.
Replace tire or wheel.
Improper wheel alignment.
Check wheel alignment.
Loose or worn steering linkage.
Tighten or replace steering linkage.
Loose steering unit.
Tighten steering unit.
Tires not adequately inflated.
Adjust tire pressure.
Loose, bent or broken front or rear
suspension parts.
Tighten or replace the appropriate
suspension parts.
Faulty shock absorber.
Replace shock absorber.
Hub bearing preload misadjustment.
Adjust preload.
Parts in power
defective.
Replace power steering unit.
steering
valve
REAR SUSPENSION
Condition
Hard Steering
Too Much Play In Steering
Possible cause
Abnormal Noise
Wandering or Poor Steering Stability
Correction
Bind in steering linkage ball studs,
upper or lower ball joint.
Replace ball joint.
Improper wheel alignment.
Check wheel alignment.
Tire not adequately inflated.
Inflate tires to proper pressure.
Bind in steering column or shaft.
Repair or replace.
Improper power steering system
operation.
Repair or replace. Refer to Steering
section.
Wheel bearings worn.
Replace wheel bearings.
Loose steering unit or linkage.
Retighten or repair.
Worn or loose
universal joint.
Poor Steering Wheel Returnability
3D–21
steering
shaft
Retighten or replace steering shaft.
Worn steering linkage ball joints.
Replace ball joints.
Worn upper or lower end ball joints.
Replace ball joints.
Bind in steering linkage ball joints.
Replace ball joints.
Bind in upper or lower ball joints.
Replace ball joints.
Bind in steering column and shaft.
Repair or replace.
Bind in steering gear.
Check and repair steering gear.
Improper wheel alignment.
Adjust wheel alignment.
Tires not adequately inflated.
Adjust pressure.
Loose steering wheel nut.
Retighten.
Worn wheel bearing.
Replace.
Misassemble Transfer Gear ASM
Reassemble Transfer Gear to proper
portion
Worn, sticky or loose upper or lower
ball joint, steering linkage ball joints
or drive axle joints.
Replace.
Faulty shock absorbers.
Replace.
Worn upper or lower control arm
bushing.
Replace.
Loose stabilizer bar.
Retighten bolts or replace bushings.
Loose wheel nuts.
Tighten nuts. Check for elongated
wheel nut holes. Replace wheel if
required.
Loose suspension bolts or nuts.
Retighten suspension bolts or nuts.
Broken or otherwise damaged wheel
bearings.
Replace wheel bearing.
Broken suspension springs.
Replace spring.
Loose steering unit.
Retighten mounting bolt.
Faulty steering unit.
Replace steering unit.
Mismatched or unevenly worn tires.
Replace tire or inflate tires to proper
pressure.
Loose steering linkage ball joints.
Replace ball joints.
Faulty shock absorbers.
Replace shock absorber.
Loose stabilizer bar.
Tighten or replace stabilizer bar or
bushings.
Broken or sagging springs.
Replace spring (pairs).
Improper wheel alignment.
Adjust wheel alignment.
3D–22
REAR SUSPENSION
Condition
Erratic Steering When Braking
Low or Uneven Trim Height
Suspension Bottoms
Body Leans
Cupped Tires
Possible cause
Correction
Worn wheel bearings.
Replace wheel bearings.
Broken or sagging springs.
Replace spring (pairs).
Leaking caliper.
Repair or replace caliper.
Warped discs.
Replace brake disc.
Badly worn brake pads.
Replace brake pads.
Tires are inflated unequally.
Inflate tires to proper pressure.
Broken or sagging springs.
Replace springs (In pairs).
Vehicle overloaded.
Reduce load.
Incorrect springs.
Adjust or replace torsion bar.
Trim Height out of spec
Adjust Trim height
Vehicle overloaded.
Reduce load.
Faulty shock absorber.
Replace shock absorber.
Incorrect, broken or sagging springs.
Replace springs.
Trim Height out of spec
Adjust Trim height
Loose stabilizer bar.
Tighten stabilizer bar bolts or replace
bushings.
Faulty shock absorber, struts or
mounting.
Replace shock absorber.
Broken or sagging springs.
Replace springs (In pairs).
Vehicle overloaded.
Reduce load.
Worn wheel bearings.
Replace wheel bearing.
Excessive tire or wheel run out.
Replace tire or wheel.
Worn ball joints.
Replace ball joints.
Tire out of balance.
Adjust tire balance.
REAR SUSPENSION
3D–23
Coil Spring
Coil Spring and Associated Parts
460R200004
Legend
(1) Stabilizer Bar
(2) Upper Link Fixing Bolt and Nut
(3) Rubber Plate
Removal
1. Raise the vehicle and support the frame with suitable
safety stands.
2. Support the rear axle case with a jack.
3. Disconnect brake hose at the crossmember.
4. Remove breather hose.
5. Remove upper link fixing bolt, nut and rubber plate on
the rear axle case (left-side only).
(4)
(5)
(6)
(7)
Coil Spring
Insulator
Shock Absorber
Breather Hose
6. Disconnect the stabilizer bar at the stabilizer link.
7. Remove the shock absorber from the axle case.
8. Remove spring insulator.
9. Remove the insulator and coil spring while lowering
the rear axle case.
CAUTION: Be sure not to let the brake hose, parking
brake cable, and breather hose extend to their full
length.
3D–24
REAR SUSPENSION
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
Check the following parts:
B Coil spring
B Insulator
3. Install the insulator on the coil spring. Jack up the axle
case gently with the top of the coil spring set to the
spring seat on the frame side.
Installation
1. Install coil spring and make sure that the coil spring is
installed in the proper position. Paint mark(1) should
be downward.
460RW013
4. Install shock absorber and tighten the nut lightly, then
retighten it to the specified torque after the vehicle is
at curb height.
NOTE: When mounting shock absorber, be sure not to
use grease on bushings or any other nearby part.
Torque: 78 N·m (58 lb ft)
5. Install stabilizer bar at the stabilizer link.
Torque: 31 N·m (23 lb ft)
460RW001
2. Fit the end of the coil spring to the coil spring seat and
mount the coil spring on the rear axle case.
6. Install upper link with rubber plate and tighten fixing
bolt.
Torque: 137 N·m (101 lb ft)
7. Install breather hose.
8. Connect brake hose and bleed the brake system.
Refer to Bleeding the Brake Hydraulic System in
Brake section.
460RW004
REAR SUSPENSION
3D–25
Shock Absorber
Shock Absorber and Associated Parts
461RW001
Legend
(1) Nut, Bush and Washer
Removal
1. Remove shock absorber fixing nut, bush and washer
(upper side).
2. Remove shock absorber fixing nut and washer (lower
side).
3. Remove shock absorber.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
Check the following parts:
B Shock absorber
B Rubber bushing
NOTE: When mounting rubber bushings, be sure not to
use grease on bushings or any other nearby part.
(2) Shock Absorber
(3) Nut and Washer
Installation
1. Install shock absorber. When mounting shock
absorber, be sure not to use grease on bushings or
any other nearby part.
2. Install nut and washer (lower side), then tighten the
nut lightly. Retighten to the bolt and nut specified
torque after the vehicle is at curb height.
Torque: 78 N·m (58 lb ft)
3. Install nut, bush and washer (upper side), then tighten
the nut lightly. Retighten to the nut specified torque
after the vehicle is at curb height.
Torque: 20 N·m (14 lb ft)
3D–26
REAR SUSPENSION
Trailing Link
Trailing Link and Associated Parts
460RW005
Legend
(1) Bolt and Nut (Axle side)
(2) Protector (Left side only)
(3) Bolt (Frame side)
Removal
1. Remove the parking brake cable from the trailing link.
2. Remove the trailing link fixing bolt, nut and protector.
3. Remove trailing link.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
1. Trailing link
2. Rubber bushing
B Remove the rubber bushing by using remover
J–39214.
901RW058
REAR SUSPENSION
B Install the rubber bushing by using installer
J–39214.
NOTE: When mounting rubber bushings, be sure not to
use grease on bushings or any other nearby part.
901RW059
Installation
1. Install trailing link. Make sure that the trailing link is in
its correct position.
NOTE: When mounting trailing link, be sure not to use
grease on bushings or any other nearby part.
460RW011
2. Install bolt, nut and protector. Tighten the bolts and
nuts lightly, then retighten them to the specified
torque after the vehicle is at curb height.
Torque: 137 N·m (101 lb ft)
3. Install parking brake cable.
CAUTION: The parking brake cable should not be
overstrained or slackened.
3D–27
3D–28
REAR SUSPENSION
Upper Link
Upper Link and Associated Parts
460RW006
Legend
(1) Bolt and Nut (Axle side)
(2) Rubber Plate
(3) Upper Link
(4) Protector (Left side only)
(5) Bolt (Frame side)
Removal
1. Remove fuel tank. Refer to Engine Fuel in Engine
section.
2. Remove the speed sensor cable from the upper link.
3. Remove bolt, nut, rubber plate and protector.
4. Remove upper link.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
1. Upper link
2. Rubber bushing
B Remove the rubber bushing by using remover
J–43008.
460RY00006
REAR SUSPENSION
B Install the rubber bushing by using to installer
J–43008.
NOTE: When mounting rubber bushings, be sure not to
use grease on bushings or any other nearby part.
460RY00007
Installation
1. Install upper link. Make sure that the upper link is in its
correct position.
NOTE: When mounting upper link, be sure not to use
grease bushings or any other nearby part.
460RW012
2. Install bolt, nut, rubber plate and protector. Tighten
the bolts and nuts lightly, then retighten them to the
specified torque after the vehicle is at curb height.
Torque: 137 N·m (101 lb ft)
3. Install speed sensor cable.
4. Install fuel tank.
3D–29
3D–30
REAR SUSPENSION
Lateral Rod
Lateral Rod and Associated Parts
460RW007
Legend
(1) Bolt and Nut (Frame side)
(2) Lateral Rod
(3) Nut and Washer (Axle side)
Removal
1. Remove nut and washer.
2. Remove bolt and nut.
3. Remove lateral rod.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
1. Lateral rod
2. Rubber bushing (Frame side)
B Remove the rubber bushing (Frame side) by using
remover J–39215.
901RW060
REAR SUSPENSION
3D–31
B Install the rubber bushing (Frame side) by using
Installer J–39215.
NOTE: When mounting rubber bushings, do not use
grease on bushings or any other nearby parts.
901RW063
Installation
901RW061
3. Rubber bushing (Axle side)
B Remove the rubber bushing (Axle side) by using
remover J–39792.
1. Install lateral rod and make sure that the lateral rod is
in its correct position.
NOTE: When mounting lateral rod, be sure not to use
grease on bushings or any other nearby part.
460RW008
901RW062
B Install the rubber bushing (Axle side) by using
installer J–39792.
Legend
(1) Frame Side
(2) Axle Side
2. Install bolt and nut (Frame side). Tighten the bolt and
nut lightly, then retighten them to the specified torque
after the vehicle is at curb height.
Torque: 137 N·m (101 lb ft)
3. Install nut and washer (Axle side). Tighten the nut
lightly, then retighten the nut to the specified torque
after the vehicle is at curb height.
Torque: 78 N·m (58 lb ft)
3D–32
REAR SUSPENSION
Stabilizer Bar
Stabilizer Bar and Associated Parts
460R200003
Legend
(1) Bracket and Bolt
(2) Link
Removal
1. Raise the vehicle and support the frame with suitable
safety stands.
2. Remove wheel and tire assembly. Refer to Wheel in
this section.
3. Remove nut.
4. Remove link.
5. Remove bracket.
6. Remove rubber bushing.
(3) Nut
(4) Stabilizer Bar
(5) Rubber Bushing
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
Check the following parts:
B Stabilizer bar
B Rubber bushing
B Link
REAR SUSPENSION
Installation
1. Install rubber bushing.
2. Install bracket to axle housing and tighten to the
specified torque.
Torque: 25 N·m (18 lb ft)
3. Install link.
4. Install nut, then tighten the nut to the specified torque.
Torque: 50 N·m (37 lb ft)
460R200002
3D–33
3D–34
REAR SUSPENSION
Main Data and Specifications
General Specifications
Rear suspension
Type
Coil spring
Free length
Shock absorber
Stabilizer bar
5–Link, coil spring type with stabilizer bar.
370.5 mm (14.59 in)
Spring diameter
12.4 mm (0.49 in)
Coil diameter
(inner)
105 mm (4.13 in)
Effective No. of
turns
5.21
Total No. of turns
6.71
Type
Hydraulic, double acting, telescopic
Piston diameter
30 mm (1.18 in)
Stroke
159 mm (6.26 in)
Extended length
518 mm (20.39 in)
Compressed
length
359 mm (14.13 in)
Diameter
18 mm (0.71 in)
REAR SUSPENSION
3D–35
Torque Specifications
E03R200006
3D–36
REAR SUSPENSION
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
J–39214
Remover and Installer;
Trailing link bushing
J–43008
Remover and Installer;
Upper link bushing
J–39792
Remover and Installer;
Lateral rod bushing
(Axle side)
J–39215
Remover and Installer;
Lateral rod bushing
(Frame side)
SECTION
WHEEL AND TIRE SYSTEM
3E–1
AXIOM
SUSPENSION
WHEEL AND TIRE SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . .
General Description . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel and Associated Parts . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3E–1
3E–2
3E–3
3E–11
3E–11
3E–11
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.
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tire Replacement . . . . . . . . . . . . . . . . . . . . . .
General Balance Procedure . . . . . . . . . . . . . .
Balancing Wheel and Tire . . . . . . . . . . . . . . . .
Main Data and Specifications . . . . . . . . . . . . .
3E–11
3E–12
3E–12
3E–12
3E–13
3E–14
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.
3E–2
WHEEL AND TIRE SYSTEM
General Description
480R200001
Replacement wheels or tires must be equivalent to the
originals in load capacity, specified dimension and
mounting configuration. Improper size or type may affect
bearing life, brake performance, speedometer/odometer
calibration, vehicle ground clearance and tire clearance
to the body and chassis. All models are equipped with
metric sized tubeless steel belted radial tires. Correct tire
pressures and driving habits have an important influence
on tire life.
Heavy cornering, excessively rapid
acceleration and unnecessary sharp braking increase
premature and uneven wear.
WHEEL AND TIRE SYSTEM
3E–3
Diagnosis
Condition
Vehicle Pulls
Possible cause
Mismatched or uneven tires.
Replace tire.
Tires not adequately inflated.
Adjust tire pressure.
Broken or sagging springs.
Replace spring.
Radial tire lateral force.
Replace tire.
Improper wheel alignment.
Adjust wheel alignment.
Brake dragging in one wheel.
Repair brake.
Loose, bent or broken front or rear
suspension parts.
Tighten or replace the appropriate
suspension part(s).
Faulty shock absorbers.
Replace shock absorber.
Parts in power
defective.
Abnormal or Excessive Tire Wear
Wheel Hop
Shimmy, Shake or Vibration
Correction
steering
valve
Replace power steering unit.
Sagging or broken spring.
Replace spring.
Tire out of balance.
Balance or replace tire.
Improper wheel alignment.
Check front end alignment.
Faulty shock absorber.
Replace shock absorber.
Hard driving.
Replace tire.
Overloaded vehicle.
Replace tire and reduce load.
Tires not rotated periodically.
Replace or rotate tire.
Worn or loose road wheel bearings.
Replace wheel bearing.
Wobbly wheel or tires.
Replace wheel or tire.
Tires not adequately inflated.
Adjust the pressure.
Blister or bump on tire.
Replace tire.
Improper shock absorber operation.
Replace shock absorber.
Tire or wheel out of balance.
Balance wheels or replace tire/or
wheel.
Loose wheel bearings.
Replace wheel bearing.
Worn steering linkage ball joints.
Replace ball joints.
Worn upper or lower end ball joints.
Replace ball joints.
Excessive wheel runout.
Repair or replace wheel and/or tire.
Blister or bump on tire.
Replace tire.
Excessive loaded radial runout of
tire/wheel assembly.
Replace tire or wheel.
Improper wheel alignment.
Check wheel alignment.
Loose or worn steering linkage.
Tighten or replace steering linkage.
Loose steering unit.
Tighten steering unit.
Tires not adequately inflated.
Adjust tire pressure.
Loose, bent or broken front or rear
suspension parts.
Tighten or replace the appropriate
suspension parts.
Faulty shock absorber.
Replace shock absorber.
Hub bearing preload misadjustment.
Adjust preload.
Parts in power
defective.
Replace power steering unit.
steering
valve
3E–4
WHEEL AND TIRE SYSTEM
Condition
Hard Steering
Too Much Play In Steering
Possible cause
Bind in steering linkage ball studs,
upper or lower ball joint.
Replace ball joint.
Improper wheel alignment.
Check wheel alignment.
Tire not adequately inflated.
Inflate tires to proper pressure.
Bind in steering column or shaft.
Repair or replace.
Improper power steering system
operation.
Repair or replace. Refer to Steering
section.
Wheel bearings worn.
Replace wheel bearings.
Loose steering unit or linkage.
Retighten or repair.
Worn or loose
universal joint.
Poor Steering Wheel Returnability
Abnormal Noise
Wandering or Poor Steering Stability
Correction
steering
shaft
Retighten or replace steering shaft.
Worn steering linkage ball joints.
Replace ball joints.
Worn upper or lower end ball joints.
Replace ball joints.
Bind in steering linkage ball joints.
Replace ball joints.
Bind in upper or lower ball joints.
Replace ball joints.
Bind in steering column and shaft.
Repair or replace.
Bind in steering gear.
Check and repair steering gear.
Improper wheel alignment.
Adjust wheel alignment.
Tires not adequately inflated.
Adjust pressure.
Loose steering wheel nut.
Retighten.
Worn wheel bearing.
Replace.
Worn, sticky or loose upper or lower
ball joint, steering linkage ball joints
or drive axle joints.
Replace.
Faulty shock absorbers.
Replace.
Worn upper or lower control arm
bushing.
Replace.
Loose stabilizer bar.
Retighten bolts or replace bushings.
Loose wheel nuts.
Tighten nuts. Check for elongated
wheel nut holes. Replace wheel if
required.
Loose suspension bolts or nuts.
Retighten suspension bolts or nuts.
Broken or otherwise damaged wheel
bearings.
Replace wheel bearing.
Broken suspension springs.
Replace spring.
Loose steering unit.
Retighten mounting bolt.
Faulty steering unit.
Replace steering unit.
Mismatched or unevenly worn tires.
Replace tire or inflate tires to proper
pressure.
Loose steering linkage ball joints.
Replace ball joints.
Faulty shock absorbers.
Replace shock absorber.
Loose stabilizer bar.
Tighten or replace stabilizer bar or
bushings.
Broken or sagging springs.
Replace spring (pairs).
Improper wheel alignment.
Adjust wheel alignment.
WHEEL AND TIRE SYSTEM
Condition
Erratic Steering When Braking
Low or Uneven Trim Height
Suspension Bottoms
Body Leans
Cupped Tires
Possible cause
3E–5
Correction
Worn wheel bearings.
Replace wheel bearings.
Broken or sagging springs.
Replace spring (pairs).
Leaking caliper.
Repair or replace caliper.
Warped discs.
Replace brake disc.
Badly worn brake pads.
Replace brake pads.
Tires are inflated unequally.
Inflate tires to proper pressure.
Broken or sagging springs.
Replace springs (In pairs).
Vehicle overloaded.
Reduce load.
Incorrect springs.
Adjust or replace torsion bar.
Vehicle overloaded.
Reduce load.
Faulty shock absorber.
Replace shock absorber.
Incorrect, broken or sagging springs.
Replace springs.
Loose stabilizer bar.
Tighten stabilizer bar bolts or replace
bushings.
Faulty shock absorber, struts or
mounting.
Replace shock absorber.
Broken or sagging springs.
Replace springs (In pairs).
Vehicle overloaded.
Reduce load.
Worn wheel bearings.
Replace wheel bearing.
Excessive tire or wheel run out.
Replace tire or wheel.
Worn ball joints.
Replace ball joints.
Tire out of balance.
Adjust tire balance.
Irregular and Premature Wear
480RS001
Irregular and/or premature wear has many causes.
Some of them are incorrect inflation pressures, lack of tire
rotation, poor driving habits or improper wheel alignment.
Incorrect inflation is common cause of tire premature
wear.
NOTE: Due to their design, radial tires tend to wear faster
in the shoulder area, particularly on the front tires. This
makes regular rotation especially necessary. After
rotation, be sure to check wheel nut torque, and set tire
pressures.
3E–6
WHEEL AND TIRE SYSTEM
Tire Rotation
Tire rotation is recommended to equalize wear for longer
tire life.
indicators may appear as wide bands. When the indicators appear in two or more grooves at three locations, tire
replacement is recommended.
Inflation of Tires
480RS002
Legend
(1) Spare Tire
710RW002
If the following conditions are noted, rotate the tires:
B Front tire wear is different from rear.
B Uneven wear exists across the tread of any tire.
B Left and right front tire wear is unequal.
B Left and right rear tire wear is unequal.
Check wheel alignment if the following conditions are
noted:
B Left and right front tire wear is unequal.
B Wear is uneven across the tread of any front tire.
B Front tire treads have a scuffed appearance with
“feather” edges on one side of the tread ribs or blocks.
Tread Wear Indicators
480RS006
The original equipment tires have built-in tread wear indicators(1) to show when tires need replacement. These
Tire pressure, in cold condition (after vehicle has set for
three hours or more, and driven less than one mile),
should be checked monthly or before any extended trip.
Tire pressure increases approximately 15% when the
tires become hot during driving. Tire pressure specification is shown on the label located on the left door lock pillar.
NOTE: Check the tire pressure whenever irregular wear
is found. Tire inflation greatly affects tire wear. If the
alignment check does not reveal any alignment problems,
check the condition of the shock absorbers and wheel/tire
balance.
Diagnosis List
If the following conditions are noted, rotation is required.
1. Front tire wear is different from rear.
2. Uneven wear exists across the tread of any tire.
3. Left and right front tire wear is unequal.
4. Left and right rear tire wear is unequal.
If the following conditions are noted, check the wheel
alignment.
1. Left and right front tire wear is unequal.
2. Uneven wear exists across the tread of any tire.
3. Front tire treads have scuffed appearance with
“feather” edges on one side of tread ribs or blocks.
4. There is cupping, flat spotting etc.
Higher than recommended pressure can cause:
1. Hard ride.
2. Poor steering stability.
3. Rapid and uneven wear at center of the tread.
Lower than recommended pressure can cause:
1. Tire squeal on turns.
2. Hard steering.
3. Rapid and uneven wear on the edges of the tread.
4. Tire rim bruises and rupture.
WHEEL AND TIRE SYSTEM
5. Tire cord breakage.
6. High tire temperatures.
7. Reduced handling.
8. Reduced fuel economy.
Unequal pressure on same axle can cause:
1. Uneven braking.
2. Steering lead.
3. Reduced handling.
4. Swerve on acceleration.
3E–7
Radial Tire Lead/Pull
“Lead/Pull” is vehicle deviation from a straight path, on a
level road with no pressure on the steering wheel.
Lead is usually caused by:
1. Poorly manufactured radial tires.
2. Uneven brake adjustment.
3. Wheel alignment.
The way in which a tire is built can produce lead in a car.
An example of this is placement of the belt. Off-center
belts on radial tires can cause the tire to develop a side
force while rolling straight down the road and the tire will
tend to roll like a cone.
The “Radial Tire Lead/Pull Correction” chart should be
used to make sure that front wheel alignment is not mistaken for tire lead.
Rear tires will not cause lead/pull.
Radial Tire Waddle
480R200006
Waddle is side-to-side movement at the front and/or rear
of the car. It can be caused by the steel belt not being
straight within the tire, or by excessive lateral runout of the
tire or wheel. It is most noticeable at low speed, about 8
to 48 km/h (5 to 30 mph). It may also cause rough ride at
80 to 113 km/h (50 to 70 mph).
The car can be road tested to see which end of the car has
the faulty tire. If the tire causing the waddle is on the rear,
the rear end of the car will “waddle”. From the driver’s
seat, it feels as if someone is pushing on the side of the
car.
If the faulty tire is on the front, the waddle is more easily
seen. The front sheet metal appears to be moving back
and forth. It feels as if the driver’s seat is the pivot point
in the car.
Another more time-consuming method of determining the
faulty tire is substituting tire and wheel assemblies that
are known to be good. Follow these steps:
1. Drive the car to determine if the waddle is coming
from the front or rear.
2. Install tire and wheel assemblies known to be good
(from a similar car) in place of those on the end of the
car which is waddling. If the waddle cannot be
isolated to front or rear, start with the rear tires.
3. Road test again. If improvement is noted, install the
original tire and wheel assemblies one at a time until
the faulty tire is found. If no improvement is noted,
install tires known to be good in place of all four. Then,
install the originals one at a time until the faulty tire is
found.
3E–8
WHEEL AND TIRE SYSTEM
Radial Tire Lead/Pull Correction Chart
Step
1
Action
Switch front tires side to side and road test again.
Was a problem corrected?
3
Did the vehicle lead in same direction?
4
Put tires back in original position and check alignment.
Was a problem corrected?
5
No
End.
Go to Step 2
If roughness
results,replace
tires.
Go to Step 3
Go to Step 4
Go to Step 5
End.
Go to Step 5
Replace tire.
Install a known
good tire in place
of other front tire.
If lead corrected,
replace tire.
1. Inflate tires to recommended pressure.
2. Road test vehicle on level uncrowned road.
Was a problem corrected?
2
Yes
Install known good tire on one front side.
Was a problem corrected?
Typical examples of abnormal tire ahead wear and major
causes:
Tread wear one-sided.
CAUTION: Similar wear patterns can be caused by
worn suspension parts, misalignment of wheels and
tires, and other suspension related problems.
Spotty wear – wear localized on shoulder sections, and
in an extreme cases, the tire becomes polygonal in
shape.
480RW003
1. Rotating parts out of balance.
2. Tire or wheel out of round.
3. Hub or knuckle out of round or distorted.
480RW002
1. Tire or wheel out of round or distorted.
2. Hub or knuckle out of round or distorted.
3. Play in hub bearings or ball joint.
4. Rotating parts out of balance.
WHEEL AND TIRE SYSTEM
Localized tread wear.
3E–9
Wear in shoulders at points opposed to each other.
480RW004
1. Once spotty wear develops in tread due to hard
braking or abrupt starting, localized wear tends to be
promoted.
Shoulder wear (generally wear develops in outer shoulder):
480RW006
1. Tire or wheel out of round or distorted.
2. Play in bearings or ball joint.
Premature wear in shoulders.
480RW007
1. Flexing of tire excessive due to under-inflation.
480RW005
1. Camber or toe-in incorrect.
2. Shoulder wear caused by repeated hard-cornering.
3E–10
WHEEL AND TIRE SYSTEM
One sided feather edging.
480RW008
1. Wear caused by repeated hard cornering.
2. Camber or toe-in incorrect.
WHEEL AND TIRE SYSTEM
3E–11
Wheel
Wheel and Associated Parts
480R200004
Legend
(1) Wheel Lug Nut
(2) Alumi Wheel and Tire
Removal
NOTE: Valve caps should be on the valve stems to keep
dust and water out.
1. Loosen wheel lug nut by approximately 180° (half a
rotation), then raise the vehicle and remove the nuts.
2. Remove wheel and tire.
NOTE: Never use heat to loosen a tight wheel lug nut.
The application of heat to the hub can shorten the life of
the wheel and may cause damage to wheel bearings.
Installation
1. Install wheel and tire.
2. Install wheel lug nut, and lower the vehicle. Tighten
the wheel lug nuts to the specified torque in numerical
order.
Torque: 118 N·m (87 lb ft)
CAUTION: Before installing wheels, remove any
build-up of corrosion on the wheel mounting surface
and brake disc mounting surface by scraping and
wire brushing. Installing wheels without good
metal-to-metal contact at mounting surfaces can
cause wheel nuts to loosen, which can later allow a
wheel to come off while the vehicle is moving.
480R200003
3E–12
WHEEL AND TIRE SYSTEM
Tire
Tire Replacement
Wheel Inspection
When replacement is necessary, the original metric tire
size should be used. Most metric tire sizes do not have
exact corresponding alphanumeric tire sizes. It is
recommended that new tires be installed in pairs on the
same axle. If necessary to replace only one tire, it should
be paired with tire having the most tread, to equalize
braking traction.
Damaged wheels and wheels with excessive run-out
must be replaced.
Wheel run out at rim (Base on hub Bore):
Aluminum
1– Vertical play: Less than 0.55 mm (0.022 in)
2– Horizontal play: Less than 0.55 mm (0.022 in)
CAUTION: Do not mix different types of tires such
as radial, bias and bias-belted tires except in
emergencies, because vehicle handling may be
seriously affected and may result in loss of control.
Tire Dismounting
Remove valve cap on valve step and deflate the tire. Then
use a tire changing machine to mount or dismount tires.
Follow the equipment manufacturer’s instruction. Do not
use hand tools or tire lever alone to change tires as they
may damage the tire beads or wheel rim.
Tire Mounting
Rim bead seats should be cleaned with a wire brush or
coarse steel wool to remove lubricants, and light rust.
Before mounting a tire, the bead area should be well
lubricated with an approved tire lubricant.
After mounting, inflate the tire to 196kPa (28 psi) so that
beads are completely seated. Inflate the air to specified
pressure and install valve cap to the stem.
WARNING: NEVER STAND OVER TIRE WHEN
INFLATING. BEAD MAY BREAK WHEN BEAD SNAPS
OVER RIM’S SAFETY HUMP AND CAUSE SERIOUS
PERSONAL INJURY.
NEVER EXCEED 240 KPA (35 PSI) PRESSURE WHEN
INFLATING. IF 240 KPA (35 PSI) PRESSURE WILL
NOT SEAT BEADS, DEFLATE, RE-LUBRICATE AND
RE-INFLATE. OVER INFLATION MAY CAUSE THE
BEAD TO BREAK AND CAUSE SERIOUS PERSONAL
INJURY.
Tire Repair
There are many different materials on the market used to
repair tires.
Manufacturers have published detailed instructions on
how and when to repair tires. These instructions can be
obtained from the tire manufacturer if they are not
included with the repair kit.
480RS012
General Balance Procedure
Deposits of mud, etc. must be cleaned from the inside of
the rim.
The tire should be inspected for the following: match
mount paint marks, bent rims, bulges, irregular tire wear,
proper wheel size and inflation pressure. Then balance
according
to
the
equipment
manufacturer’s
recommendations.
There are two types of wheel and tire balance.
Static balance is the equal distribution of weight around
the wheel.
Assemblies that are statically unbalanced cause a
bouncing action called tramp. This condition will
eventually cause uneven tire wear.
WHEEL AND TIRE SYSTEM
3E–13
Balancing Wheel and Tire
On-vehicle Balancing
On-Vehicle balancing methods vary with equipment and
tool manufacturers.
Be sure to follow each
manufacturer’s instructions during balancing operation.
Off-vehicle Balancing
Most electronic off-vehicle balancers are more accurate
than the on-vehicle spin balancers. They are easy to use
and give a dynamic balance. Although they do not correct
for drum or disc unbalance (as on- vehicle spin balancing
does), they are very accurate.
480RS013
Legend
(1) Heavy Spot Wheel Shimmy
(2) Add Balance Weights Here
Dynamic balance is the equal distribution of weight on
each side of the wheel center-line so that when the tire
spins there is no tendency for the assembly to move from
side to side. Assemblies that are dynamically unbalanced
may cause shimmy.
480RS015
480RS014
Legend
(1) Heavy Spot Wheel Hop
(2) Add Balance Weights Here
WARNING: STONES SHOULD BE REMOVED FROM
THE TREAD TO AVOID OPERATOR INJURY DURING
SPIN BALANCING AND TO OBTAIN A GOOD
BALANCE.
3E–14
WHEEL AND TIRE SYSTEM
Main Data and Specifications
General Specifications
Wheels
Standard tire
Size
17 × 7JJ
Offset
38.0 mm (1.50 in)
P.C.D., wheel studs
139.7 mm (5.50 in)
Size
P235/65R17
Pressure(Front)
180 kPa (26 psi)
Pressure(Rear)
180 kPa (26 psi)
Torque Specifications
480R200005
SECTION
INTELLIGENT SUSPENSION
3F–1
AXIOM
SUSPENSION
INTELLIGENT SUSPENSION CONTROL
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . .
General Description . . . . . . . . . . . . . . . . . . . . .
PIN ASSIGNMENT TABLE . . . . . . . . . . . . .
System Components . . . . . . . . . . . . . . . . . . .
Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . .
Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustable Damping Force Shock Absorber
Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . .
Vertical G-Sensor . . . . . . . . . . . . . . . . . . . . . .
Lateral G-Sensor . . . . . . . . . . . . . . . . . . . . . .
Acronyms and Abbreviations . . . . . . . . . . . .
General Diagnosis . . . . . . . . . . . . . . . . . . . . . . .
General Information . . . . . . . . . . . . . . . . . . . .
Service Precautions . . . . . . . . . . . . . . . . . . .
Computer System Service Precautions . . .
General Service Precautions . . . . . . . . . . . .
Parts Handling . . . . . . . . . . . . . . . . . . . . . . . .
FLASHING CODES . . . . . . . . . . . . . . . . . . . .
CLEAR DTC . . . . . . . . . . . . . . . . . . . . . . . . . .
INTERMITTENT CONDITIONS . . . . . . . . .
BULB CHECK . . . . . . . . . . . . . . . . . . . . . . . . .
DTC CHECK . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector List . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC)
Identification . . . . . . . . . . . . . . . . . . . . . . . . .
DTC2 Actuator Coil Over Current . . . . . . . . . .
Circuit Description . . . . . . . . . . . . . . . . . . . . .
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . .
DTC3 Actuator Coil/Position Sensor Open
Circuit or Short . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description . . . . . . . . . . . . . . . . . . . . .
3F–2
3F–2
3F–4
3F–4
3F–4
3F–4
3F–4
3F–4
3F–5
3F–5
3F–5
3F–5
3F–5
3F–5
3F–5
3F–5
3F–5
3F–6
3F–7
3F–8
3F–8
3F–8
3F–14
3F–16
3F–17
3F–17
3F–17
3F–19
3F–19
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . .
DTC4 G-Sensor Open Circuit or Short . . . . .
Circuit Description . . . . . . . . . . . . . . . . . . . . .
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . .
DTC5 Vehicle Speed Sensor Open Circuit
or Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description . . . . . . . . . . . . . . . . . . . . .
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . .
DTC6 Stop Lamp Switch Open Circuit
or Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description . . . . . . . . . . . . . . . . . . . . .
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . .
DTC7 Engine Speed Signal Open Circuit
or Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description . . . . . . . . . . . . . . . . . . . . .
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . .
DTC9 Control Unit Abnormality . . . . . . . . . . . .
Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Actuator . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Shock Absorber . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3F–19
3F–22
3F–22
3F–22
3F–23
3F–23
3F–23
3F–25
3F–25
3F–25
3F–27
3F–27
3F–27
3F–28
3F–32
3F–33
3F–33
3F–34
3F–35
3F–35
3F–35
3F–36
3F–37
3F–37
3F–37
3F–2
INTELLIGENT SUSPENSION
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING, REFER TO
THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or
other corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
General Description
Intellignet suspension control uses a microcomputer as a
control unit to judge running conditions including engine
revolution from Powertrain Control Module, vehicle speed
from vehicle speed sensor, a brake switch signal, and
vertical and lateral G-sensor signal, then sets optimum
damping force so that best running stability can be
achieved.
INTELLIGENT SUSPENSION
3F–3
826R200007
3F–4
INTELLIGENT SUSPENSION
PIN ASSIGNMENT TABLE
PIN
No.
NAME
PIN
No.
NAME
PIN
No.
NAME
PIN
No.
NAME
1
GND
17
KI-FR B
33
KI-RR PSW
49
STOP
2
NC
18
KI-FR D
34
KI-RL Vcc
50
T-SW
3
Vdd
19
KI-FL B
35
KI-FR GND
51
M-SW
4
KI-FR A
20
KI-FL D
36
KI-FR Vs
52
Txd
5
KI-FR C
21
KI-RR B
37
KI-FL PSW
53
Vig
6
KI-FL A
22
KI-RR D
38
KI-FL Vs
54
NC
7
KI-FL C
23
KI-RL B
39
KI-FL GND
55
G3 GND
8
KI-RR A
24
KI-RL D
40
KI-RR GND
56
G3 Vs
9
KI-RR C
25
Vig
41
KI-RL PSW
57
NC
10
KI-RL A
26
GND
42
KI-RL GND
58
NC
11
KI-RL C
27
KI-FR Vcc
43
M.L
59
E/G
12
Vbat
28
KI-FR Vout
44
G3 Vcc
60
W.L
13
GND
29
KI-FR PSW
45
G3 Vout
61
GND
14
GND
30
KI-FL Vout
46
NC
62
GND
15
NC
31
KI-FL Vcc
47
NC
63
Rxd
16
Vdd
32
KI-RR Vcc
48
VSP
64
GND
NC: NO CONNECTION
Warning Lamp
System Components
Control Unit, 3 Vertical G-sensors, Lateral G-sensor, 4
Actuators, 4 Adjustable Damping Force Shock
Absorbers, and Warning Lamp.
Control Unit
The Control Unit consists of Adjustable Damping Force
Shock Absorber control circuits, fault detector, and a
fail-safe. It drives the actuator according to the signal
from each sensor.
The Control Unit has a self-diagnosing function which can
indicate faulty circuits during diagnosis.
The Control Unit is mounted in the center of the
instrument panel.
Actuator
Front actuators installed on front shock absorbers and
rear actuator installed inside rear shock absorbers control
damping force of shock absorber by the Control Unit
signal.
Adjustable Damping Force Shock
Absorber
This type shock absorber is used in front and rear
intelligent suspension. According to running condition the
Control Unit changes shock absorber damping force and
obtains good running stability.
821R200011
Vehicles equipped with the Intelligent Suspension Control
have an amber warning lamp in the instrument panel. The
warning lamp will illuminate if a malfunction in the
Intelligent Suspension Control is detected by the Control
Unit. In case of an important electronic malfunction, the
Control Unit will turn“ON” the warning lamp.
INTELLIGENT SUSPENSION
Vertical G-Sensor
General Diagnosis
Front G-sensors installed inside front actuators and the
rear G-sensor installed on the rear left frame side detect
the vehicle vertical gravity and send a signal to the Control
Unit.
General Information
Lateral G-Sensor
The G-sensor installed inside the Control Unit detects the
vehicle turning speed and sends a signal to the Control
Unit.
Acronyms and Abbreviations
Several acronyms and abbreviations are commonly used
throughout this section:
BATT
Battery
DLC
Data Link Connector
DTC
Diagnostic Trouble Code
FL
Front Left
FR
Front Right
GND
Ground
HARN
Harness
IG
Ignition
PCM
Powertrain Control Module
RL
Rear Left
RR
Rear Right
SW
Switch
W/L
Warning Lamp
Vout
Voltage output
3F–5
Intelligent Suspension Control troubles can be classified
into two types, those which can be detected by the
warning lamp and those which can be detected as a
vehicle abnormality by the driver.
In either case, locate the fault in accordance with
the“BASIC DIAGNOSTIC FLOWCHART” and repair.
Please refer to Section 3 for the diagnosis of mechanical
troubles such as abnormal noise, vehicle pulls, excessive
tire wear, wheel hop and shimmy, shake or vibration.
Service Precautions
Required Tools and Items:
B Box Wrench
B Special Tool
Some diagnosis procedures in this section require the
installation of a special tool.
J-39200 High Impedance Multimeter
When circuit measurements are requested, use a
circuit tester with high impedance.
Computer System Service Precautions
The Intelligent Suspension Control interfaces directly
with the Control Unit which is a control computer that is
similar in some regards to the Powertrain Control Module.
These modules are designed to withstand normal current
draws associated with vehicle operation. However care
must be taken to avoid overloading any of the Control Unit
circuits. In testing for opens or shorts, do not ground or
apply voltage to any of the circuits unless instructed to do
so by the appropriate diagnostic procedure. These
circuits should only be tested with a high impedance
multimeter (J-39200) or special tools as described in this
section. Power should never be removed or applied to
any control module with the ignition in the “ON”
position.Before removing or connecting battery cables,
fuses or connectors, always turn the ignition switch to
the“OFF” position.
General Service Precautions
The following are general precautions which should be
observed when servicing and diagnosing the Intelligent
Suspension Control and/or other vehicle systems. Failure
to observe these precautions may result in Intelligent
Suspension Control damage.
B If welding work is to be performed on the vehicle using
an electric arc welder, the Control Unit connectors
should be disconnected before the welding operation
begins.
B The Control Unit connectors should never be
connected or disconnected with the ignition“ON”.
Parts Handling
Be careful when handling the actuator, control unit, or
G-sensor. They should not be dropped or thrown,
because the semi-conductor G-sensor tip damage may
result.
3F–6
INTELLIGENT SUSPENSION
FLASHING CODES
1. ON BOARD DIAGNOSIS (SELF-DIAGNOSIS)
1. The Control Unit conducts a self-test of most of the
wiring and components in the system each time the
key is turned ON. If a fault is detected the Control
Unit will store a Diagnostic Trouble Code (DTC) in
memory. It’s a number that corresponds to a
specific problem.
2. When the problem detected is important: the
warning lamp turns on until the fault is repaired and
the Control Unit memory is cleared.
2. DIAGNOSTIC TROUBLE CODES (DTC)
1. DTC can be expressed by flashing times of warning
lamp by shorting together terminals 3 and 4 or 5 of
the Diagnosis Connector (C-39) located left side of
instrument panel.
350R200002
Normal
Abnormal
F03RY00001
F03R200001
Legend
(1) Diagnostic Trouble Code 2
(2) Diagnostic Trouble Code 3
INTELLIGENT SUSPENSION
It depends below in the case that the code that also,
shows a malfunction place is added.
3F–7
2. After this, the warning lamp will be OFF for 3.5
seconds and then will flash each DTC.
a. When there are more than 9 flashes this means
that the indicator is constantly flashing, OFF for
4 seconds ON for 0.5 seconds. In this case there
is no DTC stored in memory.
b. When there are less than 9 flashes you will see
DTC codes in ascending order.
CLEAR DTC
F03R200002
Legend
(1) Diagnostic Trouble Code 2
(2) Diagnostic Trouble Code 3 + Position Code 2
Position Code
1: Actuator Front RH, G-sensor Front RH
2: Actuator Front LH, G-sensor Front LH
3: Actuator Rear RH, G-sensor Rear
4: Actuator Rear LH, Lateral G-sensor
Remark: If you clear the DTC (Diagnosis Trouble Codes)
you will not be able to read any codes recorded during the
last Trouble.
Remark: To be able to use the DTC again to identify a
problem you will need to reproduce the fault or the
problem. This may require a new test drive or just turning
the ignition on (this depends on the nature of the fault).
1. Short the Diagnosis Connector C-39 terminal 3 to
terminal 4 or 5 (ground).
B IF it is flashing and the flash is 0.5 seconds ON and 4
seconds OFF without interruption, this means that
there is no DTC. The DTCs are already cleared.
350R200002
2. IF a code is flashed, wait until the lamp is flashing.
3. Conduct brake switch ON/OFF 6 or more times on
condition that one operation is within 2 seconds.
3F–8
INTELLIGENT SUSPENSION
INTERMITTENT CONDITIONS
DTC CHECK
If the Warning Lamp flashes a diagnostic trouble code as
intermittent, or if after a test drive a DTC does not
reappear though the detection conditions for this DTC are
present: the problem is most likely a faulty electrical
connection or loose wiring. Terminals and grounds should
always be the prime suspect. Intermittents rarely occur
inside sophisticated electronic components such as the
Control Unit.
Use the DTC information to understand which wires and
sensors are involved.
When an intermittent problem is encountered, check
suspect circuits for:
1. Poor terminal to wire connection.
2. Terminals not fully seated in the connector body
(backed out).
3. Improperly formed or damaged terminals.
4. Loose, dirty, or corroded ground connections:
HINT: Any time you have an intermittent in more than
one circuit, check whether the circuits share a
common ground connection.
5. Pinched or damaged wires.
6. Electro-Magnetic Interference (EMI):
HINT: Check that all wires are properly routed away
from spark plug wires, distributor wires, coil, and
generator. Also check for improperly installed
electrical options, such as lights, 2-way radios, etc.
BULB CHECK
When the starter switch is turned on in the normal state,
the Control Unit turns on the Warning Lamp to check the
bulb. After the engine starts, the Warning Lamp turns off.
F03RY00003
1. Diagnosis Trouble Codes (DTC) have been identified
by FLASHING CODES.
2. You have written the list of the DTC. The order of the
malfunctions has no meanings for this Control Unit.
Usually only one or two malfunctions should be set for
a given problem.
3. Check directly the DTCs you identified. The DTC are
sorted by number:
DIAGNOSTIC TROUBLE CODES.
INTELLIGENT SUSPENSION
3F–9
Basic Diagnosis Flow
C07RY00022
3F–10
INTELLIGENT SUSPENSION
Circuit Diagram
826R200008
INTELLIGENT SUSPENSION
3F–11
826R200009
3F–12
INTELLIGENT SUSPENSION
826R200010
INTELLIGENT SUSPENSION
3F–13
Parts Location
810R200001
Legend
(1) C–9
(2) C–8
(3) H–8, H–11, H–14
(4) I–24, I–23 , I–22
(5) I–31
(6) F–7
(7) C–39
(8) F–8
(9) F–6
(10) H–19
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
H–9, H–10
C–30
C–31
H–5, H–6
C–26
E–34, E–35
C–46, C–45, C–44
I–10
E–23
C–10
3F–14
INTELLIGENT SUSPENSION
Connector List
No.
Connector face
No.
C–8
C–46
C–9
E–23
C–10
E–34
C–26
E–35
C–30
F–6
C–31
F–7
C–39
F–8
C–44
H–5
C–45
H–6
Connector face
INTELLIGENT SUSPENSION
No.
Connector face
No.
H–8
I–24
H–9
I–31
H–10
H–11
H–14
H–19
I–10
I–22
I–23
Connector face
3F–15
3F–16
INTELLIGENT SUSPENSION
Diagnostic Trouble Code (DTC)
Identification
DTC No.
DTC NAME
CODE
MEMORY
WARNING
LAMP
2
Actuator Coil Over Current
Yes
OFF
3
Actuator Coil/Position Sensor Open Circuit or Short
Yes
ON
4
G–Sensor Open Circuit or Short
Yes
ON
5
Vehicle Speed Sensor Open Circuit or Short
Yes
OFF
6
Stop Lamp Switch Open Circuit, Short or Contact Point Trouble
Yes
OFF
7
Engine Speed Signal Open Circuit or Short
Yes
OFF
9
Control Unit Abnormality
Yes
OFF
INTELLIGENT SUSPENSION
3F–17
DTC2 Actuator Coil Over Current
Circuit Description
Diagnostic Aids
The A, B, C, and D are the actuator motor coil terminals.
DC 12V driving voltage is applied between terminals A
and C and terminals B and D so that the shock absorber
oil valves are rotated at every 7.5° step feed.
B Inspect the wiring for poor electrical connections
between the control unit 24 way connector and the
actuator connectors. Look for possible bent, backed
out, deformed, or damaged terminals. Check for
weak terminal tension as well.
Also check for a chafed wire that could short to bare
metal or other wiring. Inspect for a broken wire inside
the insulation.
B When diagnosing for a possible intermittent short or
open condition, move the wiring harness while
observing test equipment for a change.
DTC2 Actuator Coil Over Current
Step
1
Action
4
7
10
Go to Step 4
Go to Step 3
—
Go to Step 4
—
6.4–7.2W
Go to Step 5
Go to Step 6
6.4–7.2W
Go to Step 7
Go to Step 6
—
Go to Step 7
—
6.4–7.2W
Go to Step 8
Go to Step 9
6.4–7.2W
Go to Step 10
Go to Step 9
—
Go to Step 10
—
6.4–7.2W
Go to Step 11
Go to Step 12
6.4–7.2W
Go to Step 13
Go to Step 12
1. Measure the resistance between the shock
absorber side connector F–7 terminals 3 and 4.
1. Measure the resistance between the shock
absorber side connector F–7 terminals 7 and 8.
Replace the rear shock absorber RR.
1. Measure the resistance between the shock
absorber side connector F–8 terminals 3 and 4.
Is the resistance within the specified value?
11
6.4– 7.2W
Replace the actuator FL.
Is the resistance within the specified value?
9
Go to Step 3
1. Measure the resistance between the actuator side
connector C–31 terminals 3 and 4.
Is the resistance within the specified value?
8
Go to Step 2
1. Measure the resistance between the actuator side
connector C–31 terminals 1 and 2.
Is the resistance within the specified value?
6
6.4– 7.2W
Replace the actuator FR.
Is the resistance within the specified value?
5
No
1. Measure the resistance between the actuator side
connector C–9 terminals 3 and 4.
Is the resistance within the specified value?
3
Yes
1. Turn off the starter switch.
2. Disconnect the actuator connectors C–31, C–9,
F–8, and F–7.
3. Measure the resistance between the actuator side
connector C–9 terminals 1 and 2.
Is the resistance within the specified value?
2
Value(s)
1. Measure the resistance between the shock
absorber side connector F–8 terminals 7 and 8.
Is the resistance within the specified value?
3F–18
INTELLIGENT SUSPENSION
DTC2 Actuator Coil Over Current (Cont’d)
Step
12
13
Action
15
16
Yes
No
Replace the rear shock absorber RL.
—
Go to Step 16
—
—
Go to Step 15
Go to Step 14
—
Go to Step 16
—
—
Go to Step 16
—
—
Go to “Basic
Diagnosis
Flow”.
Go to Step 16
If all steps are correct, check the continuity between the
control unit connector C–46 terminal 1 and connector
terminal C46–4, C46–17, C46–5, C46–18, C46–6,
C46–19, C46–7, C46–20, C46–8, C46–21, C46–9,
C46–22, C46–10, C46–23, C46–11, and C46–24.
Is there continuity?
14
Value(s)
Repair the circuit.
Replace the control unit.
1. Reconnect all components, ensure all components
are properly mounted.
2. Clear the DTC.
Was this step finished?
INTELLIGENT SUSPENSION
3F–19
DTC3 Actuator Coil/Position Sensor Open Circuit or Short
Circuit Description
Diagnostic Aids
The A, B, C, and D are the actuator motor coil terminals.
DC 12V driving voltage is applied between terminals A
and C and terminals B and D so that the shock absorber
oil valves are rotated at every 7.5° step feed.
The PSW is actuator position signal and detects relative
angles between the piston–rod and the control-rod. The
actuator outputs the PSW to the control unit.
B Inspect the wiring for poor electrical connections
between the control unit 16 way connector and the
actuator connectors. Look for possible bent, backed
out, deformed, or damaged terminals. Check for
weak terminal tension as well.
Also check for a chafed wire that could short to bare
metal or other wiring. Inspect for a broken wire inside
the insulation.
B When diagnosing for a possible intermittent short or
open condition, move the wiring harness while
observing test equipment for a change.
DTC3 Actuator Coil/Position Sensor Open Circuit or Short
Step
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Action
Value(s)
Yes
No
1. Turn off the starter switch.
2. Disconnect the actuator connectors C–46, C–31,
C–9, F–8, and F–7.
Is there continuity between the connector C–9
terminals 1 and 2?
—
Go to Step 2
Go to Step 3
Is there continuity between the connector C–9
terminals 3 and 4?
—
Go to Step 4
Go to Step 3
—
Go to Step 4
—
Is there continuity between the connector C–31
terminals 1 and 2?
—
Go to Step 5
Go to Step 6
Is there continuity between the connector C–31
terminals 3 and 4?
—
Go to Step 7
Go to Step 6
—
Go to Step 7
—
Is there continuity between the connector F–7
terminals 3 and 4?
—
Go to Step 8
Go to Step 9
Is there continuity between the connector F–7
terminals 7 and 8?
—
Go to Step 10
Go to Step 9
—
Go to Step 10
—
Is there continuity between the connector F–8
terminals 3 and 4?
—
Go to Step 11
Go to Step 12
Is there continuity between the connector F–8
terminals 7 and 8?
—
Go to Step 13
—
—
Go to Step 13
—
Is there continuity between the connector C–9 terminal
1 and connector C–46 terminal 4?
—
Go to Step 14
Go to Step 15
Is there continuity between the connector C–9 terminal
3 and connector C–46 terminal 17?
—
Go to Step 16
Go to Step 15
—
Go to Step 16
—
Replace the actuator FR.
Replace the actuator FL.
Replace the rear shock absorber RR.
Replace the rear shock absorber RL.
Repair the circuit.
3F–20
INTELLIGENT SUSPENSION
DTC3 Actuator Coil/Position Sensor Open Circuit or Short (Cont’d)
Step
Action
Value(s)
16
Is there continuity between the connector C–9 terminal
2 and connector C–46 terminal 5?
—
Go to Step 17
Go to Step 18
Is there continuity between the connector C–9
terminals 4 and connector C–46 terminal 18?
—
Go to Step 19
Go to Step 18
—
Go to Step 19
—
Is there continuity between the connector C–31
terminal 1 and connector C–46 terminal 6?
—
Go to Step 20
Go to Step 21
Is there continuity between the connector C–31
terminal 3 and connector C–46 terminal 19?
—
Go to Step 22
Go to Step 21
—
Go to Step 22
—
Is there continuity between the connector C–31
terminal 2 and connector C–46 terminal 7?
—
Go to Step 23
Go to Step 24
Is there continuity between the connector C–31
terminal 4 and connector C–46 terminal 20?
—
Go to Step 25
Go to Step 24
—
Go to Step 25
—
Is there continuity between the connector F–7 terminal
4 and connector C–46 terminal 8?
—
Go to Step 26
Go to Step 27
Is there continuity between the connector F–7 terminal
8 and connector C–46 terminal 21?
—
Go to Step 28
Go to Step 27
—
Go to Step 28
—
Is there continuity between the connector F–7 terminal
3 and connector C–46 terminal 9?
—
Go to Step 29
Go to Step 30
Is there continuity between the connector F–7 terminal
7 and connector C–46 terminal 22?
—
Go to Step 31
Go to Step 30
—
Go to Step 31
—
Is there continuity between the connector F–8 terminal
4 and connector C–46 terminal 10?
—
Go to Step 32
Go to Step 33
Is there continuity between the connector F–8 terminal
8 and connector C–46 terminal 23?
—
Go to Step 34
Go to Step 33
—
Go to Step 34
—
Is there continuity between the connector F–8 terminal
3 and connector C–46 terminal 11?
—
Go to Step 35
Go to Step 36
Is there continuity between the connector F–8 terminal
7 and connector C–46 terminal 24?
—
Go to Step 37
Go to Step 36
—
Go to Step 37
—
—
Go to Step 38
Go to Step 41
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
Yes
No
Repair the circuit.
Repair the circuit.
Repair the circuit.
Repair the circuit.
Repair the circuit.
Repair the circuit.
Repair the circuit.
1. Disconnect the terminals C–45, C–8, C–30, F–7,
and F–8.
Is there continuity between the connector–terminal
C45–29 and C8–6, C45–37 and C30–6, C45–33 and
F7–2, C45–41 and F8–2?
INTELLIGENT SUSPENSION
3F–21
DTC3 Actuator Coil/Position Sensor Open Circuit or Short (Cont’d)
Step
Action
Value(s)
38
Is there continuity between the connector C–46
terminal 1 (GND) and the connector C–45 terminals 29,
33, 37, and 41?
—
Go to Step 41
Go to Step 39
Is there the continuity between connector-terminal
C45–27 and C45–35, C45–31 and C45–39, C45–32
and C45–40, and C45–34 and C45–42?
—
Go to Step 41
Go to Step 40
Is there the continuity between connector C–46
terminal 1 and connector C–45 terminals 27, 31, 32,
and 34?
—
Go to Step 41
Go to Step 42
—
Go to Step 44
—
—
Go to Step 43
Go to Step 44
—
Go to Step 44
—
—
Go to “Basic
Diagnosis
Flow”.
Go to Step 44
39
40
41
42
44
No
Repair the circuit.
1. If all steps are correct, replace following units one by
one in the following order. Give a test drive and if
normal, reinstall it.
1) actuator FR, 2) actuator FL, rear shock
absorber, 3) RR and 4) RL.
Does the DTC3 remain?
43
Yes
Replace the control unit.
1. Reconnect all components, ensure all components
are properly mounted.
2. Clear the DTC.
Was this step finished?
3F–22
INTELLIGENT SUSPENSION
DTC4 G-Sensor Open Circuit or Short
Circuit Description
Diagnostic Aids
The G-sensor sends the voltage (Vout) corresponding to
the vehicle vertical gravity to the control unit.
The control unit supplies DC 5V power (Vcc) to each
G-sensor.
The control unit watches the G-sensor operation through
Vcc signal.
B Inspect the wiring for poor electrical connections
between the control unit connectors and the actuator
connectors. Look for possible bent, backed out,
deformed, or damaged terminals. Check for weak
terminal tension as well.
Also check for a chafed wire that could short to bare
metal or other wiring. Inspect for a broken wire inside
the insulation.
B When diagnosing for a possible intermittent short or
open condition, move the wiring harness while
observing test equipment for a change.
DTC4 G-Sensor Open Circuit or Short
Step
1
2
3
4
Action
6
7
Yes
No
1. Turn off the starter switch.
2. Disconnect the connectors C–45, C–44, C–8,
C–30, and F–6.
Is there the continuity between the connector-terminal
C45–28 and C8–5, C45–30 and C30–5, and C44–45
and F6–1?
—
Go to Step 2
Go to Step 5
Is there continuity between the connector-terminal
C45–27 and C8–3, C45–31 and C30–3, and C44–44
and F6–2?
—
Go to Step 3
Go to Step 5
Is there the continuity between the connector-terminal
C45–36 and C8–2, C45–38 and C30–2, and C44–56
and F6–3?
—
Go to Step 4
Go to Step 5
—
Go to Step 5
Go to Step 7
—
Go to Step 6
—
—
Go to Step 7
—
—
Go to “Basic
Diagnosis
Flow.”
Go to Step 7
1. Disconnect the connectors C–46, C–45, and C–44.
Is there the continuity between the connector-terminal
C45–28 and C45–35, C45–30 and C45–39, C44–45
and C44–55, C45–27 and C45–35, C45–31 and
C45–39, C44–44 and C44–55, C45–36 and C45–35,
C45–38 and C45–39, and C44–56 and C44–55?
5
Value(s)
Repair the circuit.
Replace following units one by one in the following
order. Give a test drive and if normal, reinstall it.
1) G3-sensor 2) Actuator FL 3) Actuator FR 4)
Control Unit
1. Reconnect all components, ensure all components
are properly mounted.
2. Clear the DTC.
Was this step finished?
INTELLIGENT SUSPENSION
3F–23
DTC5 Vehicle Speed Sensor Open Circuit or Short
Circuit Description
Diagnostic Aids
Output speed information is provided to the control unit by
the vehicle speed sensor. The vehicle speed sensor
produces a pulsing AC voltage. The AC voltage level and
number of pulses increases as the speed of the vehicle
increases. The control unit then converts the pulsing
voltage to vehicle speed.
B Inspect the wiring for poor electrical connections
between the control unit 48 way connector and the
speed sensor connectors. Look for possible bent,
backed out, deformed, or damaged terminals. Check
for weak terminal tension as well.
Also check for a chafed wire that could short to bare
metal or other wiring. Inspect for a broken wire inside
the insulation.
B When diagnosing for a possible intermittent short or
open condition, move the wiring harness while
observing test equipment for a change.
DTC5 Vehicle Speed Sensor Open Circuit or Short
Step
1
Action
6
Go to Step 2
Go to Step 3
0V and 12V
Go to Step 7
Go to Step 5
—
Go to Step 4
Go to Step 6
—
Go to Step 5
Go to Step 6
—
Go to Step 8
—
—
Go to Step 8
—
1. Check the continuity between the control unit
connector C–46 terminal 1 and control unit
connector C–44 terminal 48.
Is there continuity?
5
—
1. Turn off the starter switch and disconnect the
control connectors C–46 and C–44.
2. Check the continuity between the vehicle speed
sensor connector terminal 3 and meter B connector
I–23 terminal 7.
Is there continuity?
4
No
1. Open the throttle and rev up engine speed.
2. Using a volt meter, measure the voltage between
the meter B connector I–23 terminals 7 and 16
(GND).
Does the voltage change alternately at the specified
values?
3
Yes
1. Jack up and support the rear axle on the stand.
2. Change the transfer mode to 2WD, using TOD
switch on instrument panel.
3. Shift the transmission lever in a forward position
and rotate the rear wheels.
Does the speedo-meter operate?
2
Value(s)
Repair or replace the vehicle speed sensor.
Repair the circuit between the vehicle speed sensor
connector terminal 3 and the meter B connector I–23
terminal 7 or the circuit between the control unit
connector C–44 terminal 48 and the speed sensor
connector terminal 3.
3F–24
INTELLIGENT SUSPENSION
DTC5 Vehicle Speed Sensor Open Circuit or Short (Cont’d)
Step
7
8
Action
Value(s)
Yes
No
Repair the circuit between the connector H–6 terminal
16 and the control unit connector C–44 terminal 48 or
replace the control unit.
—
Go to Step 8
—
—
Go to “Basic
Diagnosis
Flow.”
Go to Step 8
1. Reconnect all components, ensure all components
are properly mounted.
2. Clear the DTC.
Was this step finished?
About the vehicle speed sensor connector termainal 3,
Refer to section Wiring System in Body and Accessories.
INTELLIGENT SUSPENSION
3F–25
DTC6 Stop Lamp Switch Open Circuit or Short
Circuit Description
Diagnostic Aids
The brake switch is used to indicate brake pedal status.
The normally opened brake switch signal voltage circuit is
opened.
Brake switch supplies a B+ signal on circuit RED to the
control unit when the brakes are applied. The control unit
uses this signal to work dive control when the brakes are
applied.
B Inspect the wiring for poor electrical connections at
the control unit and brake switch. Look for possible
bent, backed out, deformed or damaged terminals.
Check for weak terminal tension as well. Also check
for a chafed wire that could short to bare metal or
other wiring. Inspect for a broken wire inside the
insulation.
B When diagnosing for a possible intermittent short or
open condition, move the wiring harness while
observing test equipment for a change.
B Check customer driving habits and/or unusual driving
conditions (i.e. stop and go, highway).
B Check brake switch for proper mounting and
adjustment.
DTC6 Stop Lamp Switch Open Circuit or Short
Step
1
Action
Go to Step 4
—
Go to Step 7
Go to Step 5
—
Go to Step 13
—
—
Go to Step 8
Go to Step 6
—
Go to Step 9
Go to Step 10
—
Go to Step 8
Go to Step 10
—
Go to Step 13
Go to Step 10
Check circuit terminal I–31 terminal 4 for a short to
voltage.
Ignition switch “on”.
Is the test light “on”?
8
Go to Step 3
Check the brake switch short (I–31 terminal 1 and I–31
terminal 4).
Was a problem found?
7
—
Disconnect brake switch connector I–31 and ignition
switch “on”.
Is the test light “on”?
6
Go to Step 2
Repair the open in battery feed circuit terminal I–31
terminal 1 to the brake switch.
If fuse is open, check circuit terminal I–31 terminal 4 for
a short to ground.
Is the replacement complete?
5
—
Go to
Diagnostic
Aids
1. Connect the test light to ground.
2. Back probe circuit terminal I–31 terminal 4 at the
brake switch.
Is the test light “off”?
4
No
1. Connect the test light to ground.
2. Back probe ignition feed circuit terminal I–31
terminal 1 at the brake switch.
Is the test light “on”?
3
Yes
1. With the engine “off”, turn the ignition switch “on”. If
ABS code is set, check applicable fuse.
2. Apply then release the brake pedal.
Does the brake lamp come on when the brake pedal is
applied and does it come off when the brake pedal is
released?
2
Value(s)
1. Disconnect the control unit connector C–44.
2. Check circuit terminal I–31 terminal 4 for a short to
voltage.
Was a problem found?
3F–26
INTELLIGENT SUSPENSION
DTC6 Stop Lamp Switch Open Circuit or Short (Cont’d)
Step
9
Action
Go to Step 13
—
—
Go to
Diagnostic
Aids
Go to Step 11
—
Go to Step 13
Go to Step 12
—
Go to Step 13
—
—
Begin diagnosis
again
Go to Step 1
Replace the control unit.
Is the replacement complete?
13
—
Check the control unit for faulty or intermittent
connections.
Was a problem found and corrected?
12
No
1. Turn the ignition “off”.
2. Reconnect the control unit connector C–44
Turn the ignition “on”.
Does the brake lamp come on when the brake pedal is
applied and does it come off when the brake pedal is
released?
11
Yes
Replace the brake switch.
Is the replacement complete?
10
Value(s)
1. After the repair is complete, clear the DTC.
2. Conduct a test drive.
3. Review the DTC.
Has the last test failed or is the current DTC displayed?
Go to Repair
verified
INTELLIGENT SUSPENSION
3F–27
DTC7 Engine Speed Signal Open Circuit or Short
Circuit Description
Diagnostic Aids
PCM (Powertrain Control Module) converts signals from
the crankshaft position sensor into the engine speed
signals (pulse) and sends these to the control unit and
tachometer.
B Inspect the wiring for poor electrical connections at
the control unit connector. Look for possible bent,
backed out, deformed, or damaged terminals. Check
for weak terminal tension as well.
Also check for a chafed wire that could short to bare
metal or other wiring. Inspect for a broken wire inside
the insulation.
B When diagnosing for a possible intermittent short or
open condition, move the wiring harness while
observing test equipment for a change.
B Check harness routing for a potential short to ground
in circuit BLK/RED.
DTC7 Engine Speed Signal Open Circuit or Short
Step
1
Action
Value(s)
Yes
No
NOTE: Confirm that DTC P0336 or P0337 does not
exist.
If either exists, warning lamps, “CHECK ENGINE” and
“CHECK TRANS” are turned on. Repair the engine,
referring to section 6E Driveability and Emission.
1. Turn on the starter switch.
2. Start the engine.
3. Open the throttle and rev up engine speed.
Does the tachometer operate according to engine
speed?
2
3
5
6
Go to Step 3
Go to Step 2
—
Go to Step 6
—
—
Go to Step 4
Go to Step 5
—
Go to Step 6
—
—
Go to Step 6
—
—
Begin diagnosis
again
Go to Step 1
Repair the tachometer, referring to section 8D Wiring
System in Body and Accessories.
1. Turn off the starter switch.
2. Check continuity between the control unit connector
C–44 terminal 59 and PCM connector E–34
terminal F7.
Is there continuity ?
4
—
Replace the control unit.
Repair the circuit.
1. Reconnect all components, ensure all components
are properly mounted.
2. Clear the DTC.
3. Conduct a test drive.
Has the last test failed or does the current DTC exist?
Repair
verified
3F–28
INTELLIGENT SUSPENSION
DTC9 Control Unit Abnormality
Replace the control unit.
DTC9–1 Control Unit Blown Fuse for FR Actuator
Step
1
Action
4
6
7
6.4– 7.2W
Go to Step 2
Go to Step 3
6.4– 7.2W
Go to Step 4
Go to Step 3
—
Go to Step 7
—
—
Go to Step 5
Go to Step 6
—
Go to Step 7
—
—
Go to Step 7
—
—
Go to “Basic
Diagnosis
FLow”.
Go to Step 7
Replace the actuator FR.
1. If all steps are correct, check the continuity between
the control unit connector C–46 terminal 1 and
connector-terminal C46–4, C46–17, C46–5,
C46–18.
Is there continuity?
5
No
1. Measure the resistance between the actuator side
connector C–9 terminals 3 and 4.
Is the resistance within the specified value?
3
Yes
1. Turn off the starter switch.
2. Disconnect the actuator connector C–9.
3. Measure the resistance between the actuator side
connector C–9 terminals 1 and 2.
Is the resistance within the specified value?
2
Value(s)
Repair the circuit.
Replace the control unit.
1. Reconnect all components, ensure all components
are properly mounted.
2. Clear the DTC.
Was this step finished?
INTELLIGENT SUSPENSION
3F–29
DTC9–2 Control Unit Blown Fuse for FL Actuator
Step
1
Action
4
6
7
6.4– 7.2W
Go to Step 2
Go to Step 3
6.4– 7.2W
Go to Step 4
Go to Step 3
—
Go to Step 7
—
—
Begin diagnosis
again
Go to Step 5
—
Go to Step 7
—
—
Go to Step 7
—
—
Go to “Basic
Diagnosis
FLow”.
Go to Step 7
Replace the actuator FL.
1. If all steps are correct, check the continuity between
the control unit connector C–46 terminal 1 and
connector-terminal C46–6, C46–19, C46–7,
C46–20.
Is there continuity?
5
No
1. Measure the resistance between the actuator side
connector C–31 terminals 3 and 4.
Is the resistance within the specified value?
3
Yes
1. Turn off the starter switch.
2. Disconnect the actuator connector C–31.
3. Measure the resistance between the actuator side
connector C–31 terminals 1 and 2.
Is the resistance within the specified value?
2
Value(s)
Go to Step 6
Repair the circuit.
Replace the control unit.
1. Reconnect all components, ensure all components
are properly mounted.
2. Clear the DTC.
Was this step finished?
3F–30
INTELLIGENT SUSPENSION
DTC9–3 Control Unit Blown Fuse for RR Shock Absorber
Step
1
Action
4
6
7
6.4– 7.2W
Go to Step 2
Go to Step 3
6.4– 7.2W
Go to Step 4
Go to Step 3
—
Go to Step 7
—
—
Begin diagnosis
again
Go to Step 5
—
Go to Step 7
—
—
Go to Step 7
—
—
Go to “Basic
Diagnosis
FLow”.
Go to Step 7
Replace the shock absorber RR.
1. If all steps are correct, check the continuity between
the control unit connector C–46 terminal 1 and
connector-terminal C46–8, C46–21, C46–9,
C46–22.
Is there continuity?
5
No
1. Measure the resistance between the shock
absorber side connector F–7 terminals 7 and 8.
Is the resistance within the specified value?
3
Yes
1. Turn off the starter switch.
2. Disconnect the shock absorber connector F–7.
3. Measure the resistance between the shock
absorber side connector F–7 terminals 3 and 4.
Is the resistance within the specified value?
2
Value(s)
Go to Step 6
Repair the circuit.
Replace the control unit.
1. Reconnect all components, ensure all components
are properly mounted.
2. Clear the DTC.
Was this step finished?
INTELLIGENT SUSPENSION
3F–31
DTC9–4 Control Unit Blown Fuse for RL Shock Absorber
Step
1
Action
4
6
7
6.4– 7.2W
Go to Step 2
Go to Step 3
6.4– 7.2W
Go to Step 4
Go to Step 3
—
Go to Step 7
—
—
Begin diagnosis
again
Go to Step 5
—
Go to Step 7
—
—
Go to Step 7
—
—
Go to “Basic
Diagnosis
FLow”.
Go to Step 7
Replace the shock absorber RL.
1. If all steps are correct, check the continuity between
the control unit connector C–46 terminal 1 and
connector-terminal C46–10, C46–23, C46–11,
C46–24.
Is there continuity?
5
No
1. Measure the resistance between the shock
absorber side connector F–8 terminals 7 and 8.
Is the resistance within the specified value?
3
Yes
1. Turn off the starter switch.
2. Disconnect the shock absorber connector F–8.
3. Measure the resistance between the shock
absorber side connector F–8 terminals 3 and 4.
Is the resistance within the specified value?
2
Value(s)
Go to Step 6
Repair the circuit.
Replace the control unit.
1. Reconnect all components, ensure all components
are properly mounted.
2. Clear the DTC.
Was this step finished?
3F–32
INTELLIGENT SUSPENSION
Control Unit
Control Unit and Associated Parts
828R200001
Legend
(1) Front Console
(2) Connector
(3) Control Unit
(4) Front
INTELLIGENT SUSPENSION
3F–33
Removal
1. Disconnect the battery ground cable.
2. Remove the front console assembly.
Refer to Consoles in Body and Accessories section.
3. Disconnect the connector from the control unit.
View A
828RY00002
Legend
(1) Nut
(2) Screw
4. Remove 4 nuts.
5. Disconnect the control unit with brackets.
6. Remove 4 screws.
7. Disconnect the control unit from brackets.
Installation
To install, follow the removal steps in the reverse order,
noting the following points.
Torque:
Nut (1) 8N·m (69 lb in)
(3) Control Unit
(4) Bracket
3F–34
INTELLIGENT SUSPENSION
Front Actuator
Front Actuator and Associated Parts
RH
LH
450RY00004
Legend
(1) Connector
(2) Clip
(3) Actuator
(4) Shock Absorber
(5) Front
(6) Bracket
450RY00003
Legend
(1) Connector
(2) Clip
(3) Actuator
(4) Shock Absorber
(5) Front
(6) Bracket
INTELLIGENT SUSPENSION
Removal
3F–35
Inspection and Repair
1. Disconnect the battery ground cable.
2. Disconnect the connector from the harness and
remove the connector from the bracket.
3. Remove the clip.
View B
Refer to shock Abosorber in this section.
Installation
1. Install the shock absorber.
Refer to Shock Absorber in this section.
2. Install the washer and nut (5), then tighten it to the
specified torque.
Torque: 15 N·m (11 lb ft)
3. Install the bracket and nut (3), then tighten it to the
specified torque.
Torque: 39 N·m (29 lb ft)
NOTE: Fix the lower nut with wrench not to turn and
tighten upper nut.
4. Fit the top of the shock absorber rod in the connection
part of the actuator.
NOTE:
The mating section is width fitting across flats.
If these normally fit, the distance between the
actuator lower face and the bracket upper face is
about 1 mm.
5. Install 2 screws then tighten it to the specified torque.
3 N·m (26 lb in)
450RY00005
Legend
(1) Screw
(2) Actuator
(3) Nut
(4) Bracket
(5) Nut
(6) Washer
(7) Shock Absorber
1. Remove 2 screws.
2. Remove the actuator.
3. Remove the nut (3).
4. Disconnect bracket.
5. Remove the nut (5).
6. Disconnect the washer.
7. Remove the shock absorber.
Refer to Shock Absorber in this section.
6. Connect the connector to the harness and insert the
connector to the bracket.
7. Connect the actuator harness with the clip.
8. Connect the battery ground cable.
3F–36
INTELLIGENT SUSPENSION
Rear Shock Absorber
Rear Shock Absorber and Associated Parts
LH
461R100003
Legend
(1) Connector
(2) Clip
(3) Rear Shock Absorber
(4) Bracket
(5) Bolt
(6)
(7)
(8)
(9)
(10)
(11)
G-Sensor
Front
Upper
Right
Connector
Gusset
INTELLIGENT SUSPENSION
Removal
1. Disconnect the battery ground cable.
2. Disconnect the connector (1) from the harness and
remove the connector (1) from the bracket (4).
3. Remove the clip (2).
4. Remove the rear shock absorber (3).
Refer to Shock Absorber in this section.
5. Disconnect the connector (10) from the harness and
remove the connector (10) from the gusset (11).
6. Remove the 2 bolts (5).
7. Disconnect the G-sensor (6).
Inspection and Repair
Refer to Shock Absorber in this section.
Installation
1. Set the G-sensor on the gusset (11).
2. Install 2 bolts (5) then tighten it to the specified torque.
Torque: 7 N·m (61 lb in)
3. Connect the connector (10) to the harness and insert
the connector (10) to the gusset (11).
4. Install the rear shock absorber (3).
Refer to Shock Absorber in this section.
5. Connect the connector (1) to the harness and insert
the connector (1) to the bracket (4).
6. Insert the clip (2) to the bracket (4).
7. Connect the battery ground cable.
3F–37
SECTION
DIFFERENTIAL (FRONT)
4A1–1
AXIOM
DRIVELINE/AXLE
CONTENTS
Differential (Front) . . . . . . . . . . . . . . . . . . . . . . .
Differential (Rear) . . . . . . . . . . . . . . . . . . . . . . .
Driveline Control System . . . . . . . . . . . . . . . . .
4A1
4A2
4B1
Driveline Control System (TOD) . . . . . . . . . . .
Drive Shaft System . . . . . . . . . . . . . . . . . . . . . .
Transfer Case (TOD) . . . . . . . . . . . . . . . . . . . .
4B2
4C
4D2
Differential (Front)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . .
Front Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Shaft Oil Seal . . . . . . . . . . . . . . . . . . . . .
Pinion Shaft Oil Seal and Associated Parts
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Drive Axle Assembly . . . . . . . . . . . . . . .
Front Drive Axle Assembly and
Associated Parts . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4A1–1
4A1–2
4A1–2
4A1–3
4A1–3
4A1–3
4A1–4
4A1–4
4A1–5
4A1–5
4A1–6
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 INFOMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Assembly . . . . . . . . . . . . . . . . . . . .
Disassembled View . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Cage Assembly . . . . . . . . . . . . . . .
Disassembled View . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . .
4A1–6
4A1–8
4A1–8
4A1–9
4A1–11
4A1–20
4A1–20
4A1–20
4A1–21
4A1–21
4A1–23
4A1–25
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED , do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally,such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specification. Following these
instructions can help you avoid damage to parts and
systems.
4A1–2
DIFFERENTIAL (FRONT)
Front Drive Axle
Diagnosis
Condition
Possible cause
Oil Leak At Front Axle
Correction
Worn or defective oil seal.
Replace the oil seal.
Front axle housing cracked.
Repair or replace.
Too much gear oil.
Correct the oil level.
Oil seal worn or defective.
Replace the oil seal.
Pinion flange loose or damaged.
Tighten or replace.
Noises In Front Axle Drive Shaft
Joint
Broken or worn drive shaft joints and
bellows (BJ and DOJ).
Replace the drive shaft joints and
bellows.
“Clank” When Accelerating From
“Coast”
Loose drive shaft joint to output shaft
bolts.
Tighten.
Damaged inner drive shaft joint.
Replace.
Excessive drive shaft joint angle.
Repair.
Worn or damaged drive shaft joints.
Replace.
Sticking spider assembly (inner drive
shaft joint).
Lubricate or replace.
Sticking joint assembly (outer drive
shaft joint).
Lubricate or replace.
Out of balance or out of round tires.
Balance or replace.
Front end out of alignment.
Align.
Insufficient gear oil.
Replenish the gear oil.
Wrong or poor grade gear oil.
Replace the gear oil.
Drive pinion to ring gear backlash
incorrect.
Adjust the backlash.
Worn or chipped ring gear, pinion
gear or side gear.
Replace the ring gear, pinion gear or
side gear.
Pinion shaft bearing worn.
Replace the pinion shaft bearing.
Wheel bearing worn.
Replace the wheel bearing.
Differential bearing loose or worn.
Tighten or replace.
Wheel bearing preload too tight.
Adjust the wheel bearing preload.
Incorrect front alignment.
Adjust the front alignment.
Steering unit loose or worn.
Tighten or replace.
Tire worn or improperly inflated.
Adjust the inflation or replace.
Front or rear suspension parts loose
or broken.
Tighten or replace.
Wheel bearing worn or improperly
adjusted.
Adjust or replace.
Incorrect front alignment.
Adjust the front alignment.
Worn ball joint or bush.
Replace the ball joint or bush.
Steering unit loose or worn.
Tighten or replace.
Tire worn or improperly inflated.
Replace or adjust the inflation.
Shock absorber worn.
Replace the shock absorber.
Oil Leak At Pinion Shaft
Shudder or
Acceleration
Vibration
Vibration At Highway Speeds
Noises in Front Axle
Wanders and Pulls
Front Wheel Shimmy
During
DIFFERENTIAL (FRONT)
4A1–3
Pinion Shaft Oil Seal
Pinion Shaft Oil Seal and Associated Parts
415R200001
Legend
(1) Flange Nut
(2) Flange
(3) Oil Seal
(4) Outer Bearing
(5) Collapsible Spacer
Removal
1. Raise the vehicle and support it at the frame.
The hoist must remain under the front axle housing.
2. Drain the front axle oil by loosening the drain plug(1).
412RS001
4A1–4
DIFFERENTIAL (FRONT)
3. Remove the front propeller shaft. Refer to Front
Propeller Shaft in this section.
4. Remove flange nut by using pinion flange holder
J–8614–01.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
Check the following parts.
1. 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 J–24250 to install a
new oil seal that has been soaked in axle lubricant.
415RS018
5. Remove flange.
6. Remove oil seal.
7. Remove outer bearing by using remover J–39602.
415RS002
4. Install flange.
5. Install flange nut, refer to Differential Assembly
Overhaul for flange nut reassembly in this section.
NOTE: Discard the used nut and install a new one.
415RS001
8. Remove collapsible spacer.
DIFFERENTIAL (FRONT)
4A1–5
Front Drive Axle Assembly
Front Drive Axle Assembly and Associated Parts
412R200003
Legend
(1) Propeller Shaft
(2) Mounting Nut
(3) Front Axle Case Assembly and Front Drive
Shaft Assembly
(4) Washer
(5)
(6)
(7)
(8)
(9)
Mounting Bolt
Tie–rod End; Power Steering Unit
Knuckle and Back Plate
Hub and Disc Assembly
Suspension Crossmember
4A1–6
DIFFERENTIAL (FRONT)
CAUTION: When removing the knuckle, be careful
not to damage the oil seal inside of the knuckle.
Removal
1. Jack up the vehicle and support it using jack stand.
2. Remove the tire and wheel.
3. Remove the stone guard.
4. Remove the brake caliper fixing bolt and hang the
caliper. Refer to Disc Brakes in Brake section.
5. Remove the antilock brake system speed sensor.
Refer to Front Wheel Speed Sensor in Brake section.
6. Remove the hub and disc assembly.
Refer to Front Hub and Disc in this section.
7. Remove the propeller shaft, refer to Front Propeller
Shaft in this section.
8. Loosen the height control arm of the torsion bar, then
remove the torsion bar from lower control arm.
Refer to Torsion Bar in Suspension section.
9. Remove the suspension crossmember.
10. Remove the lower nut (1) of the stabilizer link.
11. Remove the lower bolt and nut (2) of the shock
absorber.
410RW008
17. Support the differential case by the jack.
18. Remove the front axle mounting bolts and nuts, lower
the jack slowly. Remove the left side drive shaft end
from the knuckle, then lower the axle assembly from
the vehicle.
CAUTION:
1. Make sure the axle assembly is supported
securely when performing repairs.
2. Do not damage the power steering unit when
performing the repairs.
3. Do not damage the shift–on–the fly hose bracket
when performing the repairs.
Installation
412RW057
12. Remove the tie-rod end from the knuckle. Refer to
Power Steering Unit in Steering Section.
13. Disconnect the hose of the shift on the fly.
14. Disconnect the actuator connector.
15. Remove the bolts and nuts of the lower control arm
(Frame side), then disconnect the lower control arm
from frame.
16. Disconnect between the right side upper control arm
and the knuckle, then remove the knuckle with lower
control arm.
1. Support the differential case with a jack.
2. Jack up the front drive axle assembly, install the left
side drive shaft to the knuckle, then install the mount
bolts and nuts.
CAUTION:
1. Do not damage the power steering unit when
performing the repairs.
2. Do not damage the shift–on–the fly hose bracket
when performing the repairs.
3. When installing the drive shaft to the knuckle, be
careful not to damage the oil seal inside of the
knuckle.
DIFFERENTIAL (FRONT)
3. Tighten the mounting bolts and nuts to the specified
torque.
Torque: 168 N·m (124 lb ft)
4A1–7
18. Install the tire and wheel.
19. Lower the vehicle, adjust the trim height.
Refer to Trim Height Adjustment in Steering section.
20. Tighten the bolts and nuts of the lower control arm to
the specified torque.
Refer to Lower Control Arm in Suspension section.
412R200004
4. Install the right side knuckle with lower control arm to
the upper control arm.
Refer to Knuckle in Suspension section.
CAUTION: Carefully insert the drive shaft into the
knuckle, to avoid damaging the oil seal.
5. Align the bolt hole of the lower control arm, then install
the bolts and nuts.
NOTE: Adjust the buffer clearance before tightening the
bolts and nuts of the lower control arm.
6. Install the hose of the shift on the fly.
7. Install the actuator connector of the shift on the fly.
8. Install the tie-rod end of the power steering unit to the
knuckle, tighten the nut to the specified torque.
Torque: 118 N·m (87 lb ft)
9. Install lower bolts and nuts of the shock absorber,
tighten it to the specified torque.
Torque: 93 N·m (69 lb ft)
10. Install lower nuts of the stabilizer link, tighten it to the
specified torque.
11. Install the suspension crossmember.
12. Install the torsion bar.
Refer to Torsion Bar in Suspension section.
13. Install the front propeller shaft.
Refer to Front Propeller Shaft in this section.
14. Install the hub and disc assembly and adjust the
bearing preload.
Refer to Front Hub and Disc in this section.
15. Install the wheel speed sensor of the antilock brake
system.
16. Install the brake caliper. Tighten the bolt of the caliper
bracket to the specified torque.
Torque: 50 N·m (37 lb ft)
17. Install the stone guard.
4A1–8
DIFFERENTIAL (FRONT)
Differential Assembly
Disassembled View
415R200002
Legend
(1) Differential Assembly
(2) Flange Nut
(3) Flange
(4) Oil Seal
(5) Outer Bearing
(6) Outer Bearing Outer Race
(7) Differential Carrier
(8) Bearing Cap
(9) Bolt
(10) Collapsible Spacer
(11) Inner Bearing Outer Race
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
Inner Bearing
Adjust Shim
Pinion Gear
Diff Cage Assembly
Side Bearing Outer Race
Side Bearing
Adjust Shim
Bolt
Axle Case
Final Drive Damper
Damper Bolt
Damper Bracket
DIFFERENTIAL (FRONT)
Disassembly
1. Remove differential carrier fixing bolt.
2. Remove differential assembly.
3. Using holding fixture J–37264 and holding fixture
base J–3289–20, fix the differential assembly to the
bench.
4A1–9
6. Remove differential cage assembly.
7. Remove side bearing outer race, after removal, keep
the right and left hand side bearing assemblies
separate to maintain inner and outer race
combinations.
8. Remove side bearing, using remover J–42379 and
adapter J–8107–2.
B Select insert; 303173 and collet halves; 44801 in
remover kit J–42379.
425RS008
4. Remove bearing cap bolt.
5. Apply a setting mark to the side bearing cap and the
differential carrier then remove bearing cap.
415RW003
9. Remove adjust shim, note the thickness and position
of the shims removed.
10. Remove the flange nut using holding wrench
J–8614–01.
425RS009
415RS018
4A1–10 DIFFERENTIAL (FRONT)
11. Remove flange using a universal puller.
12. Remove the drive pinion assembly using a soft metal
rod and a hammer.
425RS012
18. Remove the inner bearing outer race (1) and the outer
bearing outer race (2) by using a brass bar and a
hammer.
425RS014
13. Remove collapsible spacer.
14. Remove the inner bearing using remover J–42379.
B Select insert; 303173 and collet halves; 44801 in
remover kit J–42379.
425RS015
415RW004
15. Remove adjust shim.
16. Remove oil seal.
17. Remove outer bearing.
DIFFERENTIAL (FRONT)
19. Remove damper and bracket.
4A1–11
2. Using installer J–7818 and grip J–8092, install Inner
bearing outer race.
425RW042
415RW014
Reassembly
1. Using installer J–7817 and grip J–8092, install outer
bearing outer race.
415RW013
3. Install adjust shim and adjust drive pinion mounting
distance:
1. Apply gear oil to the inner and outer drive pinion
bearing.
Clean the pinion setting gauge set.
Then install the gauge set together with the inner
and outer bearings.
4A1–12 DIFFERENTIAL (FRONT)
2. Tighten the nut to the specified torque.
4. Set the dial indicator to “0”. Place it on the
mounting post of the gauging arbor with the
contact button touching the indicator pad. Force
the dial indicator downward until the needle has
made a half turn clockwise. Tighten down the dial
indicator in this position.
Torque: 2.3 N·m (20 lb in)
425RW030
Legend
(1) Pilot : J–21777–42
(2) Pilot : J–42479–2
(3) Gauge Plate : J–42479–1
(4) Nut and Stud : J–21777–43
425RS020
3. Clean the side bearing bores. Install the dial
indicator with the discs and arbor. Install and
tighten the bearing caps to the specified torque.
Legend
(1) Dial Indicator
(2) Ganging Arbor
(3) Plunger
(4) Gauge Plate
5. Position the plunger on the gauge plate. Move the
gauging arbor slowly back and forth and locate
the position at which the dial indicator shows the
greatest defection. At this point, once again set
the dial indicator to “0”.
Repeat the procedure to verify the “0” setting.
Torque: 97 N·m (72 lb ft)
425RW031
Legend
(1) Dial Indicator: J–8001
(2) Gauge Plate: J–42479–1
(3) Disc (2 pcs.): J–23597–8
(4) Arbor: J–23597–1
425RS021
DIFFERENTIAL (FRONT)
6. After the ZERO setting is obtained, rotate the
gauging arbor until the dial indicator rod does not
touch the gauging plate.
Record the number the dial indicator needle
points to.
425RS022
Legend
(1) Example=Dial indicator reading of 0.085
7. Record the pinion depth code on the head of the
drive pinion.
The number indicates a necessary change in the
pinion mounting distance. A plus number indicates the need for a greater mounting distance
(which can be achieved by decreasing the shim
thickness). A minus number indicates the need
for a smaller mounting distance (which can be
achieved by increasing the shim thickness). If examination reveals pinion depth code “0”, the pinion is “nominal”.
425RS023
4A1–13
4A1–14 DIFFERENTIAL (FRONT)
8. Select the shim using chart;
Pinion
marking
Dial
indicator
reading
(Inches)
+7
+6
+5
+4
+3
+2
+1
0
–1
–2
–3
–4
–5
–6
0.023
–7
0.030
0.024
0.025
0.026
0.029
0.030
0.031
0.034
0.035
0.036
0.032
0.030
0.030
0.032
0.032
0.030
0.032
0.032
0.034
0.030
0.030
0.032
0.032
0.034
0.034
0.030
0.030
0.032
0.032
0.034
0.034
0.036
0.030
0.030
0.032
0.032
0.034
0.034
0.036
0.036
0.030
0.030
0.032
0.032
0.034
0.034
0.036
0.036
0.038
0.030
0.030
0.032
0.032
0.034
0.034
0.036
0.036
0.038
0.038
0.030
0.030
0.032
0.032
0.034
0.034
0.036
0.036
0.038
0.038
0.040
0.032
0.033
0.030
0.030
0.030
0.027
0.028
0.030
0.030
0.030
0.030
0.032
0.032
0.034
0.034
0.036
0.036
0.038
0.038
0.040
0.040
0.030
0.030
0.032
0.032
0.034
0.034
0.036
0.036
0.038
0.038
0.040
0.040
0.042
0.030
0.030
0.032
0.032
0.034
0.034
0.036
0.036
0.038
0.038
0.040
0.040
0.042
0.042
0.037
0.030
0.030
0.032
0.032
0.034
0.034
0.036
0.036
0.038
0.038
0.040
0.040
0.042
0.042
0.044
0.038
0.030
0.032
0.032
0.034
0.034
0.036
0.036
0.038
0.038
0.040
0.040
0.042
0.042
0.044
0.044
0.039
0.032
0.032
0.034
0.034
0.036
0.036
0.038
0.038
0.040
0.040
0.042
0.042
0.044
0.044
0.046
0.040
0.032
0.034
0.034
0.036
0.036
0.038
0.038
0.040
0.040
0.042
0.042
0.044
0.044
0.046
0.046
0.041
0.034
0.034
0.036
0.036
0.038
0.038
0.040
0.040
0.042
0.042
0.044
0.044
0.046
0.046
0.048
0.042
0.034
0.036
0.036
0.038
0.038
0.040
0.040
0.042
0.042
0.044
0.044
0.046
0.046
0.048
0.048
0.043
0.036
0.036
0.038
0.038
0.040
0.040
0.042
0.042
0.044
0.044
0.046
0.046
0.048
0.048
0.050
0.044
0.036
0.038
0.038
0.040
0.040
0.042
0.042
0.044
0.044
0.046
0.046
0.048
0.048
0.050
0.050
0.045
0.038
0.038
0.040
0.040
0.042
0.042
0.044
0.044
0.046
0.046
0.048
0.048
0.050
0.050
0.052
0.046
0.038
0.040
0.040
0.042
0.042
0.044
0.044
0.046
0.046
0.048
0.048
0.050
0.050
0.052
0.052
0.047
0.040
0.040
0.042
0.042
0.044
0.044
0.046
0.046
0.048
0.048
0.050
0.050
0.052
0.052
0.048
0.040
0.042
0.042
0.044
0.044
0.046
0.046
0.048
0.048
0.050
0.050
0.052
0.052
0.049
0.042
0.042
0.044
0.044
0.046
0.046
0.048
0.048
0.050
0.050
0.052
0.052
0.050
0.042
0.044
0.044
0.046
0.046
0.048
0.048
0.050
0.050
0.052
0.052
0.051
0.044
0.044
0.046
0.046
0.048
0.048
0.050
0.050
0.052
0.052
0.052
0.044
0.046
0.046
0.048
0.048
0.050
0.050
0.052
0.052
0.053
0.046
0.046
0.048
0.048
0.050
0.050
0.052
0.052
0.054
0.046
0.048
0.048
0.050
0.050
0.052
0.052
0.055
0.048
0.048
0.050
0.050
0.052
0.052
0.056
0.048
0.050
0.050
0.052
0.052
0.057
0.050
0.050
0.052
0.052
0.058
0.050
0.052
0.052
0.059
0.052
0.052
0.060
0.052
DIFFERENTIAL (FRONT)
4. Place the shim on the drive pinion. Install the inner
bearing onto the pinion using an installer J–6133–01
and a press.
4A1–15
NOTE: Discard used flange nut and install new one and
do not over tighten the flange nut.
NOTE: Do not apply pressure to the roller cage and apply
pressure only to the inner race.
415RW006
3. Adjust pinion bearing preload.
425RS024
5. Discard the used collapsible spacer and install a new
one.
6. Install pinion gear.
7. Install outer bearing.
8. Use oil seal installer J–24250 to install a new oil seal
that has been soaked in front axle lubricant.
NOTE: Take care to use a front differential oil seal, NOT
the rear differential oil seal.
a. Measure the bearing preload by using a torque
meter. Note the scale reading required to
rotate the flange.
b. Continue tightening flange nut until the
specified starting torque is obtained.
Starting torque:
New bearing 0.7–1.1 N·m (5.64–9.98 lb in)
Used bearing 0.4–0.5 N·m (2.86–4.94 lb in)
NOTE: Do not tighten the flange nut more than
678 N·m(500 lb ft).
415RS011
9. Install flange.
10. Install flange nut.
1. Apply lubricant to the pinion threads.
2. Tighten the nut to the specified torque using the
pinion flange holder J–8614–01.
Torque: 177–275N·m (130–203 lb ft)
425R200001
4. Using punch J–39209, stake the flange nut at two
points.
4A1–16 DIFFERENTIAL (FRONT)
NOTE: When staking, be sure to turn the nut to insure
that there is no change in bearing preload. Make sure of
preload again as instructed in 3.
415R200004
11. Install adjust shim.
1. Attach the side bearing to the differential
assembly without shims. Support the opposite
side using a pilot to prevent bearing damage.
2. Insert the differential cage assembly with bearing
outer races into the side bearing bores of the
carrier.
425RS030
3. Using two sets of feeler gauges, insert a feeler
stock of sufficient thickness between each
bearing outer race and the carrier to remove all
end play. Make certain the feeler stock is pushed
to the bottom of the bearing bores.
Mount the dial indicator J–8001 on the carrier so
that the indicator stem is at right angles to a tooth
on the ring gear.
425RS029
Legend
(1) Drive handle:J–8092
(2) Installer:J–24244
(3) Pilot:J–8107–2
425RS031
DIFFERENTIAL (FRONT)
4. Adjust feeler gauge thickness from side to side
until ring gear backlash is in the specified range.
4A1–17
12. Install the side bearings together with the selected
shims.
Backlash: 0.13–0.20 mm(0.005 –0.008 in)
425RS029
425RS032
With zero end play and correct backlash established, remove the feeler gauge packs, determine
the thickness of the shims required and add 0.025
mm (0.001 in) to each shim pack to provide side
bearing preload. Always use new shims.
5. Use bearing remover J–42379 and pilot
J–8107–2 to remove side bearing.
B Select insert; 303173 and collet halves;44801
in remover kit J–42379.
Legend
(1) Drive Handle:J–8092
(2) Installer: J–24244
(3) Pilot: J–8107–2
13. Install side bearing outer race.
14. Install differential cage assembly.
15. Install bearing cap then align the setting marks(1)
applied at disassembly.
425RS035
415RW003
4A1–18 DIFFERENTIAL (FRONT)
16. Tighten the cap bolt to the specified torque.
Torque: 97 N·m (72 lb ft)
425RS038
425RS036
Gear Tooth
Adjustment
Contact
Pattern
Check
and
1. Apply a thin coat of prussian blue or equivalent to
at least 7–8 ring gear teeth. Rotate the ring gear
and inspect the contact point of the impressions
and make the necessary adjustments as
described in the next page.
Legend
(1) Heel
(2) Toe
(3) Concave Side(Coast)
(4) Convex Side(Drive)
425RS039
DIFFERENTIAL (FRONT)
17. Install differential assembly.
1. Clean the faces of the front axle case and
differential carrier.
Apply Three Bond TB1215 or equivalent to the
sealing side of the axle case and the carrier.
2. Attach the differential case and the carrier
assembly to the front axle case and tighten the
nuts and bolts.
Torque: 25 N·m (19 lb ft)
415RS014
3. Fill the axle case with hypoid gear lubricant, up to
the base of the filler hole.
Lubricant capacity: 1.25 liter(1.32 US qt)
18. Install damper.
1. Clean the faces and bolt thread hole of differential
carrier.
2. Install the bracket with new bolts.
3. Install the damper to the bracket with new bolts.
Torque: 25 N·m (19 lb ft)
425RW042
4A1–19
4A1–20 DIFFERENTIAL (FRONT)
Differential Cage Assembly
Disassembled View
415R200005
Legend
(1) Pinion Gear
(2) Thrust Washer
(3) Side Gear
(4) Cross Pin
(5)
(6)
(7)
(8)
Ring Gear
Bolt
Differential Cage
Lock Pin
Disassembly
1. Remove bolt.
2. Remove ring gear.
3. Remove lock pin.
425RS042
DIFFERENTIAL (FRONT)
4. Remove the cross pin, using a soft metal rod and a
hammer.
3. Tighten the fixing bolts in a diagonal sequence as
illustrated.
425RS043
5. Remove pinion gear.
6. Remove side gear.
7. Remove thrust washer.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
Check the following parts.
1. Ring gear, pinion gear
2. Bearing
3. Side gear, pinion gear, cross pin
4. Differential cage, carrier
5. Thrust washer
6. Oil seal
4A1–21
415RS016
Reassembly
1. Install thrust washer.
2. Install side gear.
3. Install the pinion gear with thrust washer by engaging
it with the side gears while turning both pinion gears
simultaneously in the same direction.
Ring gear replacement:
1. The ring gear should always be replaced with the
drive pinion as a set.
2. Discard used bolts and install new ones.
Torque: 108 N·m (80 lb ft)
425RS048
4A1–22 DIFFERENTIAL (FRONT)
4. Install cross pin.
B Be sure to install the cross pin so that it is in
alignment with the lock pin hole in the differential
cage.
425RS049
5. Install lock pin. After lock pin installation, stake the
cage to secure the lock pin.
6. Install ring gear and tighten the bolts in diagonal
sequence as illustrated.
Torque: 108 N·m (80 lb ft)
NOTE: Discard used bolts and install new ones.
415RS016
DIFFERENTIAL (FRONT)
4A1–23
Main Data and Specifications
General Specifications
Axle tube Type
It consists of a duct, a cast iron housing
and an axle tube.
Gear type
Hypoid
Gear ratio
4.300
Differential type
Oil capacity
Type of lubricant
Axle shaft type
Hub locking Type
Two pinion
liter (US qt)
1.25 (1.32) (Differential)
0.12 (0.13) (Actuator Housing: Shift on the fly)
GL–5 (75W–90)
Constant velocity joint
(Birfield joint type and double offset joint)
Rigid
Torque Specifications
412R200005
4A1–24 DIFFERENTIAL (FRONT)
415R200003
DIFFERENTIAL (FRONT)
4A1–25
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION
TOOL NO.
TOOL NAME
J–8614–01
Holder; Pinion flange
J–7817
Installer; Outer bearing
outer race
J–24250
Installer; Oil seal
J–7818
Installer; Inner bearing
outer race
J–37264
Differential holding
fixture
(Use with J–3289–20
base)
J–8092
Driver handle
J–3289–20
Holding fixture base
J–21777–42
Pilot
J–42379
Remover; Side/Pinion
bearing
J–21777–43
Nut and stud
J–8107–2
Adapter; Side bearing
plug
J–42479–1
Gauge plate
4A1–26 DIFFERENTIAL (FRONT)
ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION
TOOL NO.
TOOL NAME
J–8001
Dial indicator
J–42479–2
Pilot
J–23597–8
Disc
J–39209
Punch; End nut lock
J–23597–1
Arbor
J–6133–01
Installer; Pinion bearing
J–24244
Installer; Side bearing
J–39602
Remover; Outer bearing
SECTION
DIFFERENTIAL (REAR)
4A2–1
AXIOM
DRIVELINE/AXLE
Differential (Rear)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . .
General Description . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Housing . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Housing and Associated Parts . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Shaft, Oil Seal and Bearing . . . . . . . . . .
Axle Shaft and Associated Parts . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Oil Seal and Associated Parts . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Assembly . . . . . . . . . . . . . . . . . . . .
Disassembled View . . . . . . . . . . . . . . . . . . . .
Inspecting the Axle Before Disassembly . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
4A2–1
4A2–2
4A2–3
4A2–5
4A2–5
4A2–5
4A2–7
4A2–7
4A2–7
4A2–8
4A2–8
4A2–8
4A2–10
4A2–10
4A2–10
4A2–11
4A2–11
4A2–13
4A2–13
4A2–14
4A2–14
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 INFOMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
Inspection and Repair . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Side Bearing Preload Adjustment . . . . . . . .
Pinion Installation . . . . . . . . . . . . . . . . . . . . . .
Determination of Backlash & Preload Shims
Backlash Adjustment . . . . . . . . . . . . . . . . . . .
Gear Tooth Pattern Check . . . . . . . . . . . . . .
Adjustments Affecting Tooth Contact . . . . .
Differential Case Assembly . . . . . . . . . . . . . . .
Disassembled View . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Limited Slip Differential Assembly . . . . . . . . .
Disassembled View . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data And Specifications . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . .
4A2–16
4A2–16
4A2–20
4A2–21
4A2–22
4A2–23
4A2–23
4A2–24
4A2–25
4A2–25
4A2–26
4A2–26
4A2–26
4A2–27
4A2–27
4A2–27
4A2–29
4A2–29
4A2–31
4A2–32
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED , do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally,such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specification. Following these
instructions can help you avoid damage to parts and
systems.
4A2–2
DIFFERNTIAL (REAR)
General Description
Limited Slip Differential (LSD)
The rear axle assembly is of the semi–floating type in
which the vehicle weight is carried on the axle housing .
The center line of the pinion gear is below the center line
of the ring gear (hypoid drive).
All parts necessary to transmit power from the propeller
shaft to the rear wheels are enclosed in a salisbury type
axle housing (a carrier casting with tubes pressed and
welded into the carrier). A removable aluminum cover at
the rear of the axle housing permits rear axle service
without removal of the entire assembly from the vehicle.
The 8.9 inch ring gear rear axle uses a conventional ring
and pinion gear set to transmit the driving force of the
engine to the rear wheels. This gear set transfers this
driving force at a 90 degree angle from the propeller shaft
to the drive shafts.
The axle shafts are supported at the wheel end of the
shaft by a roller bearing.
The pinion gear is supported by two tapered roller
bearings. The pinion depth is set by a shim pack located
between the gear end of the pinion and the roller bearing
that is pressed onto the pinion. The pinion bearing
preload is set by crushing a collapsible spacer between
the bearings in the axle housing.
The ring gear is bolted onto the differential case with 10
bolts.
The differential case is supported in the axle housing by
two tapered roller bearings. The differential and ring gear
are located in relationship to the pinion by using selective
shims and spacers between the bearing and the
differential case. To move the ring gear, shims are deleted
from one side and an equal amount are added to the other
side. These shims are also used to preload the bearings
which are pressed onto the differential case. Two bearing
caps are used to hold the differential into the rear axle
housing.
The differential is used to allow the wheels to turn at
different rates of speed while the rear axle continues to
transmit the driving force. This prevents tire scuffing
when going around corners and prevents premature wear
on internal axle parts.
The rear axle is sealed with a pinion seal, a seal at each
axle shaft end, and by a liquid gasket between the rear
cover and the axle housing.
The axle assembly may be equipped with an limited slip
differential (LSD). It is similar to the standard differential
except that part of the torque from the ring gear is
transmitted through clutch packs between the side gears
and differential case.
The LSD construction permits differential action when
required for turning corners and transmits equal torque to
both wheels when driving straight ahead. However, when
one wheel tries to spin due to a patch of ice, etc., the
clutch packs automatically provide more torque to the
wheel which is not trying to spin.
In diagnosing customer complaints, it is important to
recognize two things:
1. If, both wheels slip, with unequal traction, the LSD
has done all it can possibly do.
2. In extreame cases of differences in traction, the
wheel with the least traction may spin after the LSD
has transferred as much torque as possible to the
non-slipping wheel.
Limited Slip Differntials impose additional requirements
on lubricants, and require a special lubricant or lubricant
additive. Use 80W90 GL–5 LSD lubricant.
Rear Axle Identification
The Bill of Material and build date information(1) is
stamped on the right axle tube on the rearward side.
The axle ratio is identified by a tag(3) which is secured by
a cover bolt. If the axle has limited-slip differntial, it also
will be identified with a tag(2) secured by a cover bolt.
425RX001
DIFFERENTIAL (REAR)
Diagnosis
Many noises that seem to come from the rear axle
actually originate from other sources such as tires, road
surface, wheel bearings, engine, transmission, muffler, or
body drumming. Investigate to find the source of the
noise before disassembling the rear axle. Rear axles, like
any other mechanical device, are not absolutely quiet but
should be considered quiet unless some abnormal noise
is present.
To make a systematic check for axle noise, observe the
following:
1. Select a level asphalt road to reduce tire noise and
body drumming.
2. Check rear axle lubricant level to assure correct level,
and then drive the vehicle far enough to thoroughly
warm up the rear axle lubricant.
3. Note the speed at which noise occurs. Stop the
vehicle and put the transmission in neutral. Run the
engine speed slowly up and down to determine if the
noise is caused by exhaust, muffler noise, or other
engine conditions.
4. Tire noise changes with different road surfaces; axle
noises do not. Temporarily inflate all tires to 344 kPa
(50 psi) (for test purposes only). This will change
noise caused by tires but will not affect noise caused
by the rear axle.
Rear axle nose usually stops when coasting at
speeds under 48 km/h (30 mph); however, tire noise
continues with a lower tone. Rear axle noise usually
changes when comparing pull and coast, but tire
noise stays about the same.
Distinguish between tire noise and rear axle noise by
noting if the noise changes with various speeds or
sudden acceleration and deceleration. Exhaust and
axle noise vary under these conditions, while tire
noise remains constant and is more pronounced at
speeds of 32 to 48 km/h (20 to 30 mph). Further check
for tire noise by driving the vehicle over smooth
pavements or dirt roads (not gravel) with the tires at
normal pressure. If the noise is caused by tires, it will
change noticeably with changes in road surface.
5. Loose or rough front wheel bearings will cause noise
which may be confused with rear axle noise; however,
front wheel bearing noise does not change when
comparing drive and coast. Light application of the
brake while holding vehicle speed steady will often
cause wheel bearing noise to diminish. Front wheel
bearings may be checked for noise by jacking up the
wheels and spinning them or by shaking the wheels to
determine if bearings are loose.
6. Rear suspension rubber bushings and spring
insulators dampen out rear axle noise when correctly
installed. Check to see that there is no link or rod
loosened or metal–to–metal contact.
4A2–3
7. Make sure that there is no metal–to–metal contact
between the floor and the frame.
After the noise has been determined to be in the axle, the
type of axle noise should be determined, in order to make
any necessary repairs.
Gear Noise
Gear noise (whine) is audible from 32 to 89 km/h (20 to 55
mph) under four driving conditions.
1. In drive under acceleration or heavy pull.
2. Driving under load or under constant speed.
3. When using enough throttle to keep the vehicle from
driving the engine while the vehicle slows down
gradually (engine still pulls slightly).
4. When coasting with the vehicle in gear and the throttle
closed. The gear noise is usually more noticeable
between 48 and 64 km/h (30 and 40 mph) and 80 and
89 km/h (50 and 55 mph).
Bearing Noise
Bad bearings generally produce a rough growl or grating
sound, rather than the whine typical of gear noise.
Bearing noise frequently “wow–wows” at bearing rpm,
indicating a bad pinion or rear axle side bearing. This
noise can be confused with rear wheel bearing noise.
Rear Wheel Bearing Noise
Rear wheel bearing noise continues to be heard while
coasting at low speed with transmission in the neutral.
Noise may diminish by gentle braking. Jack up the rear
wheels, spin them by hand and listen for noise at the
hubs. Replace any faulty wheel bearings.
Knock At Low Speeds
Low speed knock can be caused by worn universal joints
or a side gear hub counter bore in the cage that is worn
oversize. Inspect and replace universal joints or cage and
side gears as required.
Backlash Clunk
Excessive clunk on acceleration and deceleration can be
caused by a worn rear axle pinion shaft, a worn cage,
excessive clearance between the axle and the side gear
splines, excessive clearance between the side gear hub
and the counterbore in the cage, worn pinion and side
gear teeth, worn thrust washers, or excessive drive pinion
and ring gear backlash. Remove worn parts and replace
as required. Select close–fitting parts when possible.
Adjust pinion and ring gear backlash.
4A2–4
DIFFERNTIAL (REAR)
Rear Axle Noise
Condition
Noise in Drive
Noisy when coasting
Intermittent noise
Constant noise
Noisy on turns
Possible cause
Excessive
backlash.
pinion
to
ring
Correction
gear
Adjust.
Worn pinion and ring gear.
Replace
Worn pinion .bearings.
Replace.
Loose pinion bearings.
Adjust.
Excessive pinion end play.
Adjust.
Worn side bearings.
Replace.
Loose side bearings.
Adjust.
Excessive ring gear run-out.
Replace.
Low oil level.
Replenish.
Wrong or poor grade oil.
Replace.
Bent axle housing.
Replace.
Axle noise heard when driving will
usually be heard also on coasting,
although not as loud.
Adjust or replace.
Pinion and ring gear too tight (audible
when slowing down and disappears
when driving).
Adjust.
Warped bevel ring.
Replace.
Loose differential case bolts.
Tighten.
Flat spot on pinion or ring gear teeth.
Replace.
Flat spot on bearing.
Replace.
Worn pinion splines.
Replace.
Worn axle shaft dowel holes.
Replace.
Worn hub studs.
Replace.
Bent axle shaft.
Replace.
Worn differential side gears and
pinions.
Replace.
Worn differential shaft.
Replace.
Worn axle shaft splines.
Replace.
Limited Slip Differential
Condition
Possible cause
Correction
Does not lock
Broken clutch plates.
Replace the clutch plates.
Chatters in turns
Lubricant contaminated.
Drain lube when hot. Wipe carrier
clean. Refill with lube specified in
Main Data and Specifications at the
end of this section.
Clutch plates dateriorated.
Replace clutch plates.
Broken clutch plates.
Replace clutch plates.
Damaged case.
Replace unit.
Broken differential gears.
Replace gears.
Noise (in addition to normal clutch
engagement)
DIFFERENTIAL (REAR)
4A2–5
Axle Housing
Axle Housing and Associated Parts
420RW030
Legend
(1) Lower Link
(2) Stabilizer
(3) Upper Link
(4) Rear Propeller shaft
(5) Shock Absorber
(6)
(7)
(8)
(9)
(10)
Lateral Rod
Brake Hose
Coil Spring
Parking Cable
Axle Assembly
Removal
1. Raise the vehicle and support it with suitable safety
stands.
The hoist must remain under the rear axle housing.
2. Take out brake fluid. Refer to Hydraulic Brakes in
Brake section.
3. Remove rear wheels and tires. Refer to Wheel
Replacement in Suspension section.
4. Remove propeller shaft. Refer to Rear Propeller
Shaft in this section.
5. Drain the rear axle oil into a proper container.
6. Remove parking brake cable, release the connection
between the cable fixing clip equalizer. Refer to
Parking Brakes in Brake section.
7. Move the clip aside and pull out the breather hose.
8. Disconnect the ABS connectors (1) and remove the
brackets attached to the frame and center link.
350RW023
4A2–6
DIFFERNTIAL (REAR)
9. Loosen the brake tube flare nut, remove the clip and
take out the brake tube.
12. Remove the lateral rod fixing bolt and nut from the
frame.
13. Remove the upper link mounting bolt and nut (3) from
the axle housing.
350RW020
10. Remove the shock absorber.
11. Remove the stabilizer linkage mounting bolts and
nuts (2) from the frame side.
460RW015
14. Remove the lower link fixing bolt and nut (4) from the
axle housing.
350RW024
460RW016
15. Jack down and remove the coil spring and insulator.
16. Axle housing assembly can be separated from the
vehicle upon completion of steps 1 – 15.
17. Remove the brake caliper fixing bolt, loosen the flare
nut, release the clip and take out the brake caliper
together with the flexible hose.
18. Remove brake disc.
19. Remove antilock brake system speed sensor fixing
bolt and the clip and bracket on the axle housing.
20. Remove the brake pipe clip and fixing bolt on the axle
housing and take out the brake pipe.
DIFFERENTIAL (REAR)
Installation
1. Install brake pipe.
2. Connect Antilock brake system (ABS) speed sensor
and harness, refer to 4–Wheel Anti–Lock Brake
System (ABS) in Brake section.
3. Install brake disc.
4. Install brake caliper. Refer to Disk Brakes in Brake
section.
5. Install axle housing assembly.
6. Install coil spring and insulator.
7. Install the lower link fixing bolt and nut to the axle
housing. For the procedures in items 7–11, refer to
Suspension section.
8. Install the upper link bolt and nut to the axle housing.
4A2–7
9. Install the lateral rod fixing nut and bolt to the frame
side.
10. Install the stabilizer linkage mounting nut and bolt to
the frame side.
11. Install the shock absorber.
12. Install brake tube flare nut, Refer to Disk Brakes in
Brake section.
13. Install ABS connector and bracket.
14. Connect breather hose.
15. Install parking brake cable, Refer to Parking Brakes in
Brake section.
16. Bleed brakes. Refer to Hydraulic Brakes in Brake
section.
Axle Shaft, Oil Seal and Bearing
Drum Brake Model
Axle Shaft and Associated Parts
Disc Brake Model
420RX001
420RW008
Legend
(1) Axle Shaft
(2) Backing Plate
(3) Oil Seal
(4) Bearing
(5) Axle Housing
(6) Lock Washer
(7) Nut
Legend
(1) Axle Shaft
(2) Backing Plate
(3) Oil Seal
(4) Bearing
(5) Axle Housing
(6) Lock Washer
(7) Nut
4A2–8
DIFFERNTIAL (REAR)
Removal
1. Raise the vehicle.
2. Remove rear wheels and brake calipers or drums.
Do not let calipers hang from the vehicle by the brake
line or hose. Use a wire to hang the caliper to the
frame to prevent damage to the caliper.
8. Remove oil seal, retainer, and emergency brake
assembly.
9. Remove inner race from shaft with OTC–1126
bearing splitter and press.
3. Remove four nuts and lockwashers.
4. Remove shaft assembly from the axle housing.
5. Remove snap ring and bearing cup.
6. Break retainer ring with hammer and chisel.
420RS028
Inspection
B Shaft for spalling or grooves from seal wear.
B Retainer – bent or damaged.
B Replace items if required.
420RS026
7. Break bearing cage with hammer and chisel.
Installation
1. Emergency brake assembly.
2. Install retainer.
Note direction – do not install backwards.
420RS027
420RS029
DIFFERENTIAL (REAR)
3. Install oil seal. Note direction.
4. Install bearing assembly, using installer and press.
4A2–9
5. Install retainer ring, using installer and press.
420RS033
420RS030
NOTE: Install bearing with cup towards inboard side.
6. Install snap ring.
7. Install axle shaft assembly into housing.
8. Install bolts, lockwashers, and nuts.
Tighten the retainer nuts to the specified torque.
Torque : 75 N·m (55 lb ft)
420RS031
4A2–10
DIFFERNTIAL (REAR)
Pinion Oil Seal
Pinion Oil Seal and Associated Parts
420RW013
Legend
(1) Flange Nut and Washer
(2) Flange
(3) Oil Seal
(4) Outer Oil Seal Slinger
(5) Outer Pinion Bearing (Cup and Cone)
Removal
1. Remove the rear propeller shaft. Refer to Rear
Propeller Shaft in this section.
2. Drain the rear axle oil.
3. Check and record preload with an inch pound torque
wrench. This will give combined pinion bearing, seal,
carrier bearing, axle bearing and seal preload.
425RW018
DIFFERENTIAL (REAR)
4. Remove flange nut and washer by using pinion flange
holder J–8614–01 after raising up its staked parts
completely.
4A2–11
6. Remove oil seal.
7. Remove pinion oil seal slinger.
8. Remove outer bearing by using remover J–39602.
425RW037
5. Remove flange by using SST J–8614–1 ∼ 3.
B Have a suitable container in place to catch
lubricant.
425RS090
9. Remove collapsible spacer.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
Check the following parts.
1. Seal surface of the flange.
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.
425RW038
4A2–12
DIFFERNTIAL (REAR)
3. By using the seal installer J–37263, install a new oil
seal (1) that has grease on seal lip.
425RS004
4. Install flange.
5. The pinion washer and a new nut while holding the
pinion flange with J–8614–01.
B Tighten the nut until the pinion end play is just taken
up. Rotate the pinion while tightening the nut to seat
the bearings. Once there is not end play in the
pinion, the preload torque should be checked.
B Remove J–8614–01. Using an inch-pound torque
wrench, check to make sure the pinion preload is
equal to or slightly over the reading recorded during
removal.
425RW018
6. Install propeller shaft to the frange.
7. Install bolt and nut. Tighten the bolt and nut to the
specified torque.
Torque: 63 N·m (46 lb ft)
DIFFERENTIAL (REAR)
4A2–13
Differential Assembly
Disassembled View
420RW018
Legend
(1) ABS Speed Sensor
(2) Housing
(3) Outer Pinion Bearing (Cup and Cone)
(4) Outer Oil Slinger
(5) Oil Seal
(6) Companion Flange Assembly
(7) Pinion Nut Washer
(8) Pinion Nut
(9) Collapsible Spacer
(10) Baffle Plate
(11) Inner Pinion Bearing (Cup and Cone)
(12) Inner Oil Slinger
(13) Pinion gear adj. Shim-Selective (Position)
(14) Ring gear and Pinion Gear Assembly
(15) Exciter Ring
(16) Differential Case
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
Lock Pin
Axle Vent
Gasket
Cover and Clip Assembly
Fill Plug (with Magnet)
Mounting Bracket
Side Bearing Cap Bolt
Side Bearing Cap
Ring Gear Bolts
Differential Adjustment Shims (Side Bearing
Preload and Ring Gear/Pinion Backlash)
Side Bearing (Cup and Cone)
Differential Shaft
Differential Side Gears
Side Gear Thrust Washer
Pinion Mate Gears
Thrustwasher-Differential Pinion Mate Gear
4A2–14
DIFFERNTIAL (REAR)
4. Remove Differential case.
B Pry the case from the axle housing at the differential
“window”.
Inspecting the Axle Before
Disassembly
1. Remove the axle cover from the rear axle and drain
the axle lubricant into a suitable container.
2. Check ring gear backlash. Refer to Backlash
Adjustment in this section. This information can be
used to determine the cause of the axle problem. It
will also help when setting up the shim packs for
locating and preloading the differential cage.
3. Check case for metal chips and shavings. Determine
where these chips and shavings come from, such as
a broken gear or bearing cage.
B If possible, determine the cause of the axle problem
before disassembly.
Disassembly
1. Remove axle shafts.
B Refer to axle shaft replacement in this section.
2. Remove ABS sensor.
3. Remove bearing caps and bolts.
B Mark the caps and the housing as left and right.
CAUTION: Bearing caps are machined with the
housing and must be assembled in the same
position as removed. Note the matched letter
stamped on the caps and carrier. When assembled,
the letters on the caps must agree in both the
hosizontal and vertical position with the letters on
the carrier.
420RW010
5. Remove side bearing outer races and shims.
B Mark the races and shims as left and right, and
place them with the bearing cups.
6. Remove differential side bearings using remover
J–42379 and plug J–39830.
B Select insert ; 303174 and collet halves ; 44801 in
remover kit J–42379.
415RW003
420RW003
7. Remove ring gear bolts.
B Ring gear bolts use right handed threads.
CAUTION: DO not pry the ring gear from the case.
This will damage the ring and the differential case.
DIFFERENTIAL (REAR)
8. Remove ring gear from the differential.
B Drive the ring gear off with a brass drift if necessary.
4A2–15
12. Remove collapsible spacer(1).
B Check drive pinion bearing preload.
415RW011
425RW018
B Check the pinion assembly for looseness by
moving it back and forth. (Looseness indicates
excessive bearing wear.)
9. Remove pinion flange nut and washer.
B Use flange holder J–8614–01 to hold the pinion
flange.
10. Remove pinion flange.
B Use flange holder J–8614–01 to remove the pinion
flange.
13. Remove outer seal, outer oil slinger and outer pinion
bearing.
14. Remove inner bearing, inner oil slinger and shim from
the pinion.
B Press the bearing off the pinion using remover
J–42379.
415RW004
B Select insert ; 303174 and collet halves ; 44801 in
remover kit J–42379.
B Remove the shim.
415RS018
11. Remove pinion from the axle housing.
B Thread the pinion nut halfway onto the pinion.
B Drive the pinion out of the housing with a hammer
and a soft drift.
B Remove the nut and then remove the pinion.
15. Remove bearing cups and baffle plate from the axle
housing using a hammer and a punch.
B Work the cups out of the housing evenly, moving the
punch back and forth between one side of the cup
and the other.
B The baffle plate will be destroyed and should be
replaced with a new one.
4A2–16
DIFFERNTIAL (REAR)
16. Remove exciter ring.
B Remove the exciter ring from the differential using a
mallet or a brass hammer if it is required.
NOTE: Discard the exciter ring after removal.
B The sealing surface of the pinion flange for nicks,
burrs, or rough tool marks which would cause
damage to the seal’s inside diameter and result in an
oil leak.
B Replace all worn or broken parts.
B Ring and pinion gears are matched sets and are both
replaced anytime a replacement of either is
necessary.
Bearings
B Bearings visually and by feel.
B The bearings should feel smooth when oiled and
rotated while applying as much hand pressure as
possible.
The large end of the bearing rollers for wear.
This is where tapered roller bearing wear is most
evident.
425RS097
Cleaning
Do not steam clean drive parts which have ground and
polished surfaces such as gears, bearings, and shafts.
These parts should be cleaned in a suitable solvent. All
parts should be disassembled before cleaning.
Parts should be thoroughly dried immediately after
cleaning. Use soft, clean, lintless rags. Parts may be dried
with cimpressed air. Do not allow the bearings to spin
while drying them with compressed air.
Inspection and Repair
It is very important to carefully and thoroughly inspect all
drive unit parts before reassembly.
Thorough inspection of the drive parts for wear or stress
and subsequent replacement of worn parts will eliminate
costly drive component repair after reassembly.
B Bearing cups for wear, cracks, brinelling and scoring.
B Bearing and cups are only replaced as sets.
B If the rear axle was operated for an extended period of
time with very loose bearings, the ring gear and drive
pinion will also require replacement.
B Low mileage bearings may have minute scratches
and pits on the rollers and the bearing cups from the
initial pre-load. Do not replace a bearing for this
reason.
B Bearing cups for cracks or chips.
Shims
B Shims for cracks and chips. Damaged shims should
be replaced with an equally sized service shim.
Reassembly
1. Install pinion bearing races and baffle plate using
outer bearing race installer J–8611–01 / inner bearing
race installer J–42836 and drive handle J–8592.
NOTE: Baffle plate must be installed, when install the
inner pinion bearing race.
Axle Housing
B The carrier bore for nicks or burrs that would prevent
the outer diameter of the pinion seal from sealing,
Remove any burrs that are found.
B The bearing cap bores for nicks or burrs.
Remove any burrs that are found.
B The housing for cracks. Replace the housing if any
cracks are found.
B The housing for foreign material such as metal chips,
dirt, or rust.
Pinion and Ring Gear
B Pinion and ring gear teeth for cracking, chipping,
scoring, or excessive wear.
B Pinion splines for wear.
B Pinion flange splines for wear.
425RW019
DIFFERENTIAL (REAR)
4A2–17
10. Assemble discs J–39837–1, arbor J–23597–1 and
dial indicator J–8001 to the side bearing bores.
NOTE: The bearing bores must be clean and burr-free.
425RW020
2. Clean all the gauge parts.
3. Lubricate the outer and inner bearings with axle
lubricant.
4. Place the bearings into the pinion bearing races.
5. Place the inner oil slinger onto the inner pinion
bearing.
NOTE: The inner oil slinger must be placed between
gauge plate and inner pinion bearing when measuring the
pinion depth.
6. Install gauge plate J–39837–2, inner J–42827 stud
and nut J–21777–43 and outer pilot J–42824 to the
pinion bore.
420RW005
7. Hold the stud stationary at the flats of the stud (and).
Tighten the stud nut
Torque: 2.2 N·m (1.6 lb ft)
8. Rotate the gauge plate and bearings several
complete revolutions to seat the bearings.
9. Tighten the stud nut until a torque of 1.6 to 2.2 N·m
(1.2 to 1.6 lb ft.) is required to keep the gauge plate in
rotation.
420RW005
11. Install the side bearing caps and tighten the bolts to
the specified torque.
Torque: 108 N·m (80 lb ft)
12. Rotate the gauge plate until the gauging area is
parallel with the discs.
13. Position the arbor assembly in the carrier so that the
plunger is centered on the gauge area of the gauge
plate.
4A2–18
DIFFERNTIAL (REAR)
14. Set the dial indicator to “0”. Place it on the mounting
post of the gauging arbor with the contact button
touching the indicator pad.
Force the dial indicator downward until the needle has
made a half turn clockwise. Tighten down the dial
indicator in this position.
16. After the ZERO setting is obtained, rotate the gauging
arbor until the dial indicator rod does not touch the
gauging plate.
Record the number the dial indicator needle points to.
425RS022
425RS020
Legend
(1) Dial Indicator
(2) Ganging Arbor
(3) Plunger
(4) Gaug Plate
15. Position the plunger on the gauge plate. Move the
gauging arbor slowly back and forth and locate the
position at which the dial indicator shows the greatest
defection. At this point, once again set the dial
indicator to “0”.
Repeat the procedure to verify the “0” setting.
Legend
(1) Example=Dial indicator reading of 0.085
17. Record the pinion depth code on the head of the drive
pinion.
The number indicates a necessary change in the
pinion mounting distance. A plus number indicates
the need for a greater mounting distance (which can
be achieved by decreasing the shim thickness). A
minus number indicates the need for a smaller
mounting distance (which can be achieved by
increasing the shim thickness). If examination
reveals pinion depth code “0”, the pinion is “nominal”.
425RS023
425RS021
DIFFERENTIAL (REAR)
4A2–19
18. Select the shim using the chart;
Dial Indicator
Reading
(inches)
Marking (inches)
+3
+2
+1
0
–1
–2
0.027
–3
0.030
0.028
0.030
0.031
0.030
0.031
0.032
0.030
0.031
0.032
0.033
0.030
0.031
0.032
0.033
0.034
0.030
0.031
0.032
0.033
0.034
0.035
0.029
0.030
0.031
0.032
0.033
0.030
0.031
0.032
0.033
0.034
0.035
0.036
0.034
0.031
0.032
0.033
0.034
0.035
0.036
0.037
0.035
0.032
0.033
0.034
0.035
0.036
0.037
0.038
0.036
0.033
0.034
0.035
0.036
0.037
0.038
0.039
0.037
0.034
0.035
0.036
0.037
0.038
0.039
0.040
0.038
0.035
0.036
0.037
0.038
0.039
0.040
0.041
0.039
0.036
0.037
0.038
0.039
0.040
0.041
0.042
0.040
0.037
0.038
0.039
0.040
0.041
0.042
0.043
0.041
0.038
0.039
0.040
0.041
0.042
0.043
0.044
0.042
0.039
0.040
0.041
0.042
0.043
0.044
0.045
0.043
0.040
0.041
0.042
0.043
0.044
0.045
0.046
0.044
0.041
0.042
0.043
0.044
0.045
0.046
0.047
0.045
0.042
0.043
0.044
0.045
0.046
0.047
0.048
0.046
0.043
0.044
0.045
0.046
0.047
0.048
0.049
0.047
0.044
0.045
0.046
0.047
0.048
0.049
0.050
0.048
0.045
0.046
0.047
0.048
0.049
0.050
0.051
0.049
0.046
0.047
0.048
0.049
0.050
0.051
0.052
0.050
0.047
0.048
0.049
0.050
0.051
0.052
0.053
0.051
0.048
0.049
0.050
0.051
0.052
0.053
0.052
0.049
0.050
0.051
0.052
0.053
0.053
0.050
0.051
0.052
0.053
0.054
0.051
0.052
0.053
0.055
0.052
0.053
0.056
0.053
4A2–20
DIFFERNTIAL (REAR)
19. Remove bearing caps and depth gauging tools.
20. Install the correct pinion shim and inner oil slinger
onto pinion.
NOTE: Do not install pinion gear into housing at this time.
21. If the exciter ring was removed, install the new exciter
ring onto the differential case by pressing using the
ring gear as a pilot.
23. Install new ring gear bolts.
B Tighten the ring gear bolts alternately in stages,
gradually pulling the ring gear onto the differential
case.
Tighten the ring gear bolts in sequence
Torque: 108 N·m (80 lb ft)
NOTE: Discard used bolts and install new ones.
425RS047
415RS016
22. Install ring gear(1) to the differential case(2)
Side Bearing Preload Adjustment
1. The side bearing preload adjustment must be made
before installing the pinion.
2. The side bearing preload is adjusted by changing the
thickness of both the left and right shims equally. This
maintain the original backlash.
3. Install master side bearings J–39836 onto the case.
Remove all nicks, burrs, dirt etc., from the hubs to
allow the master bearings to rotate freely.
425RW021
425RW026
DIFFERENTIAL (REAR)
4. Assemble the differential case into the housing (less
pinion). Install bearing caps and finger tight bolts.
Mount a dial indicator with a magnetic base to the
housing and indicate on the flange or head of screw.
Force the differential assembly as far as possible in
the dirction towards the indicator.
With force still applied, set indicator at zero(0).
4A2–21
Pinion Installation
B The bearing cups should have been installed in Pinion
Depth Adjustment in this section.
1. Place the shim(1) and inner oil slinger(2) on the pinion
gear, then install the pinion inner bearing(3) using
installer J–42828.
NOTE: Dial indicator set should be capable of a minimum
travel of 5.08 mm (0.2 in).
425RW023
425RS107
5. Force the differetial assembly as far as it will go in the
opposite direction. Repeat these steps until the same
reading is obtained.
6. RECORD THE READING OF THE INDICATOR.
This amount, in shims, will be included in the final
assembly shim stack to establish side bearing
preload and ring gear and pinion backlash.
7. After marking sure the readings are correct, remove
the indicator and differetial assembly from the
housing.
B Drive the bearing until the bearing cone seats on the
pinion shims.
2. Install a new collapsible spacer.
B Lubracate the pinion bearings with axle lublicant.
3. Install pinion to the axle housing.
4. Install outer pinion bearing onto the pinion.
B Hold the pinion forward from inside the case while
driving the bearing onto the pinion.
5. Install oil seal slinger.
6. Install pinion oil seal using installer J–37263.
7. Install the pinion flange to the pinion by tapping it with
a rawhide hammer until a few threads show through
the pinion flange.
8. Install pinion washer and a new nut while holding the
pinion flange with flange holder J–8614–01.
B Tighten the nut until the pinion end play is just taken
up. Rotate the pinion while tightening the nut to seat
the bearings.
Torque:217-678 N·m (160-500 lb ft)
Once there is no end play in the pinion, the preload
torque should be checked.
B Remove flange holder J–8614–01. Using an
inch-pound torque wrench, check the pinion
preload by rotating the pinion with the wrench.
4A2–22
DIFFERNTIAL (REAR)
8. The remaining amount of shims, which is the
difference between the overall found in step 6 of Side
Bearing Pre-load Adjustment and step(7) above,
should be placed on the other side of the differential
case, plus additional 0.38 mm (0.015 in) for obtaining
preload and backlash.
9. Place the required amount of shims on each hub as
determined in the previous steps and assemble side
bearing cone by using installer J–21784 and handle
J–8592.
425RW018
Preload should be at 1.0 to 1.6 N·m (8 to 14 in lbs.)
on new bearings, or 0.46 to 0.69 N·m (4 to 6 in lbs.)
for used bearings.
B If the preload torque is below the preloads given
above, continue torquing the nut in small
increments. Check the preload after each
tightening. Each tightening increases the bearing
preload by several pounds. If the bearing preload is
exceeded, the pinion will have to be removed, and a
new collapsible spacer installed.
B Once a preload of 1.0 to 1.4 N·m (8 to 12 in lbs.)
has been obtained, rotate the pinion several times
to assure that the bearings have seated. Recheck
the preload, and adjust if necessary.
Determination of Backlash & Preload
Shims
1. Install master side bearings onto the case.
2. Install differential assembly into the carrier.
3. Install the bearing cap and finger tight bolts.
4. Set up the dial indicator.
5. Force the differential assembly away from the pinion
gear until it is completely seated against the cross
bore face of the carrier.
6. With force still applied to the differential case, place
the tip of dial indicator on a machined surface of the
differential case, if available, or on the head of a ring
gear screw, and set the indicator at zero(0).
7. Force the ring gear to mesh with the pinion gear. Rock
the ring gear slightly to make sure the gear teeth are
meshed. Repeat this procedure several times until
the same reading is obtained each time. Be sure the
indicator reads zero(0) each time the ring gear is
forced back into contact with the cross bore face. This
reading will be the necessary amount of shims to be
placed between the differential case and side bearing
cone on the ring gear side.
425RW022
10. Total torque to rotate — Increase of pinion torque to
rotate due to differential case assembly shall not
exceed 3.4 N·m (30 in lbs.) divided by the gear ratio.
11. Assembly the spreader J–24385–B and indicator to
the carrier as shown in figure. Spread the carrier
0.5 mm (0.02 in) for differential installation.
420RW004
CAUTION: Do not spread the carrier over 0.5 mm
(0.02 in).
12. Remove the indicator.
DIFFERENTIAL (REAR)
4A2–23
11. Install the cover with sealant.
Backlash Adjustment
1. Install the differential case assembly and bearing
caps.
2. Rotate the case several times to seat the bearings.
3. Remove the spreader.
4. Install the side bearing cap bolts.
Tighten side bearing cap bolts
Torque: 108 N·m (80 lb ft)
5. Install a dial indicator to the case using a magnetic
base.
6. Place the indicator stem at the heel end of a tooth.
B Set the dial indicator so that the stem is in line with
the gear rotation and perpendicular to the tooth
angle.
Torque: 40 N·m (30 lb ft)
12. Fill the axle lubricant.
Gear Tooth Pattern Check
Checking the ring gear to pinion tooth pattern is to be
done only after setting up the axle according to the
methods in this section. The pattern check is NEVER to
be used as an initial check, or instead of checking pinion
depth and backlash adjustments.
This check is only to be verify the correct adjustment of
the gear set after set up.
425RS038
425RS087
7. Check and record the backlash at three points around
the ring gear.
B The pinion must be held stationary when checking
backlash.
B The backlash should be the same at each point
within 0.07 mm (0.003 in). If the backlash varies
more than 0.07 mm (0.003 in), check for burrs, a
distorted case flange, or uneven bolting conditions.
8. Backlash at the minimum lash point measured should
be between 0.13 and 0.20 mm (0.005 and 0.008 in)
for all new gear sets.
9. If the backlash is not within specifications, move the
ring gear in or out from the pinion by increasing the
thickness of one shims, and decreasing the thickness
of the other shim by the same amount.
This will maintain the correct rear axls side bearing
preload.
B Moving 0.05 mm (0.002 in) worth of shim from one
side of the differential to the other will change the
backlash adjustment by 0.03 mm (0.001 in).
10. After obtaining correct tooth contact described in
later, install ABS speed sensor.
Legend
(1) Heel
(2) Toe
(3) Concave Side (Coast)
(4) Convex Side (Drive)
1. Wipe all oil out of the carrier, and carefully clean each
tooth of the ring gear.
2. Use gear marking compound 1052351 or equivalent
and apply this mixture sparingly to all ring gear teeth,
using a medium-stiff brush. When properly used, the
area of pinion tooth contact will be visible when hand
load is applied.
3. Tighten the bearing cap bolts to the specified torque.
4. Expand the brake shoes until a torque of 54 to 68 N·m
(40 to 50 lb ft.) is required to turn the pinion. A test
made without loading the gears will not give a
satisfactory pattern. Turn the pinion flange with a
wrench so that the ring gear rotates one full
revolution, then reverse the rotation so that the ring
gear rotates one revolution in the opposite direction.
5. Observe the pattern on the ring gear teeth and
compare this with figure.
4A2–24
DIFFERNTIAL (REAR)
425RS039
Adjustments Affecting Tooth Contact
Two adjustments can be made which will affect tooth
contact pattern: backlash, and the position of the drive
pinion in the case. The effects of bearing preloads are not
readily apparent on head loaded tooth contact pattern
tests; however, these adjustments should be within
specifications before proceeding with backlash and drive
pinion adjustments.
The position of the drive pinion is adjusted by increasing
or decreasing the distance between the pinion head and
the centerline of the ring gear.
Decreasing the distance will move the pinion closer to the
centerline of the ring gear. Increasing the distance will
move the pinion farther away from the centerline of the
ring gear.
Backlash is adjusted by means of the side bearing
adjusting shims which move the entire case and ring gear
assembly closer to, or farther from, the drive pinion. (The
adjusting shims are also used to set side bearing
preload.)
If the thickness of the right shim is increased (along with
decreasing the left shim thickness), backlash will
increase.
The backlash will decrease if the left shim thickness is
increased (along with a decrease in right shim thickness).
DIFFERENTIAL (REAR)
4A2–25
Differential Case Assembly
Disassembled View
425RW014
Legend
(1) Thrust Washer (for Pinion Gear)
(2) Pinion Mate Gear
(3) Thrust Washer(for Side Gear)
(4) Side Gear
(5)
(6)
(7)
(8)
Differential Shaft
Lock Pin
Bolt
Differential Case
4A2–26
DIFFERNTIAL (REAR)
Disassembly
Reassembly
1. Remove lock pin using a small drift.
1. Install side gear with thrust washer.
2. Install the pinion mate gear with thrust washer by
engaging it with the side gears while turning both
pinion mate gears simultaneously in the same
direction.
425RS098
2. Remove the differential shaft by using a soft metal rod
and a hammer.
425RS048
3. Install differential shaft.
1. Be sure to install the differential shaft so that it is in
alignment with the lock pin hole in the differential
case.
425RS043
3. Remove pinion mate gear and thrust washer.
4. Remove side gear and thrust washer.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
Check the following parts.
B Ring gear, pinion gear
B Bearing
B Side gear, pinion mate gear, differential shaft
B Differential case, carrier
B Thrust washer
B Oil seal
425RS049
4. Install lock pin.
After lock pin installation, stake the case to secure the
lock pin.
DIFFERENTIAL (REAR)
4A2–27
Limited Slip Differential Assembly
Disassembled View
425RW004
Legend
(1) Thrust Washer–Differential Pinion Mate Gear
(2) Pinion Mate Gear
(3) Dished Spacer
(4) Disc
(5) Plate
(6)
(7)
(8)
(9)
(10)
(11)
Differential Plate Retainer
Lock Pin
Differential Case
Ring Gear Bolts
Differential Shaft
Differential Side Gear
Disassembly
1. Place the holder J–39824 into a vise.
Position the differential on the holder with the ring
gear side down.
2. Remove Lock pin (1) from differential shaft using a
punch.
3. Remove Differential shaft (2) using hammer and
punch.
Place shop towel behind case to prevent differential
shaft from dropping out of case.
425RW005
4A2–28
DIFFERNTIAL (REAR)
4. Assemble clutch pack unloading tool .
a. Install cap J–34174–1 to the bottom differential
side gear.
b. Install threaded screw cap J–34174–2 to top
differential side gear. Thread forcing screws
J–22342–15 into threaded screw cap until it
becomes centered into the bottom cap.
NOTE:
B You may have to adjust the forcing screw slightly to
allow the case to rotate.
7. Assemble LSD service adapter J–39834 onto long
drive handle J–8592.Insert it into differential shaft
hole of case. Pull on handle and rotate case until
pinion mate gears can be removed.
901RW153
c. Tighten forcing screw until tight enough to collapse
dished spacers and allow looseness between side
and pinion mate gears.
5. Both pinion mate gear thrust washers using a shim
stock (1) of 0.51 mm (0.020 in.) or equivalent tool to
push out washers.
901RW068
8. Remove pinion mate gears.
9. Hold side gear top clutch pack (1) with one hand and
remove positraction unloading tools.
425RW008
10. Remove top side gear and clutch pack.
425RW007
6. Relieve tension of dished spacers by loosening
forcing screw.
NOTE:
B Keep the stack of plates and discs intact and in
exactly the same position while they are being
removed.
11. Remove case from holder. Turn case with flange or
ring gear side up to allow side gear and clutch pack to
be removed from case.
DIFFERENTIAL (REAR)
12. Remove differential plate retainer from both clutch
packs to allow separation of the plates and discs.
NOTE:
B Keep the discs and plates in the same order as they
were removed.
4A2–29
Reassembly
1. Lubricate thrust face of side gears, plates and discs
with the proper limited slip rear axle lubricant.
2. Assemble plates and discs in exactly in the same
position as they were removed, regardless of whether
they are new or original.
3. Install differential plate retainer to ears of plates.
NOTE:
B Make sure both retainers are Completely seated on
ears of plates.
4. Install clutch pack and side gear into bottom side gear
bore. Make sure clutch pack stays assembled to side
gear splines, and that retainers are completely seated
into pockets of case.
NOTE:
425RW009
Legend
(1) Differential Plate
(2) Differential Disc
(3) Dished Spacer
(4) Side Gear
B To prevent clutch pack from falling out of case, hold
clutch pack in place by hand while repositioning case
on bench.
5. Install other side gear and clutch pack. Make sure
clutch pack stays assembled to side gear splines, and
retainers are completely seated into pockets of case.
6. Hold clutch pack in position and assemble screw cap
J–34174–2, cap J–34174–1 and forcing screw
J–22342–15. Tighten forcing screw into bottom cap
to hold both clutch packs in position.
7. With tools assembled to case, position case on holder
J–39824 by aligning splines of side gear with those of
shaft. Tighten forcing screw to compress clutch packs
in order to provide clearance for pinion mate gears.
Inspection and Repair
Cleaning
B All parts with solvent.
Visual Inspection
B Clean all parts with solvent.
B Plates and Discs. If any one disc or plate in either
stack shows evidence of excessive wear or scoring,
the complete stack is to be replaced on both sides.
B Side Gears and Pinion Mate Gears. The gear teeth of
these parts should be checked for extreme wear and
possible cracks. The external teeth of the side gear,
which retain the concentric groove discs, should also
be checked for wear or cracks.
B If replacement of one gear is required due to wear,
etc., then both side gears, pinion mate gears, and
thrust washers are to be replaced.
B Differential Shaft. If excessive wear is evident, the
differential shaft should be replaced.
B Differential Plate Retainers. If wear is evident on any
one of the differential plate retainers, all four retainers
must be replaced.
B Differential Case. If scoring, wear or metal pickup is
evident on the machined surfaces, replacement of
the case is necessary.
901RW069
8. Install pinion mate gears.
B Place the pinion mate gears into the differential 180
degrees apart.
4A2–30
DIFFERNTIAL (REAR)
9. While holding gears in place, insert LSD service
adapter J–39834 with long drive handle J–8592 in
differential shaft hole of case. Pull on long drive
handle J–8592 and rotate case, allowing gears to
turn. Make sure that holes in pinion mate gears align
with holes in case.
12. Position differential shaft in case and drive in with
hammer. Be sure lock pin hole of differential shaft (5)
is properly aligned to allow installation of lock pin (3).
Be sure that thrust washers and differential pinion
mate gears are aligned with the differential case (4).
Install new lock pin to proper depth using a punch.
Stake metal of case over pin in two places, 180
degrees apart.
901RW070
B It may be necessary to adjust tension on forcing
screw to rotate case.
10. Tighten forcing screw to compress the clutch packs,
to allow installation of spherical thrust washers.
11. Lubricate spherical thrust washers (2), and assemble
into case (1). Use a small screw driver to push
washers into place. Remove tools.
425RW012
425RW013
DIFFERENTIAL (REAR)
4A2–31
Main Data And Specifications
General Specifications
Rear axle
Type
Rear axle Size
Salisbury, Semi–floating
226 mm (8.9 in)
Gear type
Hypoid
Gear ratio
4.300
Differential type
Two pinion
Lubricant Grade
GL–5: (Standard differential)
GL–5, LSD: (Limited slip differential)
Locking Differential Lubricant
Capacity
80W90 GL–5
(USE Limited Slip Differential Gear Lubricant or Friction
Modifier Organic Additive)
1.77 liter (1.87 US qt)
Torque Specifications
E04RX002
4A2–32
DIFFERNTIAL (REAR)
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION
TOOL NO.
TOOL NAME
J–8614–01
Pinion flange holder
J–42836
Installer; Inner bearing
outer race
J–37263
Installer; Pinion oil seal
J–42824
Pilot;Outer
J–42379
Remover; Bearing
J–21777–43
Nut & Stud
J–39830
Adapter; Side bearing
plug
J–42827
Pilot;Inner
J–8611–01
Installer; Outer bearing
outer race
J–39837–2
Gauge plate
J–8592
Grip
J–8001
Dial indicator
DIFFERENTIAL (REAR)
ILLUSTRATION
TOOL NO.
TOOL NAME
J–39837–1
Disc (2 required)
J–23597–1
Arbor
J–42828
Installer; Pinion bearing
J–21784
Installer; Side bearing
J–39602
Remover; Outer bearing
J–24385–B
Spreader
ILLUSTRATION
4A2–33
TOOL NO.
TOOL NAME
J–39858
Clutch pack unloading
tool kit Includes
J–34174–1/J–34174–2
Screw cap and Cap
J–22342–15
Forcing screw
J–39834
Limited–slip differential
(LSD) service adapter
J–39824
Holder
J–39836
Side bearing preload
master bearings
SECTION
DRIVELINE CONTROL SYSTEM 4B1–1
AXIOM
DRIVELINE/AXLE
DRIVELINE CONTROL SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . .
Shift On The Fly System . . . . . . . . . . . . . . . . .
Outline of Shift on The Fly System . . . . . . . . .
Functions of Indicator Lamp . . . . . . . . . . . . . .
Shift On The Fly Electrical Equipment . . . . . .
Axle Shaft Connection and Disconnection . .
4B1–1
4B1–2
4B1–2
4B1–4
4B1–5
4B1–5
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.
Shift On The Fly Controller . . . . . . . . . . . . . . .
Shift On The Fly Controller and
Associated Parts . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4B1–7
4B1–7
4B1–7
4B1–7
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.
4B1–2 DRIVELINE CONTROL SYSTEM
Shift On The Fly System
Outline of Shift on The Fly System
The shift on the fly system switches between 2 wheel
drive (2WD) and 4 wheel drive (4WD) electronically by the
driver turning the TOD switch on the instrument panel.
This system will control the following operations. (Shifting
between “4H” and “4L” must be performed by TOD
switch.)
1. Transmitting the torque to the front propeller shaft.
2. Connecting front wheels to, and disconnecting them
from, the front axles by axle motor actuator.
3. Indicating on instrument panel.
4. 4WD out signal to other Electronic Brake Control
Module (EBCM).
System Diagrams
412R200008
DRIVELINE CONTROL SYSTEM 4B1–3
Normal Operation
The axle disconnect controller is driven by the signal from
TOD control unit and the axle motor actuator connects (or
disconnects when the 4WD switch is deactivated) the
front wheels to the front axles.
Time Chart of Shifting Under Normal Condition
F04R200002
4WD out signal to other Electronic Brake Control
Module : TOD Control Unit of shift on the fly sends 4WD
out signal to other Electronic Brake Control Module as
below.
4WD out signal
(Period)
Vehicle Condition
Transfer position switch
Front axle switch
120 ms
2WD
2WD (Open)
2WD (Open)
240 ms
4WD
4WD (Close)
4WD (Close)
4B1–4 DRIVELINE CONTROL SYSTEM
Functions of Indicator Lamp
TOD Switch and Indication of Drive Mode
The TOD switch sends signals to the TOD control unit
which selects drive modes and controls the shift on the fly
system (axle disconnect : ADC).
TOD
switch
t t
state
Drive mode
2H
Rear-wheel
drive (RWD)
TOD
Electronic
torque split
4WD (HIGH)
(TOD)
4L
Low range
mechanical
direct 4WD
(LOW) (4L)
Transfer shift condition
Permissible during
driving (less than
100 km/h or 62 mph)
AT: Neutral
Brake: Applied
Th car stops
The
t
(less
(l
than 2 km/h or
1.2 mph and less than
1500 rpm)
Transfer position detection
Shift on the fly
4HSW
4LSW
Axle
SW
ADC circuit
OFF
OFF
OFF
Turning on
electricity
OFF
OFF
ON
Turning off
electricity
OFF
ON
ON
Turning off
electricity
TOD indicator
state
ADC: Shift on the fly
SW: Switch
Bulb check :The bulb of indicator lamp is checked for 2
seconds when ignition key is turned on.
Bulb Check
When the starter switch is turned on, the TOD indicator
lamps comes on as shown below.
NOTE: Once the starter switch is turned on, all the TOD
indicator lamps are lit for two seconds even if the transfer
lever is in any position.
C07RW016
DRIVELINE CONTROL SYSTEM 4B1–5
Shift On The Fly Electrical Equipment
Axle Shaft Connection and Disconnection
412R200006
Axle Disconnect Controller
Actuator Assembly
412RY00004
828RY00009
4B1–6 DRIVELINE CONTROL SYSTEM
828RY00010
Legend
(1) Output Signal
(2) Output Signal
(3) 12V
(4) Input Signal
(5) GND
1. Connect 12V with terminal (3) and the ground with the
terminal (6).
2. Send the signal to the terminal (4)
2WD → 4WD less than 2.4V
4WD → 2WD more than 9.0V
3. Confirm the output signal from the terminals (1) & (2)
(2 seconds output)
INPUT
SIGNAL
OUTPUT SIGNAL
(2 seconds)
4
1
2
2WD → 4WD
Less than
2.4V
0V
12V
4WD → 2WD
More than
9.0V
12V
0V
4. If the trouble occurs afther above test, charge the
Axle Disconnect Controller to the new one.
DRIVELINE CONTROL SYSTEM 4B1–7
Shift On The Fly Controller
Shift On The Fly Controller and Associated Parts
828RY00003
Legend
(1) Nut
Removal
1. Disconnect the battery ground cable.
2. Remove the front console assembly.
Refer to Consoles in Body and Accessories section.
3. Disconnect the connector from the controller.
4. Remove the nut.
5. Remove the controller.
(2) SOF Controller
(3) Connector
Installation
To install, follow the removal steps in the reverse order,
noting the following points.
Torque: Nut (1) 8 N·m (69 Ib in)
SECTION
DRIVE LINE CONTROL SYSTEM (TOD)
4B2–1
AXIOM
DRIVELINE/AXLE
DRIVELINE CONTROL SYSTEM (TOD)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . .
General Description . . . . . . . . . . . . . . . . . . . . .
Transfer Position and Drive Mode . . . . . . . .
TOD Control . . . . . . . . . . . . . . . . . . . . . . . . . .
TOD Indicator Control . . . . . . . . . . . . . . . . . .
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . .
System Components . . . . . . . . . . . . . . . . . . . .
Parts Location . . . . . . . . . . . . . . . . . . . . . . . .
Front and Rear Speed Sensors . . . . . . . . . .
Electromagnetic Coil . . . . . . . . . . . . . . . . . . .
Multi Plate Disk Clutch Pack . . . . . . . . . . . .
Mechanical Lock Sleeve . . . . . . . . . . . . . . . .
High-Low Planetary Gear Set . . . . . . . . . . .
4H and 4L Switch . . . . . . . . . . . . . . . . . . . . . .
Transfer Connector (12-pin type) . . . . . . . .
Transfer Connector (8-pin type) . . . . . . . . .
TOD Indicator Lamps
(on the instrument panel) . . . . . . . . . . . . . .
Check Lamp . . . . . . . . . . . . . . . . . . . . . . . . . .
TOD ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High-Low Shift Motor . . . . . . . . . . . . . . . . . . .
Motor Position and Encoder Position Code
Encode Position Plate . . . . . . . . . . . . . . . . . .
Shift High Range and Low Range . . . . . . . .
4B2–1
4B2–2
4B2–2
4B2–3
4B2–3
4B2–3
4B2–4
4B2–4
4B2–5
4B2–5
4B2–5
4B2–5
4B2–6
4B2–6
4B2–6
4B2–6
4B2–7
4B2–7
4B2–8
4B2–9
4B2–10
4B2–10
4B2–10
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.
Functions of TOD Switch and Indicator
Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4B2–11
TOD Switch and Indication of Drive Mode .
4B2–11
Check Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . 4B2–13
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B2–14
General Information Diagnosis . . . . . . . . . . 4B2–14
Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 4B2–14
Precautions on Diagnosis . . . . . . . . . . . . . . . 4B2–16
Basic Diagnostic Flow Chart . . . . . . . . . . . . . . 4B2–18
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . . . 4B2–19
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 4B2–20
Connector List . . . . . . . . . . . . . . . . . . . . . . . . . . 4B2–24
Checking Failed Pin . . . . . . . . . . . . . . . . . . . . . 4B2–26
Connector Pin Assignment . . . . . . . . . . . . . . 4B2–26
Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B2–28
Checking Failed TOD Control Unit Pin . . . . . 4B2–30
Tech 2 Scan Tool . . . . . . . . . . . . . . . . . . . . . . 4B2–32
Getting Started . . . . . . . . . . . . . . . . . . . . . . . . 4B2–33
Operating Procedure . . . . . . . . . . . . . . . . . . . 4B2–33
Diagnostic Trouble Codes . . . . . . . . . . . . . . . . 4B2–35
Diagnosis from Trouble Codes . . . . . . . . . . . . 4B2–36
Trouble Diagnosis Depending on The Status
of TOD Indicator . . . . . . . . . . . . . . . . . . . . . . . . 4B2–67
Diagnosis from Symptom . . . . . . . . . . . . . . . . . 4B2–102
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
4B2–2
DRIVE LINE CONTROL SYSTEM (TOD)
General Description
412R200008
TOD (Torque on Demand) system is traction state control
system to vehicle.
Transfer Position and Drive Mode
Three drive modes can be selected through operation of
TOD switch and transfer lever.
Transfer Position
TOD SWITCH
Mode
HIGH
2H
RWD
TOD
4WD
(HIGH)
Electronically controlled torque split
four wheel drive
4L
4WD
(LOW)
Low-speed mechanical lock-up four
wheel drive
LOW
The electronic control unit (ECU) judges the signals from
the TOD switch and controls the transfer drive mode and
shift-on-the-fly system status.
Drive mode
Rear wheel drive
DRIVE LINE CONTROL SYSTEM (TOD)
TOD Control
The TOD position usually drives the rear wheels, and
transmits the torque to the front wheels with the help of
electronically controlled torque split mechanism
according to running conditions encountered. The driving
force is directly transmitted to the rear wheels. This force
is split by the transfer and delivered to the front wheels.
The magnitude of the torque transmitted to the front
wheels is controlled by changing the pressing force of the
multi plate disk clutch built in the transfer unit. The
pressing force of the clutch is controlled by changing the
duty ratio to the electromagnetic coil mounted to the rear
of the clutch. When the clutch is completely disengaged,
the rear wheels are driven. When the clutch is completely
engaged, a rigid four wheel drive mode is obtained. The
torque split status is controlled continuously between the
rear wheel and four wheel drive modes. This system
includes front and rear speed sensors, and receives
throttle position sensor and engine speed information
from the PCM, ABS control unit signal, brake switch
signal, and shift motor position information.
The control unit receives signals sent from these sensors
and changes the pressing force of the multi-plate disk
clutch to determine the torque distribution on the front and
rear wheels. Therefore, when the slip of the rear wheels is
increased against the current torque level in the normal
rear wheel drive mode, the control unit detects the slip
condition, determines the optimum torque based on the
feedback control logic, and increases the torque to the
front wheels.
The control unit uses the signal from the throttle position
sensor to predict the future vehicle condition and the
intention of the driver with respect to acceleration and
deceleration, and determines the initial torque distribution
using these data and the information from the speed
sensors.
In case of small circle turning in the parking lot, for
example, the control unit minimizes the clutch pressing
force to restrict a braking phenomenon. When the ABS
becomes active, the control unit optimizes the clutch
pressing force to ensure stable braking.
TOD Indicator Control
The TOD indicator on the instrument panel informs the
driver of the current working status of the transfer unit.
The information is the drive mode (2H, TOD, 4L,
transition). The indicator can display occasional errors
and corresponding error codes.
Abbreviations
ABS
Anti-lock Brake System
ADC
Axle Disconnect
(Shift on the fly system)
VB
Battery Voltage
VIGN
Ignition Voltage
4B2–3
4B2–4
DRIVE LINE CONTROL SYSTEM (TOD)
System Components
Parts Location
A04R200004
Legend
(1) Mechanical Lock Sleeve
(2) Drive Chain
(3) Clutch Pack
(4) Electromagnetic Clutch Solenoid
(5) Output Shaft
(6) Rear Output Coupling
(7) Rear Speed Sensor
(8) Drive Sprocket
(9) Spring
(10) Return Spring
(11) Lockup Shift Fork
(12) Front Speed Sensor
(13) High-Low Shift Motor
(14) Driven Sprocket
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
Shift Shaft
Front Output Coupling
Front Output Shaft
Shift Cam
Torsional Spring
High-Low Shift Fork
Shift Rod
Input Shaft
Reduction Hub
High-Low Planetary Gear
High Position
Low Position
Oil Pump
Free Position
Lock Position
DRIVE LINE CONTROL SYSTEM (TOD)
4B2–5
Front and Rear Speed Sensors
Multi Plate Disk Clutch Pack
The sensors are built in the transfer case, and detect the
rotation of rotors directly coupled to the propeller shafts.
Thirty rectangular pulses are output per one rotation of
the propeller shaft.
Transmits the torque determined by the clutch pressing
force to the front propeller shaft via the front drive chain.
262RW029
261RW045
Mechanical Lock Sleeve
Couples the front and rear propeller shaft mechanically
when the transfer shaft is in the 4L position.
Electromagnetic Coil
Receives the duty signals from the TOD control unit and
controls the pressing force of the clutch pressure cam.
262RW028
261RW044
4B2–6
DRIVE LINE CONTROL SYSTEM (TOD)
High-Low Planetary Gear Set
Transfer Connector (12-pin type)
Establishes an auxiliary transmission mechanism. When
the TOD switch is set to the 2H or TOD position, the
reduction gear ratio is 1.000 and the corresponding
driving force is generated. When the TOD switch is set to
the 4L position, the reduction gear ratio is 2.480 and the
corresponding driving force is generated.
Transmits the input and output signals of the speed
sensors, electromagnetic coil, and 4H and 4L switche to
the vehicle harness. A waterproof 12-pin type is used.
261RW046
Transfer Connector (8-pin type)
262RW030
4H and 4L Switch
Transmits the output signals of the shift motor position to
the vehicle harness and power for the shift motor to the
transfer. A waterproof 8-pin type is used.
Detects the shift position of the transfer from the
movement of the shift rod and outputs signals to the TOD
control unit.
261RY00039
261RW002
DRIVE LINE CONTROL SYSTEM (TOD)
TOD Indicator Lamps (on the instrument
panel)
Inform the following items.
B Bulb check
B Drive mode
B ABS IN status
B BRAKE ON status
4B2–7
Check Lamp
Inform the following items.
B Bulb check
B Fail (fail alarm)
B Trouble code
821R200016
821R200016
4B2–8
DRIVE LINE CONTROL SYSTEM (TOD)
TOD ECU
This control unit is mounted to the clutch pedal position
via a special bracket.
826R200019
Legend
(1) Brake Pedal Bracket
DRIVE LINE CONTROL SYSTEM (TOD)
4B2–9
High-Low Shift Motor
F07R200002
Legend
(1) Reduction Hub
(2) Mechanical Lock Sleeve (Including the built-in
Spring)
(3) Lockup Shift Fork
(4) Return Spring
(5) To TOD Control Unit
(6) Fixed Contact Point
(7) Encoder
(8) Worm gear
(9) Rotate
(10) Shift Motor
(11) The shift cam (12) can be turned freely around
the shift shaft (14).
When the TOD switch is changed to the 4L (or TOD)
position from the TOD (or 4L) position, the TOD control
unit drives the high–low shift motor according to the
signal. The transfer is shifted to low range from high range
(or to high range from low range) by the shift motor.
The high-low shift motor can run, only when the operation
meets the following conditions to prevent an unexpected
shift between high and low range by a operation error.
1. The car stops. (less than 2 km/h or 1.2 mph and less
than 1500 rpm.)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
Shift Cam
Torsional Spring
Shift Shaft
Shift Rod
High-Low Shift Fork
High
Low
2H and TOD Position
Direct Four Wheel Drive (4L Position)
Earth
High
Low
High
Low
2. The AT selector position is neutral.
3. The brake is applied. (brake switch is on.)
The shift motor has a built-in encoder which watches
motor rotation position. The control unit controls the
rotation of the shift motor based on the position code
detected by the encoder.
The encoder position plate turns together with the shift
shaft and switches on or off the current from the 4 (four)
fixed contact points on the case, then the control unit
recognizes the rotation position of the shift motor.
4B2–10 DRIVE LINE CONTROL SYSTEM (TOD)
Motor Position and Encoder Position Code
High-Low shift Motor Encoder Signal
High-Low Shift Motor Position
Position a
Position b
Position c
Position d
High End
A
OFF
OFF
OFF
ON
Near High End
B
OFF
ON
OFF
ON
High Position
C
ON
ON
OFF
ON
Middle Zone (1)
D
ON
ON
ON
ON
Middle Zone (2)
E
OFF
ON
ON
ON
Neutral Position
F
OFF
ON
ON
OFF
Middle Zone (3)
G
ON
ON
ON
OFF
Low Position
H
ON
OFF
ON
OFF
Low End
I
ON
OFF
ON
ON
State of
Motor
High Position
Low Position
Encode Position Plate
F04R100005
Legend
(1)
OFF Aria
(2)
ON Aria
Shift High Range and Low Range
When the car is stops (less than 2km/h or 1.2 mph and
less than 1500 rpm), the AT selector position is neutral,
the brake is applied, and the TOD switch is changed to 4L
from TOD (or to TOD from 4L), the high-low shift motor
starts by power applied from the TOD control unit and
turns the shift shaft through the worm gear.
The shift shaft turns the shift cam through the torsional
spring.
The end of the shift cam moves the lockup shift fork and
the spiral groove on the outside of the shift cam slides the
high–low shift fork.
(3)
(4)
(5)
Low
High
Earth
DRIVE LINE CONTROL SYSTEM (TOD)
4B2–11
Functions of TOD Switch and
Indicator Lamp
TOD Switch and Indication of Drive Mode
The TOD switch sends signals to the TOD control unit
which selects drive modes and controls the shift on the fly
system (axle disconnect : ADC).
TOD
switch
state
Drive mode
2H
Rear-wheel
drive (RWD)
TOD
Electronic
torque split
4WD (TOD)
4L
Low range
mechanical
direct 4WD
(4L)
Transfer
position
detection
Transfer shift condition
Permissible during
driving (less than
100 km/h or 62 mph)
AT: Neutral
Brake: Applied
The car sto
stopss
(less than 2 km/h or
1.2 mph and less than
1500 rpm)
Shift on the fly
4HSW
4LSW
Axle
SW
ADC circuit
OFF
OFF
OFF
Turning on
electricity
OFF
OFF
ON
Turning off
electricity
OFF
ON
ON
Turning off
electricity
TOD indicator
state
ADC: Shift on the fly
SW: Switch
TOD control unit terminal No.
TOD
Switch
state
TOD indicator
TOD indicator
state
TOD switch
7(Front)
8(Rear)
19(Auto)
30(2H)
43(4L)
2H
OFF
ON
OFF
ON
OFF
TOD
ON
ON
ON
OFF
OFF
4L
ON
ON
OFF
OFF
ON
4B2–12 DRIVE LINE CONTROL SYSTEM (TOD)
Indication During Transition of Shift Rod
When the TOD switch is turned, and the signals from the
AXLE switch do not comply with the signal conditions of
the 4H and 4L switch, the indicator lamp state selected on
the TOD switch and light-off mode are repeatedly output
at an interval of 1.0 second.
NOTE: After the TOD switch is turned to the specified
position and the AXLE switch generates compliant
signals, the normal output status is returned.
C07R100010
Bulb Check
When the starter switch is turned on, the TOD indicator
lamps go on as shown below.
NOTE: Once the starter switch is turned on, all the TOD
indicator lamps are lit for two seconds even if the TOD
switch is in any position.
C07RW016
DRIVE LINE CONTROL SYSTEM (TOD)
4B2–13
Simplified checking method of ABS IN and BRAKE ON signals:
In the event that any of the signal inputs listed below are
observed while the self-diagnostic code is being
displayed (the self-diagnostic connector is short-circuited
to GND), you can simply check the ABS IN and BRAKE
ON signals as shown in the figures below.
C07R200002
Check Lamp
Check Lamp Bulb Check
When the starter switch is turned on in the normal state,
the control unit turns on the CHECK lamp to check the
bulb.
C07RW019
4B2–14 DRIVE LINE CONTROL SYSTEM (TOD)
Diagnosis
General Information Diagnosis
The troubles on TOD are classified into the group that can
be identified by the lighting status of the TOD indicator
lamps and those that can be recognized as abnormal
phenomena of the vehicle by the driver.
The troubles that can be identified by the lighting status of
the TOD indicator lamps are examined by the procedures
“Diagnosis from Trouble Codes” and “Trouble Diagnosis
Depending on The Status of TOD Indicator”. The troubles
that can be recognized as abnormal phenomena of the
vehicle by the driver are examined by the procedure
“Diagnosis from symptom”.
Self-diagnosis
The control unit has a function of self-diagnosis. If a
trouble occurs in the course of system startup, the control
unit blinks the CHECK lamp and saves the trouble code.
C07RW021
NOTE: If an intermittent fault occurs, the control unit
stops blinking upon removal of the fault. The trouble code
is saved to the control unit.
DRIVE LINE CONTROL SYSTEM (TOD)
4B2–15
Indication Method of Trouble Code
B Turn on the starter switch, while the engine does not
start.
B Short-circuit terminal 8 of the self-diagnostic
connector to GND (terminal 4 or 5) to display the
trouble code on the CHECK lamp.
826R200011
B If no trouble codes exist, code “12” is displayed
continuously.
B If trouble codes exist, code “12” is displayed three
times, and the trouble codes, starting from the smaller
code number, are displayed three times respectively.
C07RY00018
4B2–16 DRIVE LINE CONTROL SYSTEM (TOD)
How to Clear The Trouble Code
The trouble codes saved to the control unit can be deleted
by the following procedure if the starter switch is being in
the OFF position.
1. Short-circuit terminal 8 of the self-diagnostic
connector to GND (terminal 4 or 5).
2. Turn on the starter switch while maintaining the state
of step1, and stop short-circuiting terminal 8 to GND
within five seconds.
826R200011
3. If the conditions shown in steps 1 and 2 are met, the
trouble codes saved to the control unit are cleared.
(After the codes are completely deleted, the code 12
that indicates the normal condition is continuously
displayed.)
Precautions on Diagnosis
Replacement of Control Unit
The control unit itself rarely fails. In most cases, the
harnesses have failed (i.e. short-circuit) to cause
secondary troubles. Other cases include that the cause
has been unknown due to intermittent occurrence of
troubles and the troubles are removed accidentally along
with replacement of control unit, resulting in misjudgment
of cause. Therefore, before replacing the control unit,
check the connector joints and whether the unspecified
current flows in the control unit due to short-circuit
between harnesses.
Trouble Intermittently Observed
Troubles intermittently observed are mostly attributable
to temporary imperfect connection of harnesses and
connectors.
When such troubles are found, check the associated
circuit according to the following procedure.
1. Check whether improper connectors are plugged in
or connector terminals are completely engaged.
2. Check whether the terminals are deformed or
damaged. If yes, remove the deformation or damage
and connect the terminals securely.
3. It is likely that wires in the harness are falsely broken.
Therefore, in examination of failed harness circuit,
shake the harness for check to such extent that the
harness will not be damaged.
Test Run of Failed TOD Vehicle
If the TOD indicator lamps experienced faulty operation
even once in the past, the failed portion can be identified
by use of the procedure “Diagnosis from Trouble Codes”
or “Trouble Diagnosis Depending on the Status of TOD
Indicator”. If the troubles that are only recognized as
abnormal phenomena of the vehicle by the driver are
observed, conduct the test run in the following procedure
to reproduce the faulty phenomena and diagnose the fault
for each phenomenon.
1. Start the engine, and check that the TOD indicator
lamps are turned on for about two seconds for initial
check; the CHECK lamp goes off; and the TOD
indicator lamps display the specified drive mode. (If
the CHECK lamp starts blinking, read the trouble
codes and identify the failed portion.)
2. While keeping the vehicle standstill, operate the TOD
switch to change the modes: 2H mode→TOD
mode→4L mode→TOD mode→2H mode. Check
that the TOD indicator lamps correctly display the
status whenever the mode is changed. If the
transition status is displayed during the shift
operation, run the vehicle a little to complete shifting.
3. Slowly start the vehicle in the TOD mode, and add the
power to accelerate to at least 40 km/h (25 mph)and
maintain the speed for about two minutes. Apply the
brake to completely stop the vehicle. Repeat this test
pattern at least three times.
4. Turn the steering to the right end (or left end) in the
TOD mode, and slowly start the vehicle and make a
circle five times. Next, conduct the same test in the 2H
mode.
5. Slowly start the vehicle in the TOD mode, and
accelerate to at least 40 km/h (25 mph). Keep the
established speed, carefully change the mode in the
sequence “TOD mode→2H mode →TOD mode”
while checking that the shift is complete in each mode
change. After the test, apply the brake to completely
stop the vehicle.
6. Slowly start the vehicle in the TOD mode, and
accelerate to at least 40 km/h (25 mph). Apply the
brake strongly so that the ABS works, and completely
stop the vehicle.
7. Slowly start the vehicle in the 4L mode, and
accelerate to at least 20 km/h (13 mph). Apply the
brake to completely stop the vehicle.
If the CHECK lamp starts blinking during the test run, read
the trouble codes and give appropriate maintenance
according to the diagnostic procedure. If the TOD
indicator lamps are lit abnormally during the run, check
the lighting condition and give appropriate maintenance
according to the diagnostic procedure. Even if the
phenomena are not observed, try to reproduce the
abnormal state reported by the customer to the possible
extent.
DRIVE LINE CONTROL SYSTEM (TOD)
Post-Repair Check
As long as the starter is not turned off, the TOD indicator
lamps continue blinking even after the failed portion is
repaired. Therefore, upon completion of repair, be sure to
turn off the starter switch once and then turn on it to
conduct the test run sequence specified in steps 1
through 7 above and check that the TOD indicator lamps
no longer show any faulty status.
4B2–17
4B2–18 DRIVE LINE CONTROL SYSTEM (TOD)
Basic Diagnostic Flow Chart
C07R100011
DRIVE LINE CONTROL SYSTEM (TOD)
4B2–19
Parts Location
D04R200019
Legend
(1) C–10
(2) C–6
(3) C–5
(4) H–13 H–14
(5) A–1
(6) A–2
(7) I–31
(8) C–41
(9) I–23
(10) I–24
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
I–25
C–39
H–10
C–37 C–38
C–26
C–29
H–3 H–5
E–35
E–34
E–41
H–7
4B2–20 DRIVE LINE CONTROL SYSTEM (TOD)
Circuit Diagram
D04R200026
DRIVE LINE CONTROL SYSTEM (TOD)
4B2–21
D04R200002
4B2–22 DRIVE LINE CONTROL SYSTEM (TOD)
D04R200020
DRIVE LINE CONTROL SYSTEM (TOD)
4B2–23
D04R200004
4B2–24 DRIVE LINE CONTROL SYSTEM (TOD)
Connector List
No.
Connector face
No.
A-1
C-41
A-2
E-23
C-6
E-34
C-10
E-41
C-26
H-5
6VD1
C-29
H-3
C-37
H-7
C-38
H-10
C-39
H-11
Connector face
DRIVE LINE CONTROL SYSTEM (TOD)
No.
H-13
I-23
I-24
I-25
I-31
Connector face
4B2–25
4B2–26 DRIVE LINE CONTROL SYSTEM (TOD)
Checking Failed Pin
Connector Pin Assignment
B TOD control unit pin assignment
D04RY00011
No.
NAME
CONTENTS
1
N.C
2
ENG REV
3
N.C
Not used
4
N.C
Not used
5
N.C
Not used
6
N.C
Not used
7
IND.A
Display Front
8
IND. C
Display Rear
9
N.C
Not used
10
N.C
Not used
11
EMC
Clutch Solenoid
12
REF
Speed Reference
13
COM (–)
14
VIG
Ignition
15
TPS
TPS (PWM)
16
TECH 2
TECH–2
17
N. C
Not used
18
N. C
Not used
19
IND. B
Display Auto
20
CHK TOD
Check TOD
21
N.C
22
PWR GND
23
ADC (+)
24
COM GND
Shift Motor Position GND
25
MTR POS3
Shift Motot Position 3
Not used
Engine Speed
Speed GND
Not used
Power Ground
Axle Disconnect Output
DRIVE LINE CONTROL SYSTEM (TOD)
No.
NAME
CONTENTS
26
MTR POS1
27
POSC
AT Position C
28
POSA
AT Position A
29
DIAG
Diagnostic Input
30
TOD SW A
31
4H SW
4H Switch Input
32
FT. SIG
Front Speed Signal
33
ABS IN
ABS In
34
VB
35
MTR H-L
Power Shift Motor H-L
36
4WD OUT
4WD Signal Output
37
BRAKE SW
Brake Switch Input
38
MTR POS4
Shift Motor Position 4
39
MTR POS2
Shift Motor Position 2
40
LIGHTING SW
Lighting Switch Input
41
POSB
42
AXLE SW
Axle Switch Input
43
TOD SWB
TOD Switch B (4L)
44
4L SW
45
RR. SIG
Rear Speed Signal
46
GND. 1
ECU Ground 1
47
GND. 2
ECU Ground 2
48
MTR L-H
Shift Motor Position 1
TOD Switch A (2H)
Power Bat
AT Position B
4L Switch Input
Power Shift Motor L-H
4B2–27
4B2–28 DRIVE LINE CONTROL SYSTEM (TOD)
Reference
B Transfer connector pin assignment (connector on the
transfer case)
for inspection of transfer pins.
810RW310
No.
NAME
CONTENTS
1
Ref. (Rer. )
Rear speed sensor reference output
2
Ref. (Frt. )
Front speed sensor reference output
3
SW GND
SW GND
4
4H SW (+)
4H SW plus terminal
5
RR. SIG
Rear Speed Sensor Signal
6
FT. SIG
Front Speed Sensor Signal
7
POWER GND
8
SOL (+)
Electromagnetic solenoid
9
COM (–) (Rer. )
Rear speed sensor GND
10
COM (–) (Frt. )
Front speed sensor GND
11
NC
12
4L SW (+)
Power GND
Not used
4L SW Plus Terminal
DRIVE LINE CONTROL SYSTEM (TOD)
8–6
No.
NAME
CONTENTS
1
MTR POS2
Shift Motor Position 2
2
MTR POS3
Shift Motor Position 3
3
MTR POS4
Shift Motor Position 4
4
MTR L-H
Power Shift Motor L-H
5
POS RETURN
6
MTR POS1
Shift Motor Position 1
7
MTR H-L
Power Shift Motor H-L
8
NC
Shift Motor Position GND
Not Used
4B2–29
4B2–30 DRIVE LINE CONTROL SYSTEM (TOD)
Checking Failed TOD Control Unit Pin
NOTE:
1. Unplug the ECU connector and the pins, unless
otherwise specified.
2. Before removing the ECU, turn off the ignition switch.
3. If the standard values are not observed, check the
pins with other testers.
Check
Pin
No.
Circuit to be
tested
Ignition
Switch
Position
Engine
State
Unit
Scale/
Range
Measure
between
Pin No.
Standard Value
Note
22
P-GND
OFF
STOP
W
22, 47
Continuity : OK
46
GNDI
OFF
STOP
W
46, 47
Continuity : OK
47
GND 2
OFF
STOP
W
47, GND
Continuity : OK
31
4H SW
OFF
STOP
W
31, 47
No continuity
(high, 4L) : OK
44
4L SW
OFF
STOP
W
44, 47
No continuity
(high) and
continuity (4L) :
OK
42
AXLE SW
ON
RUN
W
42, 47
Continuity(TOD,
4L) : OK
Remove ECU connector and start
the engine. Move the vehicle forth
and back to connect axle surely.
29
DIAG
OFF
STOP
W
29 (TOD),
8 (DLC
Connector)
Continuity : OK
DLC connector terminal 8
7
IND.A
ON
STOP
DCV
7 (+), 47
(–)
8.0 ∼14.5 V
when the indicator lamp is turned
off.
20
CHECK
TOD
ON
STOP
DCV
20 (+), 47
(–)
8.0 ∼14.5 V
When the indicator lamp is turned
off.
33
ABS IN
ON
STOP
DCV
33 (+), 47
(–)
6.0 ∼11.0 V
12
REF
ON
STOP
DCV
12 (+), 47
(–)
5 ∼9 V
Connect ECU
32
FRT.(+)
ON
STOP
DCV
32 (+), 47
(–)
0.7 ∼6 V
Connect ECU and move the
vehicle (off one tooth of speed
sensor ring) making sure of
voltage change.
45
RR.(+)
ON
STOP
DCV
45 (+), 47
(–)
0.7 ∼6 V
Connect ECU and move the
vehicle (off one tooth of speed
sensor ring) making sure of
voltage change.
13
COM(-)
ON
STOP
DCV
13 (+), 47
(–)
0V
Connect ECU
14
VIG
ON
STOP
DCV
14 (+), 47
(–)
8 ∼14.5 V
34
VB
OFF
STOP
DCV
34 (+), 47
(–)
8.0 ∼14.5 V
37
BRAKE
SW
OFF
STOP
DCV
37 (+), 47
(–)
8 ∼14.5 V
Press brake pedal
15
TPS
ON
STOP
DCV
15 (+), 47
(–)
PWM duty cycle
10%(MAX) – 90
%(MIN)
Step on the accelerator pedal and
make sure that duty cycle
changes.
DRIVE LINE CONTROL SYSTEM (TOD)
Check
Pin
No.
Circuit to be
tested
Ignition
Switch
Position
Engine
State
Unit
Scale/
Range
Measure
between
Pin No.
Standard Value
4B2–31
Note
36
4WD
OUT
OFF
STOP
W
36, 47
7 ∼12 kW
Disconnect battery GND terminal
11
EMC(+)
OFF
STOP
W
11, 22
1.0 ∼5.0 W
Disconnect battery GND terminal
30
TOD SW
A
ON
STOP
DCV
30 (+), 47
(–)
SW: TOD, 4L: 0
V
SW:2H:8.0 ∼
14.5 V
43
TOD
SWB
ON
STOP
DCV
43 (+), 47
(–)
SW: 2H,
TOD:0V
SW: 4L: 8.0 ∼
14.5V
40
LIGHT
ON
STOP
DCV
40 (+), 47
(–)
SW OFF : 0 V
SW ON : 8.0 ∼
14.5 V
19
IND B
ON
STOP
DCV
19 (+), 47
(–)
8.0 ∼14.5 V
When the indicator lamp is turned
off
8
IND C
ON
STOP
DCV
8 (+), 47
(–)
8.0 ∼ 14.5 V
When the indicator lamp is turned
off
27
AT POSC
ON
STOP
DCV
27 (+), 47
(–)
ON:D, 3, 2, 1
OFF:PRN
ON:8.0 ∼ 14.5 V
OFF:0V
41
AT POSB
ON
STOP
DCV
41 (+), 47
(–)
ON:R, N, D, 3
OFF:P, 2, 1
ON:8.0 ∼ 14.5 V
OFF:0V
28
AT POSA
ON
STOP
DCV
28 (+), 47
(–)
ON:P, R, 3, 2
OFF:N, D, 1
ON:8.0 ∼ 14.5 V
OFF:0V
2
ENG REV
ON
RUN
ms
2, 47
Waveform
(PWM)
50 ms (1000 rpm)
4B2–32 DRIVE LINE CONTROL SYSTEM (TOD)
Tech 2 Scan Tool
From 98 MY, Isuzu dealer service departments are
recommended to use Tech 2. Please refer to Tech 2 scan
tool user guide.
901RW257
Legend
(1) PCMCIA Card
(2) SAE 16/19 Adaptor
(3) DLC Cable
(4) Tech 2
DRIVE LINE CONTROL SYSTEM (TOD)
Getting Started
4B2–33
Operating Procedure
B Before operating the Isuzu PCMCIA card with the
Tech 2, the following steps must be performed:
1. The Isuzu 02 System PCMCIA card (1) inserts into
the Tech 2 (4).
2. Connect the SAE 16/19 adapter (2) to the DLC cable
(4).
3. Connect the DLC cable to the Tech 2 (4)
4. Mark sure the vehicle ignition is off.
5. Connect the Tech 2 SAE 16/19 adapter to the vehicle
DLC connector.
The power up screen is displayed when you power up the
tester with the Isuzu systems PCMCIA card. Follow the
operating procedure below.
826R200011
6. The vehicle ignition turns on.
7. Power up the Tech 2.
8. Verify the Tech 2 power up display.
060R100102
060RW009
4B2–34 DRIVE LINE CONTROL SYSTEM (TOD)
060R200079
DRIVE LINE CONTROL SYSTEM (TOD)
4B2–35
Diagnostic Trouble Codes
Code
Tech 2 code
(P code)
Item
Diagnosis
Check flow No.
12
—
Start code
Normal
—
13
P1735
Ref
Shorted GND
6
14
P1731
Front speed sensor
Input abnormality (open, sig or com)
2
15
P1736
Ref
Shorted VB
6
16
P1737
Front speed sensor
Input abnormality
4
17
P1774
Inhibitor switch
Input abnormality
8
21
P1716
TPS
Shorted or disconnected wiring,
abnormality in input
7
23
—
ECU
CPU abnormality
1
24
P1733
Rear speed sensor
Input abnormality (open, sig or com)
3
27
P1738
Rear speed sensor
Input abnormality
5
28
P1760
ADC (+) & AXLE SW
Output abnormality
10
31
P1721
EMC (+)
Shorted VB, disconnected coil/wiring or
shorted GND
9
32
P1761
ADC (+)
Shorted VB or disconnected wiring
11
33
P1762
ADC (+)
Shorted GND
12
36
—
ECU
CPU abnormality
1
37
P1712
ECU
CPU abnormality
1
38
P1714
ECU
CPU abnormality
1
41
P1741
Hight-Low shift motor
Shorted GND or disconnected wiring
13
42
P1773
Hight-Low shift motor
User operation error (not failure)
14
43
P1743
Hight-Low shift motor
Motor moving more than 5s
15
55
P1755
Hight-Low shift motor
Input abnormality of motor position signal
16
TPS : Throttle Position Sensor
EMC : Electromagnetic coil
ADC : Shift on the fly (Axle Dis Connect)
4B2–36 DRIVE LINE CONTROL SYSTEM (TOD)
Diagnosis from Trouble Codes
B Diagnose the fault that have been saved to the control
unit according to the system self-diagnostic function.
Check flow
Trouble code
Phenomenon
Standard
1
23, 36, 37, 38
The ECU has failed.
—
P1712, P1714
Step
1
Action
Turn on the starter switch.
Is the trouble reproduced?
2
No
Replace the ECU
and conduct the
test run.
Go to Step 3
Go to Step 2
Replace the ECU
and conduct the
test run.
Go to Step 3
The trouble is not
reproduced.
Refer to “Trouble
intermittently
observed”.
Go to Step 3
Verify the repair.
Return to Step 3
1. Clear the trouble codes.
2. Conduct the test run.
Is the trouble reproduced during the test run?
3
Yes
1. Check that all the parts are mounted.
2. Clear the trouble codes.
Is this step complete?
DRIVE LINE CONTROL SYSTEM (TOD)
4B2–37
Check flow
Trouble code
Phenomenon
Standard
2
14
Front speed sensor signal open or
short sspeed
GND short,
eed sensor com
open.
0.2V > sensor voltage
P1731
NOTE: The following procedure shows the case that the
front or rear sensor common grounding line is broken.
D04R200005
4B2–38 DRIVE LINE CONTROL SYSTEM (TOD)
Step
1
Action
1. Turn off the starter switch.
2. Disconnect the ECU connector (C–38) and (C–37).
Is there the continuity between (C–37) terminal 10 and 25?
3
5
6
7
Go to Step 4
Go to Step 2
Repair the circuit.
Go to Step 7
Go to Step 3
Replace the front
speed sensor.
Go to Step 7
Repair the circuit.
Go to Step 7
Go to Step 5
Refer to other
trouble check
flow.
Go to Step 6
Repair the circuit.
Go to Step 7
Replace front and
rear speed
sensor.
Go to Step 7
Repair the circuit.
Go to Step 7
Verify the repair.
Return to Step 7
1. Disconnect the transfer connector (A–1).
Is there the continuity between the connector (C–37) terminal 10
and the connector (A–1) terminal 6, the connector (C–38) terminal
12 and connector (A–1) terminal 2, and the connector (C–38)
terminal 13 and connector (A–1) terminal 10?
4
No
1. Start the engine.
2. Select TOD mode.
Is there the memory except DTC 14(P1731)?
2
Yes
Is the memory DTC 24(P1733)?
Is there the continuity between harnesses of terminal 32 and 45
(vehicle side terminal of the front and rear speed sensor)?
Is there the continuity between harnesses of terminal 12 and 13
(vehicle side terminal of the speed sensor COM(–) and ref)?
1. Check that all the parts are mounted.
2. Clear the trouble code.
Is the step complete?
DRIVE LINE CONTROL SYSTEM (TOD)
4B2–39
Check flow
Trouble code
Phenomenon
Standard
3
24
Rear speed sensor signal open or
short sspeed
GND short,
eed sensor COM
open.
0.2 V > sensor voltage
P1733
NOTE: The following procedure shows the case that the
front or rear sensor common grounding line is broken.
D04R200005
4B2–40 DRIVE LINE CONTROL SYSTEM (TOD)
Step
1
Action
5
6
7
Go to Step 2
Repair the circuit.
Go to Step 7
Go to Step 3
Replace the rear
speed sensor.
Go to Step 7
Repair the circuit.
Go to Step 7
Go to Step 5
Refer to other
trouble cheek
flow.
Go to Step 6
Repair the circuit
Go to Step 7
Replace front and
rear speed
sensor.
Go to Step 7
Repair the circuit.
Go to Step 7
Verify the repair
Return to Step 7
1. Disconnect the transfer connector (A–1).
Is there the continuity between the connector (C–37) terminal 23
and the connector (A–1) terminal 5, the connector (C–38) terminal
12 and connector (A–1) terminal 1, and the connector (C–38)
terminal 13 and connector (A–1) terminal 9?
4
Go to Step 4
1. Turn off the starter switch.
2. Disconnect the ECU connector (C–38) and (C–37).
Is there the continuity between the connector (C–37) terminal 23
and 25?
3
No
1. Start the engine.
2. Select TOD mode.
Is there the memory except DTC 24(P1733)?
2
Yes
Is the memory DTC 14(P1731)?
Is there the continuity between harnesses of terminal 32 and 45
(vehicle side terminal of the front and rear speed sensor)?
Is there the continuity between harnesses of terminal 12 and 13
(vehicle side terminal of the speed sensor COM(–) and ref)?
1. Check that all the parts are mounted.
2. Clear the trouble code.
Is the step complete?
DRIVE LINE CONTROL SYSTEM (TOD)
4B2–41
Check flow
Trouble code
Phenomenon
Standard
4
16
The front speed sensor no pulse.
Hi level : 4.5 ∼ 6.0 V
Lo level : 0.7 ∼ 2.0 V
Frequency (F) =
700-850 Hz (at 50 km/h or 31 mph)
P1737
NOTE: Find the trouble in which the pulse corresponding
to the running speed is not input.
D04R200005
4B2–42 DRIVE LINE CONTROL SYSTEM (TOD)
Step
1
Action
Yes
No
Go to Step 2
Repair and
inspection front
speed sensor
tone wheel.
Go to Step 6
Go to Step 3
The trouble is not
reproduced.
Refer to
“Troubles
intermittently
observed”.
Repair the circuit.
Go to Step 6
Go to Step 4
Replace the front
speed sensor.
Go to Step 5
Repair the circuit.
Go to Step 5
Replace ECU.
Go to Step 6
Go to Step 6
Repeat the
“Diagnosis Flow”.
Return to Step 6
1. Connect TECH 2.
While running in TOD mode, does TECH–2’s front speed sensor
indication change with vehicle speed?
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?
3
1. Turn off the starter switch.
2. Disconnect the ECU connector (C–38) and (C–37).
Is there the continuity between the connector (C–37) terminal 10
and 25?
4
1. Disconnect the transfer connector (A–1).
Is there the continuity between the connector (C–37) terminal 10
and the connector (A–1) terminal 6, the connector (C–38) terminal
12 and connector (A–1) terminal 2, and the connector (C–38)
terminal 13 and connector (A–1) terminal 10?
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?
DRIVE LINE CONTROL SYSTEM (TOD)
4B2–43
Check flow
Trouble code
Phenomenon
Standard
5
27
The rear speed sensor no pulse.
Hi level : 4.5 ∼ 6.0 V
Lo level : 0.7 ∼ 2.0 V
Frequency (F) =
700-850 Hz (at 50 km/h or 31 mph)
P1738
NOTE: Find the trouble in which the pulse corresponding
to the running speed is not input.
D04R200005
4B2–44 DRIVE LINE CONTROL SYSTEM (TOD)
Step
1
Action
Yes
No
Go to Step 2
Repair and
inspection front
speed sensor
tone wheel.
Go to Step 6
Go to Step 3
The trouble is not
reproduced.
Refer to
“Troubles
intermittently
observed”.
Repair the circuit.
Go to Step 5
Go to Step 4
Replace the rear
speed sensor.
Go to Step 5
Repair the circuit.
Go to Step 5
Replace ECU.
Go to Step 6
Go to Step 6
Repeat the
“Diagnosis Flow”.
Return to Step 6
1. Connect TECH 2.
While running in TOD mode, does TECH–2’s rear speed sensor
indication change with vehicle speed?
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?
3
1. Turn off the starter switch.
2. Disconnect the ECU connector (C–38) and (C–37).
Is there the continuity between the connector (C–37) terminal 23
and 25?
4
1. Disconnect the transfer connector (A–1).
Is there the continuity between the connector (C–37) terminal 23
and the connector (A–1) terminal 5, the connector (C–38) terminal
12 and connector (A–1) terminal 1, and the connector (C–38)
terminal 13 and connector (A–1) terminal 9?
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?
DRIVE LINE CONTROL SYSTEM (TOD)
Check flow
Trouble code
Phenomenon
Standard
6
13 (P1735)
The reference is short-circuited to
GND.
Reference ] 5 V
15 (P1736)
The reference is short-circuited to
VB.
4B2–45
If the reference wire (12) is short-circuited to GND, the
speed signal is not generated. If the wire is short-circuited
to the battery voltage, the signal level becomes faulty.
D04R200005
4B2–46 DRIVE LINE CONTROL SYSTEM (TOD)
Step
1
Action
Yes
No
Does the voltage between terminals 12 and 47 meet the standard
5V?
Refer to “Trouble
intermittently
observed”.
Go to Step 2
Go to Step 3
Go to Step 7
Go to Step 4
The ECU is
failed. Replace
the ECU.
Go to Step 8
Go to Step 5
Short to GND
between
(C–38)12 and
(H–7)2.
Repair the circuit.
Go to Step 8
Replace the rear
speed sensor.
Go to Step 8
The reference
harness for the
rear speed
sensor is
short–circuited to
GND. Repair the
circuit.
Go to Step 6
Replace the front
speed sensor.
Go to Step 8
The reference
harness for the
rear speed
sensor is
short–circuited to
GND. Repair the
circuit.
Go to Step 8
Repair the circuit.
Go to Step 8
The ECU has
failed. Replace
the ECU.
Go to Step 8
Repeat the
“Diagnosis Flow”
Go to Step 8
1. Start the engine.
2
Is the voltage below the standard?
3
1. Turn off the starter switch.
2. Disconnect the ECU connector.
Is the continuity established between vehicle harness terminals
(C–38)12 and (C–37)25?
4
1. Disconnect the H-7 connector.
Is the continuity established between floor harness connector
terminals (H-7)2 and (H-7)15?
5
1. Disconnect the A-1 connector.
Is the continuity established between transfer harness connector
male terminals (A–1)1 and (A–1)7?
6
1. Disconnect the A-1 connector.
Is the continuity established between transfer harness connector
terminals (A–1)2 and (A–1)7?
7
1. Turn off the starter switch.
2. Disconnect the ECU connector.
3. Turn on the starter switch.
Is the battery voltage observed between harness connector
terminals (C–38)12 and (C–37)25?
8
1. Check that all the parts are mounted.
2. Clear the trouble code.
Is this step complete?
DRIVE LINE CONTROL SYSTEM (TOD)
Check flow
Trouble code
Phenomenon
Standard
7
21 (P1716)
The voltage of the throttle position
sensor (TPS) is faulty.
See below table.
4B2–47
NOTE: The signal voltage from the TPS deviates from
the standard range.
D04R200025
4B2–48 DRIVE LINE CONTROL SYSTEM (TOD)
D04RY00012
DRIVE LINE CONTROL SYSTEM (TOD)
Step
1
Action
Yes
No
Go to Step 2
Charge or
replace the
battery.
Go to Step 7
Go to Step 3
Go to Step 4
Go to Step 4
Refer to “Trouble
intermittently
observed”.
The ECU has
failed. Replace
the ECU.
Go to Step 7
Go to Step 5
Go to Step 6
Repair the
harness.
Go to Step 7
Go to Step 7
Replace the TPS.
Go to Step 7
Repeat the
“Diagnosis Flow”.
Go to Step 7
1. Turn off the starter switch.
Is the battery voltage normal?
2
1. Turn on the starter switch.
Does the voltage between terminals 15 and 47 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 (C–38)15 and (C–37)25 fall
within the standard range above?
5
6
7
4B2–49
Is the harness healthy?
Is the TPS healthy?
1. Check that all the parts are mounted.
2. Clear the trouble code.
Is this step complete?
4B2–50 DRIVE LINE CONTROL SYSTEM (TOD)
Check flow
Trouble code
Phenomenon
Standard
8
17 (P1774)
The input from the mode switch is
abnormal.
—
D04R200025
DRIVE LINE CONTROL SYSTEM (TOD)
Step
Action
1
Is the TOD control unit the regular part? (Verity the part number.)
2
3
4
5
Yes
No
Go to Step 2
Replace with the
regular part.
Go to Step 2
Does the voltage between the terminal 28 and 47 accord with the
table 1 corresponding to the AT selector positions?
Go to Step 3
Go to Step 5
Does the voltage between the terminal 41 and 47 accord with the
table 1 corresponding to the AT selector positions?
Go to Step 4
Go to Step 6
Refer to “Trouble
intermittently
observed”.
Go to Step 7
Repair the circuit
between the
connector
terminal (C–37) 6
and (E–41) 8.
Go to step 8
Replace the
inhibitor switch.
Go to Step 8
Repair the circuit
between the
connector
terminal (C–37)
19 and (E–41) 7.
Go to Step 8
Replace the
inhibitor switch.
Go to Step 8
Repair the circuit
between the
connector
terminal (C–37) 5
and (E–41) 6.
Go to Step 8
Replace the
inhibitor switch.
Go to Step 8
Verify the repair.
Go to Step 8
1. Turn on the starter switch.
Does the voltage between the terminal 27 and 47 accord with the
table 1 corresponding to the AT selector positions?
1. Disconnect the AT mode connector (E–41).
Does the continuity between the inhibitor switch terminal 5 (D)
and 8 (A) accord with the table 2 corresponding to the AT selector
positions?
6
1. Disconnect the AT mode connector (E–41).
Does the continuity between the inhibitor switch terminal 5 (D)
and 7 (B) accord with the table 2 corresponding to the AT selector
positions?
7
1. Disconnect the AT mode connector (E–41).
Does the continuity between the inhibitor switch terminal 5 (D)
and 6 (C) accord with the table 2 corresponding to the AT selector
positions?
8
4B2–51
1. Check that all the parts are mounted.
2. Clear the trouble code.
Is this step complete?
4B2–52 DRIVE LINE CONTROL SYSTEM (TOD)
Table 1
Unit: V
AT selector position
Voltage between
terminal 28 and 47
Voltage between
terminal 41 and 47
Voltage between
terminal 27 and 47
P
12
0
0
R
12
12
0
N
0
12
0
D
0
12
12
3
12
12
12
2
12
0
12
1
0
0
12
Table 2
Continuity between terminals of inhibitor switch connector (E–41)
AT selector position
Continuity between
terminal 8(A) and 5(D)
Continuity between
terminal 7(B) and 5(D)
Continuity between
terminal 6(C) and 5(D)
P
YES
NO
NO
R
YES
YES
NO
N
NO
YES
NO
D
NO
YES
YES
3
YES
YES
YES
2
YES
NO
YES
1
NO
NO
YES
DRIVE LINE CONTROL SYSTEM (TOD)
Check flow
Trouble code
Phenomenon
Standard
9
31 (P1721)
The electromagnetic coil is broken
or shorted to the battery or GND.
—
4B2–53
D04R200005
4B2–54 DRIVE LINE CONTROL SYSTEM (TOD)
Step
1
Action
5
Is the battery voltage always observed between terminals 11 and
22?
1. Turn off the starter switch.
2. Disconnect the ECU connector from ECU.
Is the resistance between the connector (C–38) terminal 11 and
22 1.0 ∼ 5.0W?
7
8
Go to Step 5
Go to Step 4
Go to Step 6
The harness is
short–circuited on
the battery.
Repair the circuit.
Go to Step 8
Go to Step 6
The harness is
broken. Repair
the circuit.
Go to Step 8
Replace the
transfer
electromagnetic
coil (solenoid
clutch).
Go to Step 8
The ECU has
failed. Replace
the ECU
Go to Step 8
Go to Step 7
The harness is
disconnection or
short to GND.
Repair the circuit.
Go to Step 8
Replace the
transfer
electromagnetic
coil (solenoid
clutch).
Go to Step 8
Repeat the
“Diagnosis Flow”.
Return to Step 8
1. Disconnect the A–1 connector.
Is the continuity established between transfer connector
terminals (A–1)8 and (A–1)7?
6
Go to Step 3
1. Connect the ECU connector.
2. Start the engine.
3. Set the TOD mode.
Does the voltage between terminals 11 and 22 indicate at least
0.4V?
4
Go to Step 2
Refer to “Trouble
intermittently
observed”.
1. Turn off the starter switch.
2. Disconnect the ECU connector from ECU.
Is the continuity established between terminals (C–38)11 and
(C–38)22?
3
No
1. Clear the trouble code.
2. Start the engine
3. Set the TOD mode.
Is there DTC31 (P1721)?
2
Yes
Is the resistance between the transfer connector (A–1) terminal 8
and 7 1.0 ∼ 5.0W?
1. Check that all the parts are mounted.
2. Clear the trouble code.
Is this step complete?
DRIVE LINE CONTROL SYSTEM (TOD)
Check flow
Trouble code
Phenomenon
Standard
10
28 (P1760)
The shift on the fly system (front
axle disconnect) works incorrectly.
—
4B2–55
NOTE: The shift on the fly system is not changed
between 2WD and 4WD modes normally.
CAUTION: If code 32 or 33 is also observed, remove
the trouble associated with code 32 or 33 first.
D04R200023
4B2–56 DRIVE LINE CONTROL SYSTEM (TOD)
Step
Yes
No
Is the battery voltage observed between terminals 23 and 47?
Go to Step 2
Go to Step 5
2
Is 5V observed between terminals 42 and 47?
Go to Step 3
Go to Step 6
3
1. Set the transfer to the TOD mode.
Go to Step 4
The ECU has
failed. Replace
the ECU.
Go to Step 7
The phenomenon
is not
reproduced.
Refer to
“Troubles
intermittently
observed”.
The shift on the
fly system is
failed (refer to
Section 4B1 and
4C).
Go to Step 7
The ECU has
failed. Replace
the ECU.
Go to Step 7
See “Trouble
Diagnosis
Depending on
The Status of
TOD Indicator”.
The shift on the
fly system has
failed (refer to
Section 4B1 and
4C).
Go to Step 7
The ECU has
failed. Replace
the ECU.
Go to Step 7
Verify the repair.
Return to Step 7
1
Action
1. Turn on the starter switch.
2. Set the transfer to the 2H mode.
Does the voltage between terminals 23 and 47 indicate 0∼1V?
4
Does the voltage between terminals 42 and 47 indicate 0V?
5
Does the TOD indicator show the 2H mode?
6
Set the transfer to the TOD mode.
Does the voltage between terminals 23 and 47 indicate 0∼1V?
7
1. Check that all the parts are mounted.
2. Clear the trouble code.
Is this step complete?
DRIVE LINE CONTROL SYSTEM (TOD)
Check flow
Trouble code
Phenomenon
Standard
11
32 (P1761)
The on/off signal (ADC) line of the
shift on the fly system (front axle
disconnect) is broken, or the line is
short-circuited to the battery.
—
4B2–57
NOTE: The on/off signal line of the shift on the fly system
is broken, or the line is short–circuited to the battery.
D04R200023
4B2–58 DRIVE LINE CONTROL SYSTEM (TOD)
Step
1
Action
1. Disconnect the battery ground cable.
Is there the continuity between the connector terminal (C–37) 1
and (C–38) 14?
3
1. Disconnect the battery ground cable.
Is there the continuity between the connector terminal (C–37) 1
and (C–37) 12?
4
5
Is the resistance between the connector terminal (C–37) 1 and
(C–37) 25 less than 1W?
1.
2.
3.
4.
Turn off the starter switch.
Connect ECU connector.
Turn on the starter switch.
Set the transfer to the 2H mode.
Is the battery voltage observed between the connector (C–37)
terminals 1 and 25?
6
No
Go to Step 2
The harness is
broken. Repair
the circuit.
Go to Step 6
The harness is
short-circuited to
VIGN. Repair the
circuit.
Go to Step 6
Go to Step 3
The harness is
short-circuited to
VB. Repair the
circuit.
Go to Step 6
Go to Step 4
The harness is
short-circuited to
GND. Repair the
circuit.
Go to Step 6
Go to Step 5
The phenomenon
is not
reproduced.
Refer to “Trouble
intermittently
observed”,
or refer to “Sec
4B1 Shift on the
Fly”.
The ECU has
failed. Replace
the ECU.
Go to Step 6
Verify the repair.
Return to Step 6
1. Turn off the starter switch.
2. Disconnect the ECU connector from ECU.
3. Disconnect ADC control unit connector (C–41).
Is the continuity established between terminals (C–37) 1 and
(C–41) 4? After checking, connect the ADC control unit
connector.
2
Yes
1. Check that all the parts are mounted.
2. Clear the trouble code.
Is this step complete?
DRIVE LINE CONTROL SYSTEM (TOD)
Check flow
Trouble code
Phenomenon
Standard
12
33 (P1762)
The ADC line is short-circuited to
GND.
—
4B2–59
NOTE:
B The on/off signal line of the shift on the fly system is
short–circuited to GND.
B The system enters into the fail-safe mode because of
fusing or system protection.
(If a short–circuit is observed on GND, the output to
the on/off signal line becomes 0V.)
D04R200023
4B2–60 DRIVE LINE CONTROL SYSTEM (TOD)
Step
1
Action
3
Is the resistance between terminals (C–37) 1 and (C–37) 25 less
than 1W?
1. Connect the ECU connector.
2. Turn on the starter switch.
3. Set the transfer to the 2H mode.
Is the battery voltage observed between the connector (C–37)
terminal 1 and 25?
4
No
Go to Step 2
The harness is
broken. Repair
the circuit.
Go to Step 4
The signal line
circuit of the shift
on the fly system
is short-circuited
to GND. Repair
the circuit.
Go to Step 4
Go to Step 3
The phenomenon
is not
reproduced.
Refer to “Trouble
intermittently
observe”,
or refer to “Sec
4B1 Shift on the
Fly”.
The ECU has
failed.Replace
the ECU.
Go to Step 4.
Verify the repair.
Return to Step 4
1. Turn off the starter switch.
2. Disconnect the ECU connector from ECU.
3. Disconnect the ADC control unit connector (C–41).
Is there the continuity between the connector terminal (C–37) 1
and (C–41) 4? After checking, connect the ADC control unit
connector.
2
Yes
1. Check that all the parts are mounted.
2. Clear the trouble code.
Is this step complete?
DRIVE LINE CONTROL SYSTEM (TOD)
Check flow
Trouble code
Phenomenon
Standard
13
41 (P1741)
The High-Low motor circuit is
broken.
The circuit is short–circuited to
GND.
—
43 (P1743)
The High-Low motor has moved
consecutive more than 5 sec.
—
4B2–61
D04R200007
4B2–62 DRIVE LINE CONTROL SYSTEM (TOD)
Step
1
2
3
Action
Yes
No
When the motor is not moving, is the voltage between the
terminals 35 and 47 8.0 ∼ 14.5V?
Go to Step 2
Go to Step 3
When the motor is not moving, is the voltage between the terminal
48 and 47 8.0 ∼ 14.5V?
Go to Step 5
Go to Step 3
Go to Step 4
Repair the circuit.
Go to Step 11
Go to Step 5
Repair the circuit
Go to Step 11
Go to Step 6
Go to Step 7
The phenomenon
is not
reproduced.
Refer to “Trouble
intermittently
observed”.
Go to Step 8
Go to Step 9
Replace the
ECU.
Go to Step 11
Go to Step 9
Replace the
ECU.
Go to Step 11
Go to Step 10
Replace the
high-low motor
asm.
Go to Step 11
Repair the
transfer asm.
Go to Step 11
Replace the
high–low motor
asm.
Go to Step 11
Verify the repair
Return to Step 11
1. Turn on the starter switch.
1. Turn off the starter switch.
2. Disconnect the ECU connector (C–37) and transfer connector
(A–2).
Is there the continuity between the connector terminal (C–37) 13
and (A–2) 7?
4
5
Is there the continuity between the connector terminal (C–37) 26
and (A–2) 4?
1. Connect the ECU connector (C–37) and transfer connector
(A–2).
2. Turn on the starter switch
Is the transfer shifted to the low range from the high range?
6
7
1. Is the transfer shifted to the high range from the low range.
1. After the starter switch is turned off, turn on the starter switch.
2. Right after the TOD switch is changed to the 4L position from
the TOD position, measure the voltage for 5 seconds.
Is the voltage between terminal 48 and 47 0V while the motor is
moving and 8.0 ∼ 14.5V after the motor moving stops?
8
1. After the starter switch is turned off, turn on the starter switch.
2. Right after the TOD switch is changed to the TOD position
from 4L position, measure the voltage for 5 seconds.
Is the voltage between terminals 35 and 47 0V while motor is
moving and 8.0 ∼14.5V after the motor moving stops?
9
1. Remove the motor asm with the connector (A–2) from the
transfer.
2. Connect the ECU connector (C–37).
3. Turn on the starter switch.
When the TOD switch is changed to the 4L position from the TOD
position, does the shaft in the motor asm rotate to the Low
direction?
10
11
When the TOD switch is changed to the TOD position from the 4L
position, does the shaft in the motor asm rotate to the High
direction?
1. Check that all the parts are mounted.
2. Clear the trouble code.
Is this step complete?
NOTE:
B Confirm the operation conditions when changing high
and low range.
– The car stops. (less than 2 km/h or 1.2 mph and
engine speed less than 1500 rpm)
– The AT selector position is neutral.
– The brake is applied (brake switch: ON)
B Verify the completion of changing the high/low range
by the TOD indicator on the instrument panel.
DRIVE LINE CONTROL SYSTEM (TOD)
Check flow
Trouble code
Phenomenon
Standard
14
42 (P1773)
Error operation was carried out
under high–low motor running.
—
Step
1
2
3
4
5
Action
Yes
No
Is the transfer changed to the low range from the high range?
Go to Step 2
Go to Step 3
Is the transfer changed to the high range from the low range?
The phenomenon
is not
reproduced.
Refer to “Trouble
intermittently
observed”.
Go to Step 3
Go to Step 4
See “Diagnosis
from Symptom”.
Go to Step 5
Remove the
trouble
associated with
codes except
DTC 42 first.
Confirm the DTC
again.
Go to Step 5
The transfer is
changed in both
ranges by the
correct operation.
Operate the
transfer
according to
“Owner’s
Manual”.
Go to Step 6
Go to Step 7
See “Diagnosis
from Symptom”.
Replace the
ECU.
Go to Step 8
Remove the
trouble
associated with
codes except
DTC 42 first.
Confirm the DTC
again.
Go to Step 5
Verify the repair.
Go to Step 8
1. Clear the trouble code.
Is the trouble code memoried?
Is the memory DTC42 (P1773)?
1. Clear the trouble code.
2. Confirm the condition and operation of the transfer range
changing and check the state of the TOD indicator. Change
the transfer to the low from the high and vice versa.
Is the transfer changed to the low from the high and to the high
from the low?
6
7
8
4B2–63
Is the trouble code memoried?
Is the memory DTC 42 (P1773)?
1. Check that all the parts are mounted.
2. Clear the trouble code.
Is this step complete?
NOTE:
B Confirm the operation conditions when changing
high/low range.
– The car stops. (less than 2 km/h or 1.2 mph and
engine speed: less than 1500 rpm)
– The AT selector position is neutral.
– The brake is applied (brake switch: ON)
B Verify the completion of changing the high/low range
by the TOD indicator on the instrument panel.
B This code does not indicate the trouble of the transfer
or ECU, and is memoried when an error operation is
carried out under high-low motor running.
Therefore this code is not memoried if the transfer is
operated according to “Owner’s Manual”.
4B2–64 DRIVE LINE CONTROL SYSTEM (TOD)
Check flow
Trouble code
Phenomenon
Standard
15
55 (P1755)
High-Low motor position signal is
abnormal.
Circuit is shorted to GND.
—
D04R200007
DRIVE LINE CONTROL SYSTEM (TOD)
Step
Yes
No
Is the transfer changed to the low range from the high range?
Go to Step 2
Go to Step 4
2
Is the transfer changed to the high range from the low range?
Go to Step 3
Go to Step 5
3
1. Clear the trouble code.
2. Turn on the starter switch.
Go to Step 1
The phenomenon
is not
reproduced.
Refer to “Trouble
intermittently
observed”.
Go to Step 8
Go to Step 6
Go to Step 8
Go to Step 7
Go to Step 8
The encoder has
failed. Replace
the high-low
motor asm.
Go to Step 9
Go to Step 8
The encoder has
failed. Replace
the high-low
motor asm.
Go to Step 9
The encoder has
failed. Replace
the high-low
motor asm.
Go to Step 9
The circuit in
which there is no
continuity is
broken. Repair
the circuit.
Go to Step 9
Verify the repair.
Go to Step 9
1
Action
4B2–65
1. Turn on the starter switch.
Is the memory DTC 55 (P1755)?
4
1. Turn off the starter switch.
2. Disconnect the ECU connector (C–37).
Is the continuity between the terminals ranged within the any case
(case1, 2 or 3) in the following table (1)?
5
1. Turn off the starter switch.
2. Disconnect the ECU connector (C–37).
Does the continuity between the terminals comply with the
following table (2)?
6
1. Turn off the starter switch.
2. Disconnect the transfer connector (A–2).
Is the continuity between the male terminals ranged within the any
case (case1, 2 or 3) in the following table (3)?
7
1. Turn off the starter switch.
2. Disconnect the transfer connector (A-2).
Does the continuity between male terminals comply with the
following table (4)?
8
1. Turn off the starter switch.
2. Disconnect the ECU connector (C–37) and transfer connector
(A–2).
Is there the continuity between connector terminal (C–37) 4 and
(A–2) 6, (C–37) 17 and (A–2) 1, (C–37) 3 and (A–2) 2, (C–37) 16
and (A–2) 3, and (C–37) 2 and (A–2) 5?
9
1. Check that all the parts are mounted.
2. Clear the trouble code.
Is this step complete?
NOTE:
B Confirm the operation conditions when changing high
and low range.
– The car stops. (less than 2 km/h or 1.2 mph and
engine speed: less than 1500 rpm)
– The AT selector position is neutral.
– The brake is applied (brake switch: ON)
B Verify the completion of changing the high/low range
by the TOD indicator on the instrument panel.
B When changing high/low range, start the engine to
prevent the battery dead.
4B2–66 DRIVE LINE CONTROL SYSTEM (TOD)
Table (1) (high position standard)
Continuity between terminals:
Case
26 and
24
39 and
24
25 and
24
38 and
24
1
NO
NO
NO
YES
2
NO
YES
NO
YES
3
YES
YES
NO
YES
Table (2) (low position standard)
Continuity between terminals:
26 and 24
39 and 24
25 and 24
38 and 24
YES
NO
YES
YES or NO
Table (3) (high position standard)
Continuity between the connector (A–2)
terminals:
Case
6 and 5
1 and 5
2 and 5
3 and 5
1
NO
NO
NO
YES
2
NO
YES
NO
YES
3
YES
YES
NO
YES
Table (4) (low position standard)
Continuity between the connector (A–2) terminals:
6 and 5
1 and 5
2 and 5
3 and 5
YES
NO
YES
YES or NO
DRIVE LINE CONTROL SYSTEM (TOD)
Trouble Diagnosis Depending on The
Status of TOD Indicator
Functional check with TOD indicator light is conducted
prior to check on Charts A–H.
B After the starter is switched on, check and see if the
status has become as tabulated below.
C04R200003
B If the status is as tabulated above, there is no
problem. If not as tabulated above, inspect the
harness.
4B2–67
4B2–68 DRIVE LINE CONTROL SYSTEM (TOD)
Chart A
Indicator drive circuit
Function of circuit
The circuit informs the indicator of the working condition of the ECU.
Fail condition
All the TOD indicator lamps and CHECK lamp are lit.
Indicator lamp state
TOD switch position
—
2H/TOD/4L
—
D04R200023
DRIVE LINE CONTROL SYSTEM (TOD)
Step
1
Action
Turn on the starter switch.
Is the battery voltage observed between terminals 14 and 47?
2
Check that all the parts are mounted.
Is this step complete?
4B2–69
Yes
No
The ECU has
failed. Replace
the ECU.
Go to Step 2
Check the battery
circuit.
Go to Step 2
Repeat the
“Diagnosis Flow”.
Return to Step 2
4B2–70 DRIVE LINE CONTROL SYSTEM (TOD)
Chart B–1
The TOD switch A circuit wires are broken or short-circuited to the GND
Function of circuit
—
Fail condition
Even after the TOD switch position is selected from TOD to 2H, the indicator lamp status
is not changed.
Indicator lamp state
TOD switch position
—
2H
—
DRIVE LINE CONTROL SYSTEM (TOD)
4B2–71
D04R200022
4B2–72 DRIVE LINE CONTROL SYSTEM (TOD)
Step
1
Action
Yes
No
Go to Step 2
Repair the TOD
switch circuit.
Go to Step 4
Go to Step 3
Repair the TOD
switch circuit.
Go to Step 4
The phenomenon
is not
reproduced.
Refer to “Trouble
intermittently
observed”.
Repair the TOD
switch circuit.
Go to Step 4
Verify the repair.
Return to Step 4
1. Turn on the starter switch.
When the TOD switch is selected to the TOD position, is 0V
observed between terminal 30 and 47, and 43 and 47? Does the
voltage between the terminals 7 and 47, 19 and 47, and 8 and 47
comply with the TOD mode in the following table?
2
When the TOD switch is selected to the 2H position, is 12 V
observed between terminals 30 and 47 and is 0V observed
between terminal 43 and 47? Does the voltage between the
terminals 7 and 47, 19 and 47, and 8 and 47 comply with the 2H
mode is the following table?
3
When the TOD switch is selected to the 4L position, is 0V
observed between terminals 30 and 47 and is 12V observed
between terminal 43 and 47? Does the voltage between terminals
7 and 47, 19 and 47, and 8 and 47 comply with the 4L mode in the
following table?
4
Check that all the parts are mounted.
Is this step complete?
Table: Indicator Voltage
Unit: V
TOD
switch
mode
Terminals measured
Front 7
and 47
AUTO 19
and 47
Rear 8 and
47
2H
8.0 ∼ 14.5
8.0 ∼ 14.5
0
TOD
0
0
0
4L
0
8.5 ∼ 14.5
0
DRIVE LINE CONTROL SYSTEM (TOD)
4B2–73
Chart B–2
The TOD switch A circuit is shorted to battery.
Function of circuit
—
Fail condition
Even after the transfer mode is selected from 2H to TOD, the indicator lamp state does
not change.
Indicator lamp state
TOD switch position
TOD
4B2–74 DRIVE LINE CONTROL SYSTEM (TOD)
D04R200022
DRIVE LINE CONTROL SYSTEM (TOD)
Step
1
Action
Yes
No
Go to Step 2
Replace TOD
indicator lamp
bulb.
Go to Step 6
Go to Step 3
Replace TOD
indicator lamp
bulb.
Go to Step 6
Go to Step 4
Repair the TOD
switch circuit.
Go to Step 6
Go to Step 5
Repair the TOD
switch circuit.
Go to Step 6
The phenomenon
is not
reproduced.
Refer to “Trouble
intermittently
observed”.
Repair the TOD
switch circuit.
Go to Step 6
Verify repair.
Go to Step 6
1. Turn off the starter switch.
2. Disconnect the ECU connector (C–38).
Is the continuity established between the connector terminals
(C–38) 14 and (C–38) 7?
2
Is the continuity established between the connector terminals
(C–38) 14 and (C–38) 19?
3
4B2–75
1. Turn off the starter switch and connect the ECU connector.
2. Turn on the starter switch.
When the TOD switch is selected to the TOD position, is 0V
observed between terminals 30 and 47, and 43 and 47? Does the
voltage between the terminals 7 and 47, 19 and 47, and 8 and 47
comply with the TOD mode in the following table?
4
When the TOD switch is selected to the 2H position, is 12V
observed between terminals 30 and 47, and 0V observed
between terminals 43 and 47? Does the voltage between the
terminals 7 and 47, 19 and 47, and 8 and 47 comply with the 2H
mode in the following table?
5
When the TOD switch is selected to the 4L position, is 0V
observed between the terminal 30 and 47 and 12V observed
between the terminal 43 and 47? Does the voltage between the
terminals 7 and 47, 19 and 47, and 8 and 47 comply with the 4L
mode in the following table?
6
1. Check that all the parts are mounted.
Is this step complete?
Table: Indicator terminal voltage
Unit: V
TOD
switch
mode
Terminals measured
Front 7
and 47
AUTO 19
and 47
Rear 8 and
47
2H
8.0 ∼ 14.5
8.0 ∼ 14.5
0
TOD
0
0
0
4L
0
8.0 ∼ 14.5
0
4B2–76 DRIVE LINE CONTROL SYSTEM (TOD)
Chart B–3
The TOD switch B circuit is shorted to GND or broken.
Function of circuit
—
Fail condition
Even after the transfer mode is selected from TOD to 4L, the indicator lamp state does
not change.
Indicator lamp state
TOD switch position
4L
DRIVE LINE CONTROL SYSTEM (TOD)
4B2–77
D04R200022
4B2–78 DRIVE LINE CONTROL SYSTEM (TOD)
Step
1
Action
Yes
No
Go to Step 2
Repair the TOD
switch circuit.
Go to Step 4
Go to Step 3
Repair the TOD
switch circuit.
Go to Step 4
The phenomenon
is not
reproduced.
Refer to “Trouble
intermittentry
observed”.
Repair the TOD
switch circuit.
Go to Step 4
Verify repair.
Go to Step 4
1. Turn on the starter switch.
When the TOD switch is selected to the TOD position, is 0V
observed between terminals 30 and 47, and 43 and 47? Does the
voltage between the terminals 7 and 47, 19 and 47, and 8 and 47
comply with the TOD mode in the following table?
2
When the TOD switch is selected to the 2H position, is 12V
observed between terminals 30 and 47, and 0V observed
between terminals 43 and 47? Does the voltage between the
terminals 7 and 47, 19 and 47, and 8 and 47 comply with the 2H
mode in the following table?
3
When the TOD switch is selected to the 4L position, is 0V
observed between the terminal 30 and 47 and 12V observed
between the terminal 43 and 47? Does the voltage between the
terminals 7 and 47, 19 and 47, and 8 and 47 comply with the 4L
mode in the following table?
4
1. Check that all the parts are mounted.
Is this step complete?
Table: Indicator terminal voltage
Unit: V
TOD
switch
mode
Terminals measured
Front 7
and 47
AUTO 19
and 47
Rear 8 and
47
2H
8.0 ∼ 14.5
8.0 ∼ 14.5
0
TOD
0
0
0
4L
0
8.0 ∼ 14.5
0
DRIVE LINE CONTROL SYSTEM (TOD)
4B2–79
Chart B–4
The TOD switch B circuit is shorted to battery.
Function of circuit
—
Fail condition
Even after the transfer mode is selected from 4L to TOD, the indicator lamp state does
not change.
Indicator lamp state
TOD switch position
TOD
4B2–80 DRIVE LINE CONTROL SYSTEM (TOD)
D04R200022
DRIVE LINE CONTROL SYSTEM (TOD)
Step
1
Action
Yes
No
Go to Step 2
Replace TOD
indicator lamp
bulb.
Go to Step 5
Go to Step 3
Repair the TOD
switch circuit.
Go to Step 5
Go to Step 4
Repair the TOD
switch circuit.
Go to Step 5
The phenomenon
is not
reproduced.
Refer to “Trouble
intermittently
observed”.
Repair the TOD
switch circuit.
Go to Step 5
Verify repair.
Go to Step 5
1. Turn off the starter switch.
2. Disconnect the ECU connector (C–38).
Is the continuity established between the connector terminals
(C–38) 14 and (C–38) 19?
2
4B2–81
1. Turn off the starter switch and connect the ECU connector.
2. Turn on the starter switch.
When the TOD switch is selected to the TOD position, is 0V
observed between terminals 30 and 47, and 43 and 47? Does the
voltage between the terminals 7 and 47, 19 and 47, and 8 and 47
comply with the TOD mode in the following table?
3
When the TOD switch is selected to the 2H position, is 12V
observed between terminals 30 and 47, and 0V observed
between terminals 43 and 47? Does the voltage between the
terminals 7 and 47, 19 and 47, and 8 and 47 comply with the 2H
mode in the following table?
4
When the TOD switch is selected to the 4L position, is 0V
observed between the terminal 30 and 47 and 12V observed
between the terminal 43 and 47? Does the voltage between the
terminals 7 and 47, 19 and 47, and 8 and 47 comply with the 4L
mode in the following table?
5
1. Check that all the parts are mounted.
Is this step complete?
Table: Indicator terminal voltage
Unit: V
TOD
switch
mode
Terminals measured
Front 7
and 47
AUTO 19
and 47
Rear 8 and
47
2H
8.0 ∼ 14.5
8.0 ∼ 14.5
0
TOD
0
0
0
4L
0
8.0 ∼ 14.5
0
4B2–82 DRIVE LINE CONTROL SYSTEM (TOD)
Chart C–1
4H switch circuit is short-circuited to GND.
Function of circuit
—
Fail condition
When the TOD switch is selected to 4L from TOD, all the indicator lamps are turned off.
Indicator lamp state
TOD switch position
4L
DRIVE LINE CONTROL SYSTEM (TOD)
4B2–83
D04R200022
4B2–84 DRIVE LINE CONTROL SYSTEM (TOD)
Step
Action
1
1. Turn on the starter switch.
2. The car stops, the AT selector is N position and the brake is
applied.
When the TOD switch is changed to the TOD position, is 12V
observed between terminals 31 and 47 (4H switch)?
2
No
Go to Step 2
Go to Step 9
Go to Step 3
Go to Step 9
Go to Step 4
Replace the TOD
indicator lamp
bulb, or repair the
circuit.
Go to Step 13
Go to Step 5
Replace the TOD
indicator lamp
bulb, or repair the
circuit.
Go to Step 13
Go to Step 6
Replace the TOD
indicator lamp
bulb, or repair the
circuit.
Go to Step 13
Go to Step 7
The ECU has
frailed. Replace
the ECU.
Go to Step13
Go to Step 8
The ECU has
failed. Replace
the ECU.
Go to Step 13
The phenomenon
is not
reproduced.
Refer to “Trouble
intermittently
observed”.
The ECU has
failed. Replace
the ECU.
Go to Step 13
Go to Step 11
Go to Step 10
1. The car stops the AT selector is N position and the brake is
applied.
When the TOD switch is changed to the 4L position, is 12V
observed between terminals 31 and 47 (4H switch)?
3
Yes
1. Turn off the starter switch.
Is there the continuity terminal 14 and 7?
4
5
6
Is there the continuity between the terminals 14 and 19?
Is there the continuity between the terminal 14 and 8?
1. Turn on the starter switch.
2. The car stops the AT selector is N position and the brake is
applied.
When the TOD switch is changed to the 4L position, is 0V
observed between terminal 7 and 47? (for 2 seconds after the
starter switch ON) ?
7
8
9
Is 0V observed between terminal 19 and 47? (for 2 seconds after
the starter switch ON)
Is 0V observed between terminal 8 and 47? (for 2 seconds after
the starter switch ON)
1. The car stops, the AT selector is N position, and the brake is
applied.
2. The TOD switch is changed to the TOD (or 2H) position.
3. Turn off the starter switch.
4. Disconnect the ECU connector (C–37).
Is there the continuity between the connector (C–37) terminal 9
and 25?
DRIVE LINE CONTROL SYSTEM (TOD)
Step
Action
10
1. Connect the ECU connector (C–37) and turn on the starter
switch.
2. The car stops, the AT selector is N position, and the brake is
applied.
3. Change the TOD switch to the 4L position.
4. Turn off the starter switch and disconnect the ECU connector
(C–37).
Is there the continuity between the connector (C–37) terminal 9
and 25?
11
Yes
No
Go to Step 11
The ECU has
failed. Replace
the ECU.
Go to Step 13
Go to Step 12
The harness is
broken between
terminal (H–7) 4
and (C–37) 9.
Repair the circuit.
Go to Step 13
Repair the
transfer.
Go to Step 13
The harness
between the
connector
terminal (C–37) 9
and (A–1) 4 is
short-circuited to
GND. Repair the
circuit.
Go to Step 13
Verify the repair.
Return to Step 13
1. Disconnect the connector (H–7).
Is the continuity established between the transfer connector
terminals (H–7)4 and (C–37) 9?
12
1. Connect the connector (H–7).
2. Disconnect the connector (A–1).
Is there the continuity between the connector terminal (A–1) 4 and
(C–37) 9?
13
4B2–85
Check that all the parts are mounted.
Is this step complete?
4B2–86 DRIVE LINE CONTROL SYSTEM (TOD)
Chart D–1
4L switch circuit wires are broken or the battery circuit is short-circuited.
Function of circuit
—
Fail condition
When the TOD switch is changed to the 4L position, the indicator 4L mode goes on and
off.
Indicator lamp state
TOD switch position
4L
DRIVE LINE CONTROL SYSTEM (TOD)
4B2–87
D04R200022
4B2–88 DRIVE LINE CONTROL SYSTEM (TOD)
Step
Action
1
1. Turn on the starter switch.
2. The car stops, the AT selector is the N position, and the brake
is applied.
When the TOD switch is changed to the TOD (or 2H) position, is
12V observed between terminals 44 and 47 (4L switch)?
2
4
Is 0V observed between the terminal 44 and 47?
1. Turn off the starter switch and connect the EUC connector.
2. The car stops, the AT selector is the N position, and the brake
is applied.
When the TOD switch is changed to the 4L position, is 0V
observed between terminals (C–37) 22 and (C–37) 25 (4L
switch)?
6
1. Turn off the starter switch and connect the ECU connector.
2. Turn on the starter switch.
3. The car stops, the AT selector is the N position, and the brake
is applied.
4. Change the TOD switch to the 4L position.
5. After the transfer has changed to the 4L mode, turn off the
starter switch.
6. Disconnect the ECU connector.
Is there the continuity between the connector (C–37) terminal 22
and 25?
8
Go to Step 4
Go to Step 3
Refer to
“Diagnosis from
symptom”.
The ECU has
failed.Replace
the ECU.
Go to Step 10
Go to Step 10
Go to Step 5
Go to Step 6
The phenomenon
is not
reproduced.
Refer to “Trouble
intermittently
observed”.
Go to Step 6
Go to Step 9
Go to Step 7
The phenomenon
is not
reproduced.
Refer to “Trouble
intermittently
observed”.
Go to Step 8
Repair the
transfer.
Go to Step 10
Repair the circuit
between (C–37)
22 and (A–1) 12.
Go to Step 10
1. Turn off the starter switch and connect ECU connector.
2. Turn on the starter switch.
3. The car stops, the AT selector is the N position, and the brake
is applied.
4. Change the TOD switch to the TOD (or 2H) position.
5. After the transfer has changed to the TOD (or 2H) mode, turn
off the starter switch and disconnect the ECU connector
(C–37).
Is there the continuity between the connector (C–37) terminal 22
and 25?
7
Go to Step 2
1. The car stops, the AT selector is the N position, and the brake
is applied.
When the TOD switch is changed to the TOD (or 2H) position, is
12V observed between the connector (C–37) terminal 22 and 25?
5
No
1. The car stops, the AT selector is the N position, and the brake
is applied.
When the TOD switch is changed to the 4L position, does the
transfer become the 4L state?
3
Yes
1. Turn off the starter switch and connect the ECU connector.
2. Turn on the starter switch.
3. The car stops, the AT selector is the N position, and the brake
is applied.
4. Change the TOD switch to the TOD (or 2H) position.
5. After the transfer has changed to the TOD (or 2H) mode, turn
off the starter switch.
6. Disconnect the transfer connector (A–1).
Is there the continuity between the connector terminal (A–1) 12
and GND?
DRIVE LINE CONTROL SYSTEM (TOD)
Step
Action
9
1. Turn off the starter switch and connect the connector (A–1).
2. Turn on the starter switch.
3. The car stops, the AT selector is N position, and the brake is
applied.
4. Change the TOD switch to the 4L position.
5. After the transfer has changed to the 4L mode, turn off the
starter switch.
6. Disconnect the transfer connector (A–1).
Is there the continuity between the connector terminal (A–1) 12
and GND?
10
4B2–89
Yes
No
Repair the circuit
between
(C–37)22 and
(A–1)12.
Go to Step 10
Repair the
transfer.
Go to Step 10
Verify the repair.
Go to Step 10
Check that all the parts are mounted.
Is this step complete?
4B2–90 DRIVE LINE CONTROL SYSTEM (TOD)
Chart D–2
The 4L switch circuit is short-circuited to GND.
Function of circuit
—
Fail condition
When the TOD switch is changed to the 2H or TOD position, the indicator 2H or TOD
mode goes on and off.
Indicator lamp state
TOD switch position
2H or TOD
DRIVE LINE CONTROL SYSTEM (TOD)
4B2–91
D04R200022
4B2–92 DRIVE LINE CONTROL SYSTEM (TOD)
Step
Action
1
1. The car stops, the AT selector is the N position, and the brake
is applied.
When the TOD switch is changed to the TOD (or 2H) position, is
12V observed between terminals 44 and 47 (4L switch)?
2
1. The car stops, the AT selector is the N position, and the brake
is applied.
When the TOD switch is changed to the 4L position, is 0V
observed between terminals 44 and 47 (4L switch)?
3
1. Connect the ECU connector (C–37) and turn on the starter
switch.
2. The car stops, the AT selector is the N position, and the brake
is applied.
3. Select the TOD switch to the 4L position.
4. Turn off the starter switch and disconnect the ECU connector
(C–37).
Is there the continuity between the connector (C–37) terminal 22
and 25?
5
Go to Step 3
Refer to “Trouble
intermittently
observed”.
Go to Step 3
Go to Step 5
Go to Step 4
The ECU has
failed.Replace
the ECU.
Go to Step 9
Go to Step 5
Go to Step 7
Go to Step 6
Go to Step 7
GND is
short-circuited
between
terminals (C–37)
2 and (H–7) 5.
Repair the circuit.
Go to Step 9
Repair the
transfer.
Go to Step 9
Go to Step 8
1. Connect the connector (H–7) and turn on the starter switch.
2. The car stops, the AT selector is the N position, and the brake
is applied.
3. Select the TOD switch to the 4L position.
4. After the transfer has changed to the 4L mode, turn off the
starter switch and disconnect the connector (H–7).
Is there the continuity between the connector terminal (H–7) 5 and
(C–37) 25?
7
Go to Step 2
1. Connect the ECU connector (C–37) and turn on the starter
switch.
2. The car stops, the AT selector is the N position, and the brake
is applied.
3. Select the TOD switch to the TOD (or 2H) position.
4. Turn off the starter switch and disconnect the connector (H–7).
Is there the continuity between the connector terminal (H–7) 5 and
(C–37) 25?
6
No
1. The car stops, the AT selector is the N position, and the brake
is applied.
2. Select the TOD switch to the TOD (or 2H) position.
Is there the continuity between the connector (C–37) terminal 22
and 25?
4
Yes
1. Connect the connector (H–7) and turn on the starter switch.
2. The car stops, the AT selector is the N position, and the brake
is applied.
3. Select the TOD switch to the TOD (or 2H) position.
4. After the transfer has changed to the TOD (or 2H) mode, turn
off the starter switch and disconnect the connector (A–1).
Is there the continuity between the connector terminal (A–1) 12
and GND?
DRIVE LINE CONTROL SYSTEM (TOD)
Step
Action
8
1. Connect the connector (A–1) and turn on the starter switch.
2. The car stops, the AT selector is the N position, and the brake
is applied.
3. Select the TOD switch to the 4L position.
4. After the transfer has changed to the 4L mode, disconnect the
connector (A–1).
Is there the continuity between the connector terminal (A–1) 12
and GND?
9
4B2–93
Yes
No
GND is
short-circuited
between
terminals (A–1)
12 and (H–7) 5.
Repair the circuit.
Go to Step 9
Repair the
transfer.
Go to Step 9
Verify the repair.
Go to Step 9
Check that all the parts are mounted.
Is this step complete?
4B2–94 DRIVE LINE CONTROL SYSTEM (TOD)
Chart E–1
AXLE switch circuit wires are broken.
Function of circuit
—
Fail condition
Both the TOD and 4L modes are disabled. (The transition status is not removed.)
Indicator lamp state
TOD switch position
TOD
4L
D04R200023
DRIVE LINE CONTROL SYSTEM (TOD)
Step
1
2
Action
Yes
No
When the TOD switch is selected to the TOD position, is 0V
observed between terminals 42 and 47?
Go to Step 2
Go to Step 4
Go to Step 3
Go to Step 4
The phenomenon
is not
reproduced.
Refer to
“Troubles
intermittently
observed”.
The ECU has
failed.Replace
the ECU.
Go to Step 8
When the TOD switch is selected to the 2H position, is the battery
voltage observed between the terminal 23 and 47.
Go to Step 5
Go to Step 7
When the TOD switch is selected to the TOD position (TOD
mode), is 0 ∼ 1V observed between terminals 23 and 47?
Go to Step 6
Go to Step 7
Repair the circuit
or check the
“Front Axle
Disconnect”.
(Refer to section
4B)
Go to Step 8
Go to Step 7
Examine the
trouble based on
“Diagnosis from
Trouble Codes”.
The ECU has
failed. Replace
the ECU.
Go to Step 8
Verify the repair.
Go to Step 8
Start the engine.
1. The car stops, the AT selector is N position, and the brake is
applied.
2. Select the TOD switch to the 4L position.
Is 0V observed between terminals 42 and 47?
3
1. The car stops, the AT selector is N position, and the brake is
applied.
When the TOD switch is selected to the 4L position, is 12V
observed between the terminal 19 and 47?
4
5
6
4B2–95
1. The car stops, the AT selector is N position, and the brake is
applied.
1. The car stops, the AT selector is N position, and the brake is
applied.
When the TOD switch is selected to the 4L position, is 0V
observed between terminals 23 and 47?
7
Is any of the trouble codes 28 (P1760), 32 (P1761) and 33
(P1762) recorded?
8
Check that all the parts are mounted.
Is this step complete?
4B2–96 DRIVE LINE CONTROL SYSTEM (TOD)
Chart E–2
The AXLE switch circuit is short-circuited to GND.
Function of circuit
—
Fail condition
Even after the TOD switch is selected to the 2H position, the 2H mode is not enabled.
(The transition status is not removed.)
Indicator lamp state
TOD switch position
2H
D04R200023
DRIVE LINE CONTROL SYSTEM (TOD)
Step
1
2
Action
Yes
No
When the TOD switch is selected to the TOD position, is 0V
observed between terminals 42 and 47?
Go to Step 2
Go to Step 6
Go to Step 3
Go to Step 6
Go to Step 4
Go to Sep 6
Go to Step 5
Replace the
ECU.
Go to Step 10
The phenomenon
is not
reproduced.
Refer to
“Troubles
intermittently
observed”.
The ECU has
failed.Replace
the ECU.
Go to Step 10
Go to Step 7
Go to Step 9
Go to Step 8
Go to Step 9
Repair the circuit
or check the
“Front Axle
Disconnect”.
(Refer to section
4B)
Go to Step 10
Go to Step 9
Examine the
trouble based on
“Diagnosis from
Trouble Codes”.
The ECU has
failed. Replace
the ECU.
Go to Step 10
Verify the repair.
Go to Step 10
Start the engine.
1. The car stops, the AT selector is N position, and the brake is
applied.
When the TOD switch is selected to the 4L position, is 0V
observed between terminals 42 and 47?
3
1. The car stops, the AT selector is N position, and the brake is
applied.
2. Select the TOD switch to the 2H position.
Is 5V observed between terminals 42 and 47?
4
5
6
Is 12V observed between terminals 7 and 47?
Is 12V observed between terminals 19 and 47?
1. The car stops, the AT selector is N position, and the brake is
applied.
When the TOD switch is selected to the 2H position, is the battery
voltage observed between terminals 23 and 47?
7
1. The car stops, the AT selector is N position, and the brake is
applied.
When the TOD switch is selected to the TOD position, is 0V
observed between terminals 23 and 47?
8
4B2–97
1. The car stops, the AT selector is N position, and the brake is
applied.
When the TOD switch is selected to the 4L position, is 0V
observed between terminals 23 and 47?
9
Is any of the trouble codes 28 (P1760), 32 (P1761) and 33
(P1762) recorded?
10
Check that all the parts are mounted.
Is this step complete?
4B2–98 DRIVE LINE CONTROL SYSTEM (TOD)
Chart G
The trouble codes are displayed.
Function of circuit
—
Fail condition
Indicator lamp state
TOD switch position
—
D04R200009
DRIVE LINE CONTROL SYSTEM (TOD)
Step
1
Action
2
3
Yes
No
Go to Step 2
The ECU has
failed. Replace
the ECU.
Go to Step 3
Go to Step 3
Open the
self-diagnostic
connector.
Go to Step 3
Verify the repair.
Go to Step 3
Disconnect the ECU connector from ECU.
Is there the continuity established between terminals (C–37)7 and
(C–37)25?
4B2–99
Is the self-diagnostic connector short-circuited?
1. Check that all the parts are mounted.
2. Clear the trouble codes.
Is this step complete?
4B2–100 DRIVE LINE CONTROL SYSTEM (TOD)
Chart H
Lighting switch circuit
Function of circuit
Reads in the status of lighting switch, and reduces the indicator at night.
Fail condition
Even if the lighting switch is pressed on and off, brightness does not change.
Indicator lamp state
TOD switch position
All position (exsample TOD mode)
D04R200009
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–101
Step
1
Action
Yes
No
Go to Step 2
Lighting switch
battery circuit
short. Repair the
circuit.
Go to Step 4
Go to Step 3
Wires are broken
in lighting switch
circuit. Repair the
circuit.
Go to Step 4
The phenomenon
is not
reproduced.
Refer to
“Troubles
intermittently
observed”
The ECU has
failed. Replace
the ECU.
Go to Step 4
Verify the repair.
Go to Step 4
1. Turn on the starter switch.
2. Turn off the lighting switch.
Is 0V observed between the EUC terminal 40 and 47?
2
Turn lighting switch “ON”.
Is the battery voltage observed between ECU terminal 40 and 47?
3
4
While the lighting switch is pressed on and off, does the
brightness of the indicator change?
Check that all the parts are mounted.
Is this step complete?
4B2–102 DRIVE LINE CONTROL SYSTEM (TOD)
Diagnosis from Symptom
Troubles that are not indicated by the warning lamp are
listed in the table below. These troubles are caused by the
faults that cannot be detected by the self-diagnostic
function of the control unit.
If this type of trouble is observed, interview the customer
and conduct test runs to reproduce the trouble,
cross-check the reported trouble with the listed
phenomena, and diagnose and analyze the trouble on the
item by item basis.
Phenomena
Major cause
Corrective action
1
The tight corner braking is
observed when the vehicle is
subject to full steering.
B
B
B
B
The standard tires are not used.
The tire pressure is incorrect.
The tires are worn inuniformity.
The transfer or wiring is
imperfect.
B The limited slip differential is
failed.
Check and recondition the
vehicle according to Chart 1.
2
Even if the TOD switch is selected
to the TOD position, the F4WD
mode is not active, resulting in
remarkable rear wheel spin.
B The transfer or wiring is
imperfect.
B The shift on the fly system is
failed.
Check and recondition the
vehicle according to Chart 2.
3
B When the TOD switch is
selected to the TOD position,
the drive resistance of the
F4WD system is too large to get
sufficient running speed.
B Noised drive line.
B The standard tires are not used.
B The tires are worn inuniformity.
B The transfer or wiring is
imperfect.
B The limited slip differential is
failed.
Check and recondition the
vehicle according to Chart 1.
4
The shift on the fly system (front
axle disconnect) generates gear
noises.
B The wiring is imperfect.
B The shift on the fly system is
failed.
Check and recondition the
vehicle according to Chart 3.
5
The braking distance gets long
even when the ABS is active.
B The wiring is imperfect.
B The ABS is failed.
Check and recondition the
vehicle according to Chart 4.
6
The transfer does not change to the
low range from the high range.
Check and recondition the
vehicle according to chart 5.
7
The transfer does not change to the
high range from the low range.
B The transfer or wiring is
imperfect.
B The TOD switch is imperfect.
B The AT inhibitor switch is
imperfect.
im
erfect.
B The brake switch is imperfect.
B The engine speed signal is
imperfect.
B The speed sensor is imperfect.
8
The transfer stays neutral and the
vehicle does not run.
B The transfer is imperfect.
Check and recondition the
vehicle according to chart 7.
Check and recondition the
vehicle according to chart 6.
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–103
Chart 1
The tight corner braking is observed.
Function of circuit
—
Fail condition
When the vehicle is subject to full steering in the TOD mode, the drive resistance gets
large or the judder occurs. Otherwise, the above phenomenon is observed only when the
brake is applied.
D04R200021
4B2–104 DRIVE LINE CONTROL SYSTEM (TOD)
Step
Yes
No
Go to Step 2
Replace the tires
with specified
ones, and service
the new tires.
Go to Step 16
Go to Step 3
Inflate the tires
with specified
pressure.
Go to Step 16
Go to Step 4
Replace the tires
with specified
ones, and service
the new tires.
Go to Step 16
Go to Step 5
Replace the tires
with specified
ones, and service
the new tires.
Go to Step 16
Go to Step 6
Go to Step 11
Does the tight corner braking occur? Is the judder with chug-chug
sound observed? * Use caution on the operation.
Go to Step 7
Go to Step 14
7
Is an LSD mounted to the rear differential?
Go to Step 8
Go to Step 9
8
Is the genuine LSD oil used in the rear differential?
Go to Step 9
Replace the
differential oil.
Go to Step 16
Go to Step 10
Check the
engine.
Go to Step 16
The ECU has
failed. Replace
the ECU.
Go to Step 16
Replace the
speed sensors.
Go to Step 16
Go to Step 12
Conduct full
steering under
WOT.
Go to Step 5
Go to Step 13
Repair the circuit
of the ECU
connector
terminal 33 (ABS
IN).
Go to Step 16
1
2
3
4
5
Action
Are the front and rear tires in specified size?
Is the tire pressure correct?
Are the tires free from abnormal wear?
Are different types of tires used?
1. Start the engine.
2. Select the TOD switch to the TOD position.
3. Fully turn the steering to the left (or right) end, and select the D
range and start the creep run.
Does the tight corner braking occur? Is the judder with chug-chug
sound observed? * Use caution on the operation.
6
9
10
11
12
1. Select the TOD switch to the 2H position.
2. Fully turn the steering to the left (or right) end, and select the D
range and start the creep run.
Does the engine output the power correctly?
Do the speed sensors work correctly? (Check trouble codes.)
Is the tight corner braking observed only when the brake is
applied?
1. Turn on the starter switch.
Is 8 ∼ 10 V observed between terminals 33 and 47?
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–105
Step
Action
Yes
No
13
1. Apply the brake and fully turn the steering to the left (or right)
end, and start the creep run.
Repair the
transfer
assembly.
Go to Step 16
The ECU has
failed. Replace
the ECU.
Go to Step 16
Go to Step 15
Go to Step 10
The phenomenon
is not
reproduced.
Refer to
“Troubles
intermittently
observed”.
Repair the
transfer
assembly.
Go to Step 16
Verify the repair
Go to Step 16
Does the voltage between terminals 11 and 22 range between 0.1
and 1.0V?
14
1. Select the TOD switch to the TOD position.
2. Fully turn the steering to the left (or right) end, and select the D
range and start the creep run.
Does the voltage between terminals 11 and 22 range between 0.1
and 1.0V?
15
1. Select the TOD switch to the 2H position.
2. Jack up the right front wheel.
Does the front tire rotate smoothly?
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.
4B2–106 DRIVE LINE CONTROL SYSTEM (TOD)
Chart 2
The TOD mode is not active.
Function of circuit
—
Fail condition
The rear wheels spin in the TOD mode, so the driving torque is not transmitted to the
front wheels. The indicator lamps will not show the 4L and TOD status.
D04R200021
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–107
Step
1
2
3
4
5
Action
Is the trouble code 31(P1721) recorded?
Is any of the trouble codes 28(P1760), 32(P1761) and 33(P1762)
recorded?
7
No
Examine the
trouble based on
“Diagnosis from
Trouble Codes”.
Go to Step 2
Examine the
trouble based on
“Diagnosis from
Trouble Codes”.
Go to Step 3
Go to Step 4
Examine the
trouble based on
“Trouble
Diagnosis
Depending on
The Status of
TOD Indicator”.
Go to Step 5
Repair the
transfer
assembly.
Go to Step 7
Go to Step 6
The ECU has
failed. Replace
the ECU.
Go to Step 7
The TOD clutch
is worn. Repair
the transfer
assembly.
Go to Step 7
The ECU has
failed. Replace
the ECU.
Go to Step 7
Verify the repair.
Go to Step 7
When the TOD switch is selected to the specified position, do the
TOD indicator lamps show the correct status?
Select the TOD switch to the 4L position, fully turn the steering to
the left (or right) end, and start the creep run. Does the tight corner
braking occur?
1. Select the TOD switch to the TOD position.
2. Turn on the starter switch.
Does the voltage between terminals 11 and 22 indicate at least 3V
while the throttle is completely open?
6
Yes
Does the voltage between terminals 11 and 22 indicate at least
0.1V while the throttle is completely closed?
Check that all the parts are mounted.
Is this step complete?
4B2–108 DRIVE LINE CONTROL SYSTEM (TOD)
Chart 3
The shift on the fly system generates gear noises.
(The fuel economy is bad in the 2H mode.)
Function of circuit
—
Fail condition
When the vehicle is run in the 2H mode, the shift on the fly system generates gear
noises or the front wheel gears are engaged to generate a shock.
D04R200021
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–109
Step
1
2
3
Action
5
6
No
Go to Step 2
Examine the
trouble based on
“Trouble
Diagnosis
Depending on the
Status of TOD
Indicator”.
Examine the
trouble based on
“Diagnosis from
Trouble Codes”.
Go to Step 3
Go to Step 4
Go to Step 5
The phenomenon
is not
reproduced.
Refer to “Trouble
intermittently
observed”.
The shift on the
fly system is
failed (refer to
Section 4B1 and
4C).
Repair the battery
circuit.
Go to Step 6
Repair the battery
and charging
system.
Go to Step 6
Verify the repair.
Go to Step 6
Do the indicator lamps show the correct status?
Is any of the trouble codes 28(P1760), 32(P1761) and 33(P1762)
recorded?
Turn on the starter switch.
Is the battery voltage observed between terminals 14 and 47?
4
Yes
When the TOD Switch is selected to the 2H position, are the front
axle gears correctly disengaged (and when the left front tire is
jacked up and turned, is the front propeller shaft standstill)?
Does the battery voltage maintain the correct level?
Check that all the parts are mounted.
Is this step complete?
4B2–110 DRIVE LINE CONTROL SYSTEM (TOD)
Chart 4
The braking distance gets long even when the ABS is active.
Function of circuit
—
Fail condition
Enough deceleration is not obtained and the braking distance gets long even when the
ABS is active in the 2H mode.
D04R200021
DRIVE LINE CONTROL SYSTEM (TOD)
Step
1
2
3
Action
5
Yes
No
Go to Step 2
Repair the brake
and ABS. (Refer to
section 5A and 5B)
Go to Step 3
Repair the
battery system.
Go to Step 5
Go to Step 4
The ECU has
failed. Replace
the ECU.
Go to Step 5
Are the brake and ABS systems healthy?
Turn on the starter switch.
Is the battery voltage observed between terminals 14 and 47?
1. Select the TOD switch to the 2H position.
Does the voltage between terminals 36 and 47 range between
7.5 and 16V (0.12 seconds make a cycle)?
4
4B2–111
1. Turn off the starter switch.
2. Disconnect the connector (C–37).
Is there the continuity between the connector terminal (C–37) 14
and (C–6) 8?
Check that all the parts are mounted.
Is this step complete?
The
phenomenon is
not reproduced.
Refer to
“Trouble
intermittently
observed".
Verify the repair.
Repair the
harness.
Go to Step 5
Go to Step 5
4B2–112 DRIVE LINE CONTROL SYSTEM (TOD)
Chart 5
The transfer does not change to low from high.
Function of circuit
—
Fail condition
When the TOD switch is selected to the 4L position, the transfer does not change to the
low range.
D04R200018
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–113
Step
1
Action
Yes
No
Examine the
trouble based on
“Diagnosis from
Trouble Codes”.
Go to Step 2
Examine the
trouble based on
“Diagnosis from
Trouble Codes”.
Go to Step 3
Examine the
trouble based on
“Diagnosis from
Trouble Codes”.
Go to Step 4
Go to Step 5
Examine the
trouble based on
“Trouble
Diagnosis
Depending on the
Status of TOD
Indicator”.
The phenomenon
is not
reproduced.
Refer to “Trouble
intermittently
observed”.
Go to Step 6
The phenomenon
is not
reproduced.
Refer to “Trouble
intermittently
observed”.
Go to Step 7
Examine the
trouble based on
“Trouble
diagnosis
Depending on
The Status of
TOD Indicator”.
Go to Step 8
Is the battery voltage observed between the terminal 37 and 47?
Go to Step 10
Go to Step 9
1. Turn off the starter switch.
2. Disconnect the ECU connector (C–37) and the brake switch
connector (I–31).
The brake switch
is abnormal.
Repair or replace
the brake switch.
Go to Step 13
Repair the
harness.
Go to Step 13
Go to Step 12
Go to Step 11
Repair or replace
the AT mode
switch.
Go to Step 13
Repair the circuit
which has no
continuity.
Go to Step 13
1. Turn on the starter switch.
Is any of the trouble codes 41 (P1741), 42 (P1773), 43 (P1743)
and 55 (P1755) recorded?
2
3
4
Is any of the trouble codes 13 (P1735), 14 (P1731), 15 (P1736),
16 (P1737), 24 (P1733), and 27 (P1738) recorded?
Is the trouble code 17 (P1774) recorded?
1. Turn on the starter switch.
2. The car stops, engine speed is less than 1500 rpm, the AT
selector is N position, and select the TOD switch to the 4L
position.
Do the front lamp and rear lamp in the indicator blink?
5
1. Step on the brake pedal.
Is the transfer changed to the 4L mode?
6
7
8
9
When the vehicle is moved forth and back, is the transfer changed
to the 4L mode?
Does the continuity corresponding to the encoder position
between the terminals comply with the 4L position in the following
table (continuity)?
1. Step on the brake pedal.
Is there the continuity between the connector terminal (C–37) 15
and (I–31) 4?
10
1. Select the AT selector to the N position.
Is the voltage between the terminals ranged within the following
table (voltage)?
11
1. Turn off the starter switch.
2. Disconnect the ECU connector (C–37).
3. Disconnect the AT mode switch connector (E–41).
Is there the continuity between the following connector terminals?
(C–37)6 and (E–41)8 (C–37)19 and (E–41)7 (C–37)5 and
(E–41)6
4B2–114 DRIVE LINE CONTROL SYSTEM (TOD)
Step
12
Action
No
Replace the
ECU.
Go to Step 13
The engine pulse
signal is
abnormal. Repair
or replace the
PCM.
Go to Step 13
Verify the repair.
Go to Step 13
1. Start the engine.
Is the engine pulse signal between terminal 2 and 47 at engine
speed under 1500 rpm within the standard? Standard: less than
4500 Hz
13
Yes
Check that all the parts are mounted.
Is this step complete?
Continuity between terminal in 4L position
(Table: continuity)
Terminals
No.
26 and
24
39 and
24
25 and
24
38 and
24
Continuity
of 4L
position
YES
NO
YES
YES or
NO
Standard (Table: voltage)
Unit: V
Terminals
28 and 47
41 and 47
27 and 47
Voltage
0
12
0
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–115
Chart 6
The transfer does not change to high from low.
Function of circuit
—
Fail condition
When the TOD switch is selected to the TOD, the transfer does not change to the high
range.
D04R200018
4B2–116 DRIVE LINE CONTROL SYSTEM (TOD)
Step
1
Action
Yes
No
Examine the
trouble based on
“Diagnosis from
Trouble Codes”.
Go to Step 2
Examine the
trouble based on
“Diagnosis from
Trouble Codes”.
Go to Step 3
Examine the
trouble based on
“Diagnosis from
Trouble Codes”.
Go to Step 4
Go to Step 5
Examine the
trouble based on
“Trouble
Diagnosis
Depending on the
Status of TOD
Indicator”.
The phenomenon
is not
reproduced.
Refer to “Trouble
intermittently
observed”.
Go to Step 6
The phenomenon
is not
reproduced.
Refer to “Trouble
intermittently
observed”.
Go to Step 7
Examine the
trouble based on
“Trouble
diagnosis
Depending on
The Status of
TOD Indicator”.
Go to Step 8
Is the battery voltage observed between the terminal 37 and 47?
Go to Step 10
Go to Step 9
1. Turn off the starter switch.
2. Disconnect the ECU connector (C–37) and the brake switch
connector (I–31).
The brake switch
is abnormal.
Repair or replace
the brake switch.
Go to Step 13
Repair the
harness.
Go to Step 13
Go to Step 12
Go to Step 11
Repair or replace
the AT mode
switch.
Go to Step 13
Repair the circuit
which has no
continuity.
Go to Step 13
1. Turn on the starter switch.
Is any of the trouble codes 41 (P1741), 42 (P1773), 43 (P1743)
and 55 (P1755) recorded?
2
3
4
Is any of the trouble codes 13 (P1735), 14 (P1731), 15 (P1736),
16 (P1737), 24 (P1733), and 27 (P1738) recorded?
Is the trouble code 17 (P1774) recorded?
1. Turn on the starter switch.
2. The car stops, engine speed is less than 1500 rpm, the AT
selector is N position, and select the TOD switch to the TOD
position.
Do the front, rear, and AUTO lamps in the indicator blink?
5
1. Step on the brake pedal.
Is the transfer changed to the TOD mode?
6
7
8
9
When the vehicle is moved forth and back, is the transfer changed
to the TOD mode?
Is the continuity corresponding to the encoder position between
the terminals ranged within the any case (case 1, 2 and 3) of TOD
position in the following table (continuity)?
1. Step on the brake pedal.
Is there the continuity between the connector terminal (C–37) 15
and (I–31) 4?
10
1. Select the AT selector to the N position.
Is the voltage between the terminals ranged within the following
table (voltage)?
11
1. Turn off the starter switch.
2. Disconnect the ECU connector (C–37) and brake switch
connector (I–31).
3. Disconnect the AT mode switch connector (E–41).
Is there the continuity between the following connector terminals?
(C–37)6 and (E–41)8 (C–37)19 and (E–41)7 (C–37)5 and
(E–41)6
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–117
Step
12
Action
No
Replace the
ECU.
Go to Step 13
The engine pulse
signal is
abnormal. Repair
or replace the
PCM.
Go to Step 13
Verify the repair.
Go to Step 13
1. Start the engine.
Is the engine pulse signal between terminal 2 and 47 at engine
speed under 1500 rpm within the standard? Standard: less than
4500 Hz
13
Yes
Check that all the parts are mounted.
Is this step complete?
Continuity in TOD position (Table: continuity)
Continuity between terminals
Case
26 and
24
39 and
24
25 and
24
38 and
24
1
NO
NO
NO
YES
2
NO
YES
NO
YES
3
YES
YES
NO
YES
Standard (Table: voltage)
Unit: V
Terminals
28 and 47
41 and 47
27 and 47
Voltage
0
12
0
4B2–118 DRIVE LINE CONTROL SYSTEM (TOD)
Chart 7
The transfer does not change to low from high.
Function of circuit
—
Fail condition
When the TOD switch is selected to the 4L position, the transfer does not change to the
low position. (The transfer stays neutral and the vehicle does not run.)
Step
1
Action
No
Go to Step 2
Go to Step 3
The phenomenon
is not
reproduced.
Refer to “Trouble
intermittently
observed”.
Go to Step 3
Examine the
trouble based on
“Diagnosis from
Trouble Codes”.
The transfer is
abnormal. Repair
the transfer.
Go to Step 4
Verify the repair.
Go to Step 4
1. Turn on the starter switch.
2. Set the TOD switch to the any position.
Is the transfer changed to high or low?
2
Yes
Is the transfer changed to high from low and the low from high?
3
Is any of the trouble codes 41 (P1741), 42 (P1773), 43 (P1743),
and 55 (P1755) recorded?
4
Check that all the parts are mounted.
Is this step complete?
SECTION
DRIVE SHAFT SYSTEM
4C–1
AXIOM (Vehicles Produced Before July/31/2001)
DRIVELINE/AXLE
DRIVE SHAFT SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . .
General Description . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Hub and Disc (2WD Model) . . . . . . . . .
Disassembled View . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Hub and Disc (4WD Model) . . . . . . . . .
Disassembled View . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Drive Shaft Joint . . . . . . . . . . . . . . . . . . .
Front Drive Shaft Joints Replacement . . . .
Front Axle Drive Shaft . . . . . . . . . . . . . . . . . . .
Front Axle Drive Shaft and Associated
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair . . . . . . . . . . . . . . . . . .
Bushing Replacement . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift On The Fly System . . . . . . . . . . . . . . . . .
Shift On The Fly System and Associated
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4C–1
4C–2
4C–2
4C–3
4C–3
4C–3
4C–4
4C–5
4C–8
4C–8
4C–8
4C–10
4C–10
4C–13
4C–13
4C–14
4C–14
4C–15
4C–16
4C–16
4C–17
4C–19
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . . .
General Description . . . . . . . . . . . . . . . . . . . .
Front Propeller Shaft . . . . . . . . . . . . . . . . . . . . .
General Description . . . . . . . . . . . . . . . . . . . .
Front Propeller Shaft and Associated Parts
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications . . . . . . . . . . .
Rear Propeller Shaft . . . . . . . . . . . . . . . . . . . . .
Rear Propeller Shaft and Associated Parts
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Slip Joint Disassembly . . . . . . . . . . . . . . . . .
Universal Joint Disassembly . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Universal Joint Reassembly . . . . . . . . . . . . .
Slip Joint Reassembly . . . . . . . . . . . . . . . . . .
Main Data and Specifications . . . . . . . . . . .
4C–20
4C–21
4C–23
4C–26
4C–28
4C–29
4C–29
4C–30
4C–30
4C–31
4C–31
4C–32
4C–35
4C–36
4C–36
4C–36
4C–36
4C–37
4C–38
4C–40
4C–41
4C–42
4C–43
4C–19
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.
4C–2
DRIVE SHAFT SYSTEM
General Description
This publication contains essential removal, installation,
adjustment and maintenance procedures.
The front axle utilizes a central disconnect type front
axle/transfer case system.
The drive axles are completely flexible assemblies,
consisting of inner and outer constant velocity (CV) drive
shaft joints connected by an axle shaft.
For description of front propeller shaft and universal joint,
refer to Front Propeller Shaft in this section.
Diagnosis
Condition
Possible cause
Oil Leak At Front Axle
Correction
Worn or defective oil seal.
Replace the oil seal.
Front axle housing cracked.
Repair or replace.
Too much gear oil.
Correct the oil level.
Oil seal worn or defective.
Replace the oil seal.
Pinion flange loose or damaged.
Tighten or replace.
Noises In Front Axle Drive Shaft
Joint
Broken or worn drive shaft joints and
bellows (BJ and DOJ).
Replace the drive shaft joints and
bellows.
“Clank” When Accelerating From
“Coast”
Loose drive shaft joint to output shaft
bolts.
Tighten.
Damaged inner drive shaft joint.
Replace.
Excessive drive shaft joint angle.
Repair.
Worn or damaged drive shaft joints.
Replace.
Sticking spider assembly (inner drive
shaft joint).
Lubricate or replace.
Sticking joint assembly (outer drive
shaft joint).
Lubricate or replace.
Out of balance or out of round tires.
Balance or replace.
Front end out of alignment.
Align.
Insufficient gear oil.
Replenish the gear oil.
Wrong or poor grade gear oil.
Replace the gear oil.
Drive pinion to ring gear backlash
incorrect.
Adjust the backlash.
Worn or chipped ring gear, pinion
gear or side gear.
Replace the ring gear, pinion gear or
side gear.
Pinion shaft bearing worn.
Replace the pinion shaft bearing.
Wheel bearing worn.
Replace the wheel bearing.
Differential bearing loose or worn.
Tighten or replace.
Wheel bearing preload too tight.
Adjust the wheel bearing preload.
Incorrect front alignment.
Adjust the front alignment.
Steering unit loose or worn.
Tighten or replace.
Tire worn or improperly inflated.
Adjust the inflation or replace.
Front or rear suspension parts loose
or broken.
Tighten or replace.
Wheel bearing worn or improperly
adjusted.
Adjust or replace.
Incorrect front alignment.
Adjust the front alignment.
Worn ball joint or bush.
Replace the ball joint or bush.
Steering unit loose or worn.
Tighten or replace.
Tire worn or improperly inflated.
Replace or adjust the inflation.
Shock absorber worn.
Replace the shock absorber.
Oil Leak At Pinion Shaft
Shudder or
Acceleration
Vibration
Vibration At Highway Speeds
Noises in Front Axle
Wanders and Pulls
Front Wheel Shimmy
During
DRIVE SHAFT SYSTEM
4C–3
Front Hub and Disc (2WD Model)
Disassembled View
411RX001
Legend
(1) Bolt
(2) Cover and Gasket
(3) Lock Washer and Lock Screw
(4) Hub Nut
(5) Outer Bearing
(6)
(7)
(8)
(9)
(10)
(11)
Hub and Disc Assembly
ABS Sensor Ring
Inner Bearing
Oil Seal
Bolt
Wheel Pin
Disassembly
1. Before disassembly, jack up the front of vehicle and
support frame with jack stands.
2. Remove the two bolts from the rear side of the
knuckle arm, then remove the brake caliper, with the
brake hose attached.
Use a wire to attach the brake caliper to the upper link.
Refer to Disk Brakes in Brake section.
3. Remove cover bolt.
4. Remove cover and gasket.
5. Remove lock washer and Lock screw.
6. Remove hub nut, using front hub nut wrench
J–36827.
901RW054
4C–4
DRIVE SHAFT SYSTEM
7. Remove hub and disc assembly.
8. Remove ABS sensor ring.
9. Remove outer bearing.
10. Remove oil seal.
11. Remove inner bearing.
12. Use a brass bar to remove the outer bearing outer
race(1), oil seal, inner bearing and inner bearing outer
race(2) from the hub.
B Clamp hub and disc assembly in vise, using
protective pads.
Remove six(6) disc-to-hub
retaining bolts.
411RS021
B Place hub on a suitable work surface and remove
wheel studs, as required, using a hammer.
411RS002
13. Remove bolt.
14. If necessary, replace the wheel pin in the following
manner.
B Scribe mark(1) on hub to disc before disassembly
to insure proper assembly.
411RS004
Inspection and Repair
411RS003
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
Check the following parts.
B Hub
B Hub bearing oil seal
B Knuckle spindle
B Disc
B Caliper
B ABS sensor ring
For inspection and servicing of disc caliper and related
parts, refer to Disc Brake in Brake section.
DRIVE SHAFT SYSTEM
Reassembly
1. Install wheel pin.
B Place hub on a wood workbench or a block of wood
approx. 6” by 6” to protect the wheel stud ends and
threads.
4C–5
3. Install inner bearing.
Install the outer race by driving it into the hub by using
installer J–36829 and grip J–8092.
B Install wheel stud, using a hammer.
NOTE: Be sure wheel stud is started squarely and seats
completely.
411RS023
4. Install outer bearing.
Install the outer race by driving it into the hub by using
installer J–36828 and grip J-8092.
411RS005
2. Align scribe marks(1) and attach the hub to disc then
tighten the bolts to the specified torque.
Torque: 103 N·m (76 lb ft)
901RW056
411RS003
4C–6
DRIVE SHAFT SYSTEM
5. Install oil seal by using installer J–36830 and grip
J–8092.
Apply Multipurpose grease (NLGI No. 2 or equivalent)
to the lip portion.
8. Install hub nut.
Turn the place where there is a chamfer in the tapped
hole to the outer side, then attach the nut by using
front hub nut wrench J–36827.
901RW057
6. Inatall ABS sensor ring, then tigthen the bolts to the
specified torque.
Torque: 18 N·m (13 lb ft)
7. Install hub and disc assembly.
B Apply grease in the hub.
901RW054
Preload Adjustment
1. Tighten the hub nut to 29.4 N·m (21.7 lb ft), then
fully loosen the nut.
2. Tighten the hub nut to the value given below,
using a spring scale on the wheel pin.
B Apply wheel bearing type grease (NLGI No.2 or
equivalent) to the outer and inner bearing.
Hub
35 g (1.23 oz)
Outer bearing
10 g (0.35 oz)
Inner bearing
15 g (0.53 oz)
Bearing Preload
New bearing and New
oil seal
19.6 – 24.5 N
(4.4 – 5.5 lb)
Used bearing and New
oil seal
11.8 – 17.7 N
(2.6 – 4.0 lb)
If the measured bearing preload is outside the
specifications, adjust it by loosening or tightening
the hub nut.
411RS011
DRIVE SHAFT SYSTEM
9. Install lock washer and lock screw.
B Turn the side with larger diameter of the tapered
bore to the vehicle outer side, then attach the
washer.
B If the bolt holes in the lock plate are not aligned with
the corresponding holes in the nut, reverse the lock
plate.
B If the bolt holes are still out of alignment, turn in the
nut just enough to obtain alignment.
B Screw is to be fastened tightly so its head may
come lower than the surface of the washer.
411RS012
10. Install cover and gasket then tighten the cover bolt.
Torque: 59 N·m (43 lb ft)
11. Install brake caliper and tighten fixing bolt.
4C–7
4C–8
DRIVE SHAFT SYSTEM
Front Hub and Disc (4WD Model)
Disassembled View
411RW001
Legend
(1) Bolt
(2) Cap
(3) Snap Ring and Shim
(4) Hub Flange
(5) Lock Washer and Lock Screw
(6) Hub Nut
Disassembly
1. Before disassembly, select the 2WD position with the
4WD switch.
2. Jack up the front of vehicle and support frame with
jack attached.
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Outer Bearing
Bolt
Hub and Disc Assembly
Wheel Pin
ABS Sensor Ring
Inner Bearing
Oil Seal
3. Remove the two bolts from the rear side of the
knuckle arm, then remove the brake caliper, with the
brake hose attached.
Use a wire to attach the brake caliper to the upper link.
Refer to Disk Brakes in Brake section.
4. Remove Bolt.
5. Remove cap.
DRIVE SHAFT SYSTEM
6. Remove snap ring and shim.
7. Remove hub flange.
8. Remove lock washer and lock screw.
9. Remove hub nut, using front hub nut wrench
J–36827.
4C–9
16. Remove bolt.
If necessary, replace the wheel pin in the following
manner.
B Scribe mark(1) on the hub to disc before
disassembly to insure proper assembly.
B Clamp the hub and disc assembly in a vise, using
protective pads. Remove the 6 disc–to–hub
retaining bolts.
901RW054
10. Remove hub and disc assembly.
11. Remove ABS sensor ring.
12. Remove outer bearing.
13. Remove oil seal.
14. Remove inner bearing.
15. Use a brass bar to remove the outer bearing outer
race(1), oil seal, inner bearing and inner bearing outer
race(2) from the hub.
411RS003
B Place hub on a suitable work surface and remove
wheel studs, as required, by using a hammer.
411RS004
411RS002
4C–10
DRIVE SHAFT SYSTEM
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
Check the following parts.
B Hub
B Hub bearing, oil seal
B Knuckle spindle
B Disc
B Caliper
B Shift on the fly system parts (Cap, Hub flange, Shim,
Snap ring)
B ABS sensor ring
For inspection and servicing of disc caliper and related
parts, refer to Disc Brakes in Brake section.
2. Align scribe marks(1) and attach the hub to the disc,
then tighten the bolts to the specified torque.
Torque: 103 N·m (76 lb ft)
Reassembly
1. Install wheel pin.
B Place the hub on a wood workbench or a block of
wood approx. 6” by 6” to protect the wheel stud
ends and threads.
B Insert a wheel stud using a hammer.
NOTE: Be sure the wheel stud is started squarely and
seats completely.
411RS003
3. Install inner bearing.
Install the outer race by driving it into the hub by using
insatller J–36829 and grip J–8092.
901RW055
411RS005
DRIVE SHAFT SYSTEM
4. Install outer bearing.
Install the outer race by driving it into the hub by using
install J–36828 and grip J–8092.
4C–11
Grease Amount
Hub
35 g (1.23 oz)
Outer bearing
10 g (0.35 oz)
Inner bearing
15 g (0.53 oz)
901RW056
5. Install oil seal by using installer J–36830 and grip
J–8092.
Apply Multipurpose grease (NLGI No.2 or equivalent)
to the lip portion.
411RS009
Legend
(1) Inner Bearing
(2) Hub
(3) Outer Bearing
8. Install hub nut.
Turn to the place where there is a chamfer in the
tapped hole to the outer side, then attach the nut by
using front hub nut wrench J–36827.
901RW057
6. Install ABS sensor ring, then tighten the bolts to the
specified torque.
Torque: 18 N·m (13 lb ft)
7. Install hub and disc assembly.
B Apply grease in the hub.
B Apply wheel bearing type grease NLGI No. 2 or
equivalent to the outer and inner bearing.
901RW054
4C–12
DRIVE SHAFT SYSTEM
Preload Adjustment
1. Tighten the hub nut to 29 N·m (22 lb ft), then fully
loosen the nut.
2. Tighten the hub nut to the value given below,
using a spring scale on the wheel pin.
New bearing and New
oil seal
19.6 – 24.5 N
(4.4 – 5.5 lb)
Used bearing and New
oil seal
11.8 – 17.7 N
(2.6 – 4.0 lb)
If the measured bearing preload is outside the
specifications, adjust it by loosening or tightening the
hub nut.
411RS012
10. Apply adhesive (LOCTITE 515 or equivalent) to both
joining flange faces then install hub flange.
11. Install snap ring and shim.
B Adjust the clearance between the free wheeling hub
body and the snap ring.
Clearance: 0 mm–0.3 mm (0 in–0.012 in)
Shims Available: 0.2 mm, 0.3 mm, 0.5 mm,
1.0 mm (0.008 in, 0.012 in, 0.020 in, 0.039 in)
411RS011
9. Install lock washer and lock screw.
B Turn the side with larger diameter of the tapered
bore to the vehicle outer side, then attach the
washer.
B If the bolt holes in the lock plate are not aligned with
the corresponding holes in the nut, reverse the lock
plate.
B If the bolt holes are still out of alignment, turn in the
nut just enough to obtain alignment.
B Screw is to be fastened tightly so its head may
come lower than the surface of the washer.
411RW002
12. Install hub cap.
13. Tighten the bolts to the specified torque.
Torque: 59 N·m (43 lb ft)
14. Install brake caliper and tighten fixing bolt.
DRIVE SHAFT SYSTEM
4C–13
Front Drive Shaft Joint
Front Drive Shaft Joints
Replacement
B Refer to Front Drive Axle Assembly Replacement in
this section, and refer to Front Hub and Disc Overhaul
in Suspension section.
Front Hub Bearing Preload Check
Check the hub bearing preload at the wheel pin.
New bearing and New oil seal:
19.6 – 24.5 N (4.4 – 5.5 lb)
Used bearing and New oil seal:
11.8 – 17.7 N(2.6 – 4.0 lb)
411RS011
Inspection Of Shift On The Fly System
Gear Oil
412RY00008
1. Open filler plug and make sure that the oil up to the
plug port.
If the oil is short, replenish with gear oil GL–5 grade.
2. Tighten the filler plug to specified torque.
Torque: 78 N·m (58 lb in)
4C–14
DRIVE SHAFT SYSTEM
Front Axle Drive Shaft
Front Axle Drive Shaft and Associated Parts
412RY00036
Legend
(1) Axle Case and Differential
(2) Snap Ring
(3) Bearing
(4) Snap Ring
(5) Oil Seal
(6) Bracket
(7) DOJ Case
(8) Circlip
(9) Bolt
(10) Drive Shaft Joint Assembly
(11) Ball
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
Snap Ring
Ball Retainer
Ball Guide
Band
Bellows
Band
Band
Bellows
Band
BJ Shaft
Dust Seal
DRIVE SHAFT SYSTEM
Disassembly
NOTE: For the left side, follow the same steps as right
side.
4C–15
4. Remove drive shaft joint assembly.
5. Remove the six balls (1) with a screwdriver or
equivalent.
1. Raise the hooked end of the band with a screwdriver
or equivalent.
412RS012
6. Using snap ring pliers, remove the snap ring (1)
fastening the ball retainer to the center shaft.
412RS009
2. Remove band(1).
3. Pry off circlip (1) with a screwdriver or equivalent.
412RS013
412RS010
4C–16
DRIVE SHAFT SYSTEM
7. Remove ball retainer, ball guide and bellows.
8. Raise the hooked end of the band with a screwdriver
or equivalent.
Bushing Replacement
B Remove the bushings using a remover J–39378–1
and hammer.
412RS014
9. Remove band(1).
10. Remove bellows.
11. Remove dust seal.
12. Remove BJ shaft assembly.
13. Remove the mounting bracket fixing bolts, and then
remove DOJ case assembly from the axle case.
14. Remove snap ring and bearing.
15. Remove snap ring and oil seal.
16. Remove bracket.
412RS015
B By using installer J–39378–2 and base J–39378–3,
press fit the bushings into the bracket.
Inspection And Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
Check the following parts.
1. Drive shaft joint assembly
2. DOJ case, ball, ball guide, ball retainer
3. Bellows
4. Bearing
5. Dust seal, oil seal
412RS016
DRIVE SHAFT SYSTEM
4C–17
Reassembly
1. Install DOJ case to bracket.
2. Install oil seal and fix snap ring.
3. Install bearing and fix snap ring.
4. Install bracket to axle case. Tighten the bracket bolt to
the specified torque.
Torque: 116 N·m (85 lb ft)
5. Apply 150g of the specified grease in BJ.
6. Install dust seal.
7. Apply a thin coat of grease to the shaft for smooth
installation then install bellows.
8. Install band. Note the setting direction.
After
installation, check that the bellows is free from
distortion.
412RS013
13. Align the track on the ball (1) retainer with the window
in the cage, and install the six balls into position.
412RS017
9. Install another bellows and fix band.
10. Install the ball guide with the smaller diameter side
ahead onto the shaft.
11. Install ball retainer.
12. Using snap ring pliers, install the snap ring (1)
securing the ball retainer to the shaft.
412RS018
14. Pack 150g of the specified grease in DOJ case, then
install drive shaft joint assembly. After reassembly,
move the DOJ longitudinally several times to get to fit.
4C–18
DRIVE SHAFT SYSTEM
15. Install the circlip (1) so that open ends are positioned
away from the ball groove.
16. Install bellows. Adjust the air pressure within the
bellows by inserting a screwdriver or equivalent, so
that it equals atmospheric pressure.
412RS019
412RS021
17. Install band. After installation, check that the bellows
is free from distortion.
412RS020
Legend
(1) Outer Case
(2) Circlip
(3) Open Ends
DRIVE SHAFT SYSTEM
4C–19
Shift On The Fly System
Shift On The Fly System and Associated Parts
412RY00007
Legend
(1) Filler Plug
(2) Bolt
(3) Oil Seal
(4) Snap Ring(External)
(5) Inner Shaft Bearing
(6) Snap Ring(Internal)
(7) Inner Shaft
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Needle Bearing
Clutch Gear
Sleeve
Housing
Front Axle Drive Shaft(LH side) with Bracket
Bolt
Actuator Assembly
Bolt
4C–20
DRIVE SHAFT SYSTEM
10. Remove inner shaft bearing.
Disassembly
1. Remove filler plug and gasket, drain oil.
2. Loosen mounting bracket fitting bolts and remove
front axle drive shaft from front axle case.
3. Remove actuator assembly and draw out actuator
ASM.
4. Remove housing.
5. Remove sleeve.
6. Remove clutch gear.
7. Remove snap ring from front axle case by using snap
ring pliers.
NOTE: Be careful not to damage the shaft.
412RW015
11. Remove needle bearing from inner shaft by using a
remover J–26941 and sliding hammer J–2619–01.
412RW017
8. Take out inner shaft from front axle case.
9. Remove snap ring from inner shaft by using snap ring
pliers.
412RS045
12. Remove oil seal from front axle case.
NOTE: Be careful not to damage the front axle case.
412RW016
DRIVE SHAFT SYSTEM
4C–21
Inspection And Repair
Inner Shaft Run–Out
Inspect the removed parts. If there are abnormalities
such as wear and damage, take corrective action or
replace.
With both end centers supported, rotate the shaft slowly
and measure deflection with a dial gauge.
Limit: 0.5 mm (0.02 in)
Visual Check
NOTE: Do not heat the shaft to correct its bend.
1. Check and see if the inner shaft has such
abnormalities as wear and damage.
412RS026
412RW014
Inner Shaft Bearing
2. Replace the shaft if any signs of deterioration in the
gear is present.
412RW006
420RS008
Legend
(1) Inner Shaft Bearing
(2) Inner Shaft
(3) Clutch Gear
1. Inspect the inner shaft bearing for any signs of
deterioration, replace if uneven.
2. Insert the clutch gear and inspect the needle bearing.
3. Replace the needle bearing if found to be uneven.
4C–22
DRIVE SHAFT SYSTEM
Sleeve Condition
Clutch Gear Condition
Check and see that there is not wear damage, or cracking
in the sleeve.
Check for wear, damage, crack or any other deterioration
in the clutch gear.
NOTE: Close inspection of the groove and inner gear are
required because those are important parts.
Clutch Gear Function
Sleeve Function
412RY00038
Test the sleeve for smoothness by sliding it across the
clutch gear, replace the clutch gear if its difficult to slide.
412RY00039
Test the sleeve for smoothness by sliding it between the
inner shaft and the clutch gear, replace the sleeve if its
difficult to slide.
NOTE: Gear oil should be applied to the contact surface
of gear.
Check the width of sleeve center groove.
Limit: 7.1 mm (0.28 in)
NOTE: When inspecting, gear oil should be applied to the
contact surface of gear.
Clutch Gear Journal Diameter
Make sure of the size illustrated.
Limit: 36.98 mm (1.456 in)
412RY00037
412RW022
DRIVE SHAFT SYSTEM
4C–23
NOTE: Be careful not to permit the entry of water or dust
into of the actuator.
Actuator
Check for damage, cracking or other abnormality.
Dimentional Check
Measure illustrated sizes 1, 2, and 3.
Functional Check
412RY00041
412RY00010
Limit
1=64.3 mm (2.53 in)
2=6.7 mm (0.26 in)
3=6.7 mm (0.26 in)
Reassembly
1. Install the new oil seal which has been immersed in
differential gear oil, by using an oil seal installer
J–41693 and grip J–8092.
412RY00009
Verify functionality by applying voltage (12V) to terminals
3 and 4 and set the tester to terminal 1 and 2 according to
the table bellow.
State
Trminal 3
Trminal 4
Electric
circuit
between
terminal
1&2
A
+12V
Ground
OK
2WD
B
Ground
+12V
NONE
4WD
Functio
n
If there is an abnormality, replace the actuator as an
assembly.
412RW034
4C–24
DRIVE SHAFT SYSTEM
2. Install a new needle bearing into inner shaft by using a
Installer J–41694 and grip J–8092.
NOTE: Be sure to install the snap ring properly.
412RW017
412RS051
3. Place a new snap ring(internal) in inner shaft.
Install a new inner shaft bearing into the inner shaft.
7. Apply differential gear oil to clutch gear, then install
clutch gear.
8. Apply differential gear oil to sleeve, then install
sleeve.
9. Clean contact surface with the front axle and actuator
mounting surface. Apply liquid gasket to the contact
surface on the front axle case, then install in the
housing.
412RS044
4. Install snap ring(external).
NOTE: Be careful not to damage the inner shaft.
5. Clean the housing contact surface of the front axle
case and insert inner shaft assembly into the front
axle case.
NOTE: Be careful not to damage seal.
6. Install snap ring internal in the groove of front axle
case.
412RW023
10. Tighten bolts to specified torque.
Torque: 75N·m(55 lb ft)
11. Clean the actuator contact surface with the housing
then Install and tighten shift position switch to
specified torque.
Torque: 39N·m (29 lb ft)
DRIVE SHAFT SYSTEM
12. Apply liquid gasket to the contact surface on the
actuator side.
412RW012
13. Align shift arm with the groove of sleeve and install the
actuator.
14. Tighten bolts to specified torque.
Torque: 9N·m(78 lb in)
15. Install front axle drive shaft and mounting bracket.
Tighten fitting bolts to specified torque.
Torque: 116N·m (85 lb ft)
16. Pour specified amount of differential gear oil to filler
plug.
Front Differential
Oil Capacity: 1.4lit (1.48US qt)
Actuator Housing
Oil Capacity: 0.12lit(0.13US qt)
17. Install filler plug through gasket and tighten to
specified torque.
Torque: 78N·m (58lb ft)
4C–25
4C–26
DRIVE SHAFT SYSTEM
Main Data and Specifications
General Specifications
Front drive axle oil capacity
1.25 liter (1.32 US qt)(Differential)
0.12 liter (0.13 US qt)(Actuator Housing:Shift on the fly)
Type of lubricant
Axle shaft type
GL–5 (75W–90) Refer to chart in General Information
Constant velocity joint(Birfield joint type and double offset joint)
Torque Specifications
412RY00040
DRIVE SHAFT SYSTEM
4C–27
E04RW001
4C–28
DRIVE SHAFT SYSTEM
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION
TOOL NO.
TOOL NAME
J–39378
Remover and Installer;
Front Axle mount
bushing
J–36827
Wrench; Hub nut
J– 26941
Remover; Bearing
needle
J–36829
Installer; Inner bearing
J–2619–01
Hammer; Sliding
J–36828
Installer; Outer bearing
J–41693
Installer; Oil seal
J–36830
Installer; Oil seal
J–41694
Installer; Bearing needle
J–8092
Grip
DRIVE SHAFT SYSTEM
4C–29
Propeller Shaft
General Description
401R200001
Legend
(1) Front Propeller Shaft
(2) Rear Propeller Shaft;
Aluminum Tube with Flange Yoke Type (for
4×2 model)
(3) Rear Propeller Shaft;
Steel Tube Type (for 4×4 model)
Torque is transmitted from the transmission to the axle
through the propeller shaft and universal joint assembles.
All propeller shafts are the balanced tubular type. A
splined slip joint is provided in some drivelines.
B Since the propeller shaft is balanced carefully,
welding or any other modification is not permitted.
B Alignment marks should be applied to each propeller
shaft before removal.
B Park, turn the engine off and apply the parking brake
to secure the vehicle.
B Carefully attach the propeller shaft to the vise, do not
overtighten the vise when securing the propeller
shaft, this may cause deformation.
4C–30
DRIVE SHAFT SYSTEM
Front Propeller Shaft
General Description
Since the propeller shaft is balanced carefully, welding or
any other modifications are not permitted.
Alignment marks should be applied to each propeller
shaft before removal.
401R200004
DRIVE SHAFT SYSTEM
4C–31
Front Propeller Shaft and Associated Parts
401R200006
Legend
(1) Bolt, and Washer (Front Axle Side)
(2) Front Propeller Shaft (with TOD)
(3) Bolt and Washer (Transfer Side)
(4) BJ Constant Velocity Joint
(5) LJ Constant Velocity Joint
Removal
1. Jack up the vehicle and support it on the chassis
stands.
2. Gear shift lever should be placed in neutral position
and parking brake released.
3. Remove the exhaust and transfer protectors.
NOTE: Apply alignment marks on the flange at the front
propeller shaft both front and rear side.
401RS020
4C–32
DRIVE SHAFT SYSTEM
401RW053
401RW051
Installation
NOTE: Never install the shaft assembly backwards.
Completely remove the black paint from the connecting
surface of flange coupling on each end of propeller shaft.
Clean so that no foreign matter will be caught in between.
1. Align the mark which was applied at removal. Install
front propeller shaft and tighten the bolts to the
specified torque.
Torque: 63 N·m (46 lb ft)
2. Install the exhaust and transfer protectors.
Constant Velocity Joint
NOTE: LJ and BJ constant velocity joints are
unremovable types. Check the joint for play and the boot
for damage, wear, and leak of grease. If abnormality is
found, replace propeller shaft as an assembly.
401RW052
4. Remove bolt, nut and washer (Front axle side).
5. Remove bolt, nut and washer (Transfer side).
6. Remove front propeller shaft.
NOTE: When removing, installing or carring the front
propeller shaft, be sure to wrap a piece of cloth around the
part of the boot with which fittings may interfere so that the
boot can be protected. The boot may be damaged if
bending force is applied to the constant velocity joint of
the shaft.
DRIVE SHAFT SYSTEM
4C–33
Play in Constant Velocity Joint
Boot of Constant Velocity Joint
Position the shaft in a vise between two pieces of wood,
then secure.
Test for shaft movement by attempting to move back and
forth, and side to side.
Secure as needed.
Check the following: boot (2) for crack, damage and
grease leakage, the boot band (1) for looseness and
damage, and both sides of the joint for gease leakage
coming from the cover press-in parts (3).
401RW048
401RW050
401RW047
401RW049
4C–34
DRIVE SHAFT SYSTEM
Front Axle Flange Run-out
1. Set a dial gage at right angle near the outer
circumference of the flange face and check the
run-out of the flange face.
3. If vibration is felt during the 4H AUTO drive, disconnct
the propeller shaft at the front axle. Reinstall the
propeller shaft at 60°, 120°, 180°, 240°, and 300°
and conduct test drive in each position and check if
there is vibration.
Limit: 0.15 mm (0.006 in)
401RW044
401RW046
2. Set a dial gage at right angle near the inner
circumference and check the run-out of the flange.
Limit: 0.15 mm (0.006 in)
401RW045
DRIVE SHAFT SYSTEM
4C–35
Main Data and Specifications
General Specifications
Engine
6VE1(3.5 L)
Transmission
A/T with TOD
Construction
Hollow steel tube with constant velocty joints.
Outside diameter
40.0 mm (1.57 in)
Length
597 mm (23.50 in)
Torque Specifications
401R200005
4C–36
DRIVE SHAFT SYSTEM
Rear Propeller Shaft
Rear Propeller Shaft and Associated Parts
401R200002
Legend
(1) Bolt, Nut and Washer (Transfer Side)
Removal
1. Raise the vehicle on a hoist.
NOTE: Apply alignment marks on the flange at the rear
propeller shaft both front and rear side.
2. Remove transfer side bolt, nut and washer (except
spline yoke type).
3. Remove rear axle side bolt, nut and washer.
4. Remove rear propeller shaft.
NOTE: Plug the hole of the transmission rear end to
prevent oil leakage (spline yoke type only).
(2) Rear Propeller Shaft
(3) Bolt, Nut and Washer (Rear Axle Side)
Installation
NOTE: Never install the shaft assembly backwards.
Never insert bar between yoke lugs when tightening or removing bolts.
Completely remove the dust or foreign matter from the
connecting surface of flange coupling on each end of the
propeller shaft.
1. Align the mark which is applied at removal.
2. Install rear propeller shaft and tighten the bolts to the
specified torque.
Torque: 63 N·m(46 lb ft)
DRIVE SHAFT SYSTEM
4C–37
Slip Joint Disassembly
401RX00001
Legend
(1) Spline Yoke and Universal Joint Assembly
(2) Clamp
1. Lay the shaft horizontally on a bench and secure.
2. Indicate the original assembled position by marking
the phasing of the shaft prior to disassembly.
3. Using the flat blade of a screwdriver, pry the loose end
of the boot clamp upwards and away from the
propeller shaft boot. Be careful not to damage the
boot.
(3) Boot
(4) Clamp
(5) Tube and Universal Joint Assembly
4. When boot clamps becomes loose, remove by hand.
5. Repeat for the other boot clamp.
6. Remove the slip yoke assembly from the driveshaft,
by securing the boot with one hand and pulling on the
slip yoke.
7. Remove the boot from the shaft assembly.
4C–38
DRIVE SHAFT SYSTEM
Universal Joint Disassembly
401RX00007
Legend
(1) Spline Yoke
(2) Spider
(3) Propeller Shaft Assembly
(4) Spider
NOTE: Aluminum is softer than steel. Care must be
taken not to remove excessive material or damage
bearing holes.
If the vehicle has aluminum tube type propeller shaft,
flange yoke, boot kit, journal kit can be replaced. If other
parts are damaged, replace propeller shaft assembly.
(5)
(6)
(7)
(8)
Flange Yoke
Bearing
Snap Ring
Flange Yoke
DRIVE SHAFT SYSTEM
1. Apply alignment marks on the yokes of the universal
joint, then remove the snap ring.
4C–39
2. Set the yoke in the arbor press with a piece of tube
stock beneath it.
Place a solid plug on the upper bearing and press it
through to release the lower bearing.
401RW024
If the snap ring is stuck in position, remove paint from
the hole in the yoke or tap around the edge of the
bearing lightly with a soft drift.
401RW027
3. If the bearing will not pull out by hand after pressing,
tap the base of the lug near the bearing to dislodge it.
4. To remove the opposite bearing, turn the yoke over
and straighten the spider in the open spider hole.
Then carefully press on the end of the spider so the
remaining bearing moves straight out of the bearing
spider hole. If the spider or bearing are cocked, the
bearing will score the walls of the spider hole and ruin
it.
401RW025
401RW026
4C–40
DRIVE SHAFT SYSTEM
5. Repeat this procedure on the remaining bearing to
remove the spider from the yoke.
Inspection
B Propeller shaft for run-out Aluminum tube type.
Static run-out limit : 1.0 mm(0.04 in)
TIR full length of tubing maximum.
(TIR : Total Indicator Reading)
B Propeller shaft for runout (Steel tube type).
Static runout limit : 0.13 mm(0.005 in)
TIR on the neck of the slip tube shaft (with a
boot).
0.25 mm(0.010 in)
TIR on the ends of the tubing 3 inch from the
welds.
401RW028
B Preload of the universal joint.
Preload should be 0 to 49 N (0 to 11.0 lb).
Joints should rotate smoothly and freely and should
exhibit no rough or ratchety movement.
0.38 mm(0.015 in)
TIR at the linear center of the tube.
0.38 mm(0.015 in)
TIR for the full length of tube with 30” or less of
tubing.
(TIR: Total Indicator Reading)
401RW019
401RW017
B Play in universal joint.
Limit: Less than 0.15 mm(0.006 in)
B Spider pin should be smooth and free from fretting or
galling.
Visible signs of needle presence is normal, but wear
should not be felt.
B Inspect splines of slip joint for wear.
The nylon-coated spline should be free from nicks
and dings and the underlying steel spline should not
be visible.
After cleaning the nylon coating spline, the coating
should exhibit only slight indication of wear.
Grease volume is approximately 10 grams of grease
in total. Grease should be evenly applied to both the
female and the male slip splines using a small brush.
After assembly of the slip joint, the sliding joint should
be fully worked from the full collapsed to the full
extended position.
DRIVE SHAFT SYSTEM
B Aluminum tube type only: Inspect the aluminum
tubing for surface scratches and dents. These
scratches may not exceed 0.2 mm (0.008 in) in depth.
4C–41
Universal Joint Reassembly
1. Pack the four grease cavities of the spider with a high
quality, extreme pressure N.L.G.I. Grade 2 grease.
Do not add additional grease to bearing cup
assembly.
2. Move one end of the spider to cause a trunnion to
project through the spider hole beyond the outer
machined face of the yoke lug. Place a bearing over
the trunnion diameter and align it to the spider hole.
Using an arbor press, hold the trunnion in alignment
with the spider hole and place a solid plug on the
upper bearing. Press the bearing into the spider hole
enough to install a snap ring.
401RW022
B Aluminum tube type only: Visually inspect the circle
welds and fittings for any signs of cracks or signs of
deterioration. If there are any cracks that exceed 0.2
mm (0.008 in) in depth, the assembly must be
replaced.
B Aluminum tube type only: Check to be sure there are
no missing balance weights. If balance weights are
missing and void has occurred in the aluminum tubing
greater than 0.2 mm (0.008 in), the assembly must be
replaced.
401RW026
3. Install a snap ring.
NOTE: Be sure the snap rings are properly seated in the
grooves.
4. Repeat steps 2 and 3 to install the opposite bearing. If
the joint is stiff, strike the yoke ears with a soft
hammer to seat the bearing.
5. Align the setting marks and join the yokes.
4C–42
DRIVE SHAFT SYSTEM
Slip Joint Reassembly
401RX00001
Legend
(1) Spline Yoke and Universal Joint Assembly
(2) Clamp
1. Apply grease evenly to both the female and male
splines.
2. Apply a small amount of grease by finger to the outer
lips of the boot.
3. Slide the boot (smaller diameter side) onto the spline
yoke shaft being careful not to damage the spline
coating or boot.
4. Insert the spline yoke shaft spline into the tube
assembly being careful to maintain proper phasing.
The spider holes should be in line as originally marked
prior to disassembly.
5. Position boot onto tube and yoke shaft in its
assembled position.
6. Attach boot clamps and secure using pliers.
(3) Boot
(4) Clamp
(5) Tube and Universal Joint Assembly
7. Be sure clamp is properly seated and secure.
CAUTION: Only use a similar type or same as the
original type clamp. Using any other clamp may
create an imbalanced shaft or lead to grease leakage.
DRIVE SHAFT SYSTEM
4C–43
Main Data and Specifications
General Specifications
Engine
Transmission
Type (See illustration)
Length
between two spiders center)
Universal joint type
2WD Model
4WD Model
6VD1
6VD1
A/T
A/T
1
2
1323.0mm
(52.09in)
1030.0mm
(40.55in)
Cardan type
Torque Specifications
401R200007
4C–44
DRIVE SHAFT SYSTEM
AXIOM (Vehicles Produced After Aug./1/2001)
DRIVE SHAFT SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . .
General Description . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Hub and Disc (2WD Model) . . . . . . . . .
Disassembled View . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Hub and Disc (4WD Model) . . . . . . . . .
Disassembled View . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Drive Shaft Joint . . . . . . . . . . . . . . . . . . .
Front Drive Shaft Joints Replacement . . . .
Front Axle Drive Shaft . . . . . . . . . . . . . . . . . . .
Front Axle Drive Shaft and Associated
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair . . . . . . . . . . . . . . . . . .
Bushing Replacement . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift On The Fly System . . . . . . . . . . . . . . . . .
Shift On The Fly System and Associated
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
4C–44
4C–45
4C–45
4C–46
4C–46
4C–46
4C–47
4C–48
4C–49
4C–49
4C–49
4C–50
4C–51
4C–52
4C–52
4C–53
4C–53
4C–54
4C–55
4C–55
4C–55
4C–59
4C–59
4C–59
4C–61
4C–63
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.
Main Data and Specifications . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . . .
General Description . . . . . . . . . . . . . . . . . . . . .
Universal Joint . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis of Propeller Shaft and Universal
Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Propeller Shaft . . . . . . . . . . . . . . . . . . . . .
Front Propeller Shaft and Associated Parts
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Universal Joint Disassembly . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Universal Joint Reassembly . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications . . . . . . . . . . . . .
Rear Propeller Shaft . . . . . . . . . . . . . . . . . . . . .
Rear Propeller Shaft and Associated Parts
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Slip Joint Disassembly . . . . . . . . . . . . . . . . .
Universal Joint Disassembly . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Universal Joint Reassembly . . . . . . . . . . . . .
Slip Joint Reassembly . . . . . . . . . . . . . . . . . .
Main Data and Specifications . . . . . . . . . . .
4C–66
4C–68
4C–69
4C–69
4C–70
4C–71
4C–72
4C–72
4C–72
4C–72
4C–73
4C–74
4C–75
4C–76
4C–77
4C–78
4C–79
4C–79
4C–79
4C–79
4C–80
4C–81
4C–83
4C–84
4C–85
4C–86
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED , do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
DRIVE SHAFT SYSTEM
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.
4C–45
The drive axles are completely flexible assemblies,
consisting of inner and outer constant velocity (CV) drive
shaft joints connected by an axle shaft.
For description of front propeller shaft and universal joint,
refer to Front Propeller Shaft in this section.
Diagnosis
Condition
Possible cause
Oil Leak At Front Axle
Correction
Worn or defective oil seal.
Replace the oil seal.
Front axle housing cracked.
Repair or replace.
Too much gear oil.
Correct the oil level.
Oil seal worn or defective.
Replace the oil seal.
Pinion flange loose or damaged.
Tighten or replace.
Noises In Front Axle Drive Shaft
Joint
Broken or worn drive shaft joints and
bellows (BJ and DOJ).
Replace the drive shaft joints and
bellows.
“Clank” When Accelerating From
“Coast”
Loose drive shaft joint to output shaft
bolts.
Tighten.
Damaged inner drive shaft joint.
Replace.
Excessive drive shaft joint angle.
Repair.
Worn or damaged drive shaft joints.
Replace.
Sticking spider assembly (inner drive
shaft joint).
Lubricate or replace.
Sticking joint assembly (outer drive
shaft joint).
Lubricate or replace.
Out of balance or out of round tires.
Balance or replace.
Front end out of alignment.
Align.
Insufficient gear oil.
Replenish the gear oil.
Wrong or poor grade gear oil.
Replace the gear oil.
Drive pinion to ring gear backlash
incorrect.
Adjust the backlash.
Worn or chipped ring gear, pinion
gear or side gear.
Replace the ring gear, pinion gear or
side gear.
Pinion shaft bearing worn.
Replace the pinion shaft bearing.
Hub unit bearing worn.
Replace the hub unit bearing.
Differential bearing loose or worn.
Tighten or replace.
Incorrect front alignment.
Adjust the front alignment.
Steering unit loose or worn.
Tighten or replace.
Tire worn or improperly inflated.
Adjust the inflation or replace.
Front or rear suspension parts loose
or broken.
Tighten or replace.
Hub unit bearing worn.
Replace.
Incorrect front alignment.
Adjust the front alignment.
Worn ball joint or bush.
Replace the ball joint or bush.
Steering unit loose or worn.
Tighten or replace.
Tire worn or improperly inflated.
Replace or adjust the inflation.
Shock absorber worn.
Replace the shock absorber.
Oil Leak At Pinion Shaft
Shudder or
Acceleration
Vibration
Vibration At Highway Speeds
Noises in Front Axle
Wanders and Pulls
Front Wheel Shimmy
During
4C–46
DRIVE SHAFT SYSTEM
Front Hub and Disc (2WD Model)
Disassembled View
411R200011
Legend
(1) Disc Rotor
(2) Hub unit, Bearing
(3) Wheel Pin
(4) Bolt
Disassembly
1. Raise the vehicle with a jack. Support the frame with
chassis stands.
2. Remove the brake caliper from the bracket. Secure
the caliper with a wire so that it does not interfere with
the work process.
Refer to Front disc caliper assembly in Section 5C of this
Manual.
3. Remove the disk rotor
Apply penetrating oil to the bearing and disc rotor contact
surfaces if the surfaces are stuck together because of
rust.
4. Inspect the hub unit bearing. Refer to Inspection
below.
5. Use a dial gauge to measure the bearing axial rattle.
Bearing axial rattle: 0.05 mm max
411R200002
DRIVE SHAFT SYSTEM
If abnormal conditions are discovered during
inspection, go to Step 6. If there are no abnormal
conditions, reassemble the front disc rotor and
caliper.
4C–47
10. If necessary, replace the wheel pin in the following
manner.
B Place hub on a suitable work surface and remove
wheel studs, as required, using a hammer.
NOTE: Hub, wheel bearing and spindle is integrated to
the hub unit bearing so it must not be disassembled. If it
has abnormal rattle or noise, replace the hub unit bearing.
6. Remove the ABS sensor connector.
411RS004
Inspection
411R200004
Legend
(1) ABS Sensor Connector
(2) Bolt
7. Remove the 4 bolts fixing the hub unit bearing to the
knuckle.
Apply penetrating oil to the bearing and knuckle contact
surfaces if the surfaces are stuck together because of
rust.
8. Temporarily install long bolts to 2 of the fixing bolt
holes (the bolts must have the same diameter and
thread width).
9. Strike the long bolts with a hammer to loosen and
remove the hub unit bearing from the knuckle.
Take care not to drop the bearing.
Inspect the parts listed below for abrasion, breakage, and
other abnormal conditions.
Repair, or replace the parts as required.
B Disc
B Caliper
B Wheel pin
B Hub unit bearing
4C–48
DRIVE SHAFT SYSTEM
Reassembly
1. Install wheel pin.
411RS005
B Place hub on a wood workbench or a block of wood
approx. 6” by 6” to protect the wheel stud ends and
threads.
B Install wheel stud, using a hammer.
NOTE: Be sure wheel stud is started squarely and seats
completely.
2. Install the hub unit bearing to the knuckle.
Tighten the bolts to the specified torque.
Hub unit bearing bolt
Torque: 103±10 N·m (10.5 ± 1 kg·m)
If there is rust on the bearing and knuckle contact
surfaces, use sandpaper to remove it before installation.
3. Install the ABS sensor connector.
4. Install the disc rotor.
5. Install the brake caliper to the bracket.
Refer to Front disc caliper assembly in Section 5C of this
Manual.
DRIVE SHAFT SYSTEM
4C–49
Front Hub and Disc (4WD Model)
Disassembled View
411R200010
Legend
(1) Disc Rotor
(2) Hub Unit, Bearing
Disassembly
1. Move the transfer case lever to the 2WD position.
2. Raise the vehicle with a jack. Support the frame with
chassis stands.
3. Remove the brake caliper from the bracket. Secure
the caliper with a wire that it does not interfare with the
work process.
(3) Wheel Pin
(4) ABS Sensor Ring
(5) Bolt
Refer to Front disc caliper assembly in Section 5C of this
Manual.
4. Remove the disk rotor.
Apply penetrating oil to the bearing and disc rotor contact
surfaces if the surfaces are stuck together because of
rust.
5. Inspect the hub unit bearing. Refer to inspection
below.
4C–50
DRIVE SHAFT SYSTEM
6. Use a dial gauge to measure the bearing axial rattle.
Bearing axial rattle: 0.05 mm max
Legend
(1) Bolt
11. Strike the long bolts with a hammer to loosen and
remove the hub unit bearing from the knuckle.
B Take care not to strike the front drive shaft.
B Take care not to drop the bearing.
12. Remove the ABS rotor sensor from the bearing.
13. If necessary, replace the wheel pin in the following
manner.
B Place hub on a suitable work surface and remove
wheel studs, as required, using a hammer.
411R200002
If abnormal conditins are discovered during
inspection, go to Step 7. If there are no abnormal
conditions, reassemble the front discrotor and
caliper.
NOTE: Hub, wheel bearing and spindle is integrated to
the hub unit bearing so it must not be disassembled. If it
has abnormal rattle or noize, replace the hub unit bearing.
7. Loosen the caulking around the front drive shaft nuts.
8. Remove the nuts and discard them (they cannot be
reused).
9. Remove the 4 bolts fixing the hub unit bearing to the
knuckle.
Apply penetrating oil to the bearing and knuckle contact
surfaces if the surfaces are stuck together because of
rust.
10. Temporarily install long bolts to 2 of the fixing bolt
holes (the bolts must have the same diameter and
thread width).
411R200012
411RS004
Inspection
Inspect the parts listed below for abrasion, breakage, and
other abnormal conditions.
Repair or replace the parts as required.
B Disc
B Caliper
B Drive shaft oil seal
B ABS sensor rotor
B Wheel pin
B Hub unit bearing
DRIVE SHAFT SYSTEM
4C–51
7. Tighten the front drive shaft nuts to the specified
torque.
Reassembly
1. Install the wheel pin.
B Place hub on a wood workbench or a block of wood
approx. 6” by 6” to protect the wheel stud ends and
threads.
Front drive shaft nut
Torque: 245±19.6 N·m (25±2 kg·m)
B Install the wheel stud, using a hammer.
NOTE: Be sure wheel stud is started squarely and seats
completely.
411R200005
8. Caulk the front drive shaft nuts.
The caulking must be free of cracks.
411RS005
2. Install the ABS rotor sensor to the hub unit bearing.
Tighten the bolts to the specified torque.
ABS rotor sensor bolt
Torque: 18.7±5 N·m (1.9±0.5 kg·m)
3. Install the hub unit bearing to the knuckle. Tighten the
bolts to the specified torque.
Hub unit bearing bolt
Torque: 103±10 N·m (10.5±1 kg·m)
If there is rust on the bearing and knuckle contact
surfaces, use sandpaper to remove it before installation.
Take care not to push the front drive shaft and oil seal out
of position.
4. Hand tighten the front drive shaft nuts.
Use new nuts.
5. Install the disc rotor.
6. Install the brake caliper to the bracket.
Refer to Front disc caliper assembly in Section 5C of this
Manual.
411R200006
4C–52
DRIVE SHAFT SYSTEM
Front Drive Shaft Joint
Front Drive Shaft Joints
Replacement
B Refer to Front Drive Axle Assembly Replacement in
this section, and refer to Front Hub and Disc Overhaul
in Suspension section.
Front Hub Bearing Preload Check
Check the hub bearing preload at the wheel pin.
New bearing and New oil seal:
24.5 N (4.4 – 5.5 lb)
Used bearing and New oil seal:
11.8– 17.7 N(2.6 – 4.0 lb)
Inspection Of Shift On The Fly System
Gear Oil
412RY00008
1. Open filler plug and make sure that the oil is up to the
plug port.
If the oil is short, replenish with gear oil GL–5 grade.
2. Tighten the filler plug to the specified torque.
Torque: 78 N·m (58 lb in)
DRIVE SHAFT SYSTEM
4C–53
Front Axle Drive Shaft
Front Axle Drive Shaft and Associated Parts
412R200009
Legend
(1) Axle Case and Differential
(2) Snap Ring
(3) Bearing
(4) Snap Ring
(5) Oil Seal
(6) Bracket
(7) DOJ Case
(8) Circlip
(9) Bolt
(10) Drive Shaft Joint Assembly
(11) Ball
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
Snap Ring
Ball Retainer
Ball Guide
Band
Bellows
Band
Band
Bellows
Band
BJ Shaft
Dust Seal
4C–54
DRIVE SHAFT SYSTEM
Disassembly
NOTE: For the left side, follow the same steps as right
side.
4. Remove drive shaft joint assembly.
5. Remove the six balls (1) with a screwdriver or
equivalent.
1. Raise the hooked end of the band with a screwdriver
or equivalent.
412RS012
6. Using snap ring pliers, remove the snap ring (1)
fastening the ball retainer to the center shaft.
412RS009
2. Remove band(1).
3. Pry off circlip (1) with a screwdriver or equivalent.
412RS013
7. Remove ball retainer, ball guide and bellows.
412RS010
DRIVE SHAFT SYSTEM
8. Use a hammer and chisel to remove the 3 pawls
(above the large and small boot bands on the BJ
side).
CAUTION: Take care not to damage the bellows
during band removal.
4C–55
Bushing Replacement
B Remove the bushings using a remover J–39378–1
and hammer.
412RS015
412R100009
9. Remove band(1).
10. Remove bellows.
11. Remove dust seal from BJ.
12. Remove BJ shaft assembly.
13. Remove the mounting bracket fixing bolts, and then
remove DOJ case assembly from the axle case.
14. Remove snap ring and bearing.
15. Remove snap ring and oil seal.
16. Remove bracket.
B By using installer J–39378–2 and base J–39378–3,
press fit the bushings into the bracket.
Inspection And Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
Check the following parts.
1. Drive shaft joint assembly
2. DOJ case, ball, ball guide, ball retainer
3. Bellows
4. Bearing
5. Dust seal, oil seal
412RS016
Reassembly
1. Install DOJ case to bracket.
2. Install oil seal and fix snap ring.
3. Install bearing and fix snap ring.
4. Install bracket to axle case. Tighten the bracket bolt to
the specified torque.
Torque: 116 N·m (85 lb ft)
5. Apply 150g of the specified grease in BJ.
6. Install dust seal for BJ.
7. Apply a thin coat of grease to the shaft for smooth
installation then install bellows.
4C–56
DRIVE SHAFT SYSTEM
CAUTION: During bellows assembly, be sure to
insert both ends of the bellows into the BJ ASM and
shaft grooves.
8. Install band. Note the setting direction.
After
installation, check Standard Caulk Measure.Use the
special tool pliers J–35910 to caulk the bands to the
specified value.
412R100007
Legend
(1) Bellows
(2) Shaft
412R100012
Standard Caulk Measure
B 1.2mm (0.05in) <= (1) and (2) <= 4.0mm (0.16in)
B (1) – (2) or (2) – (1) <= 0.4mm (0.016in)
9. Install another bellows and fix band.
10. Install band. Note the setting direction.
After
installation, check that the bellows is free from
distortion. (DOJ SIDE ONLY)
412R100013
Legend
(1) BJ ASM
(2) Bellows
412RS017
11. Install another bellows and fix band.
12. Install the ball guide with the smaller diameter side
ahead onto the shaft.
DRIVE SHAFT SYSTEM
13. Install ball retainer.
14. Using snap ring pliers, install the snap ring (1)
securing the ball retainer to the shaft.
4C–57
17. Install the circlip (1) so that open ends are positioned
away from the ball groove.
412RS019
412RS013
15. Align the track on the ball (1) retainer with the window
in the cage, and install the six balls into position.
412RS020
412RS018
16. Pack 150g of the specified grease in DOJ case, then
install drive shaft joint assembly. After reassembly,
move the DOJ longitudinally several times to get to fit.
Legend
(1) Outer Case
(2) Circlip
(3) Open Ends
4C–58
DRIVE SHAFT SYSTEM
18. Install bellows. Adjust the air pressure within the
bellows by inserting a screwdriver or equivalent, so
that it equals atmospheric pressure.
412RS021
19. Install band. After installation, check that the bellows
is free from distortion.
DRIVE SHAFT SYSTEM
4C–59
Shift On The Fly System
Shift On The Fly System and Associated Parts
412RY00007
Legend
(1) Filler Plug
(2) Bolt
(3) Oil Seal
(4) Snap Ring(External)
(5) Inner Shaft Bearing
(6) Snap Ring(Internal)
(7) Inner Shaft
Disassembly
1. Remove filler plug and gasket, drain oil.
2. Loosen mounting bracket fitting bolts and remove
front axle drive shaft from front axle case.
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Needle Bearing
Clutch Gear
Sleeve
Housing
Front Axle Drive Shaft(LH side) with Bracket
Bolt
Actuator Assembly
Bolt
3. Remove actuator assembly and draw out actuator
ASM.
4. Remove housing.
5. Remove sleeve.
6. Remove clutch gear.
4C–60
DRIVE SHAFT SYSTEM
7. Remove snap ring from front axle case by using snap
ring pliers.
10. Remove inner shaft bearing.
NOTE: Be careful not to damage the shaft.
412RW017
8. Take out inner shaft from front axle case.
9. Remove snap ring from inner shaft by using snap ring
pliers.
412RW015
11. Remove needle bearing from inner shaft by using a
remover J–26941 and sliding hammer J–2619–01.
412RS045
412RW016
12. Remove oil seal from front axle case.
NOTE: Be careful not to damage the front axle case.
DRIVE SHAFT SYSTEM
4C–61
Inspection And Repair
Inspect the removed parts. If there are abnormalities
such as wear and damage, take corrective action or
replace.
Visual Check
1. Inspect the inner shaft for wear and damage.
412RS026
Inner Shaft Bearing
412RW014
2. Replace the shaft if any signs of deterioration in the
gear is present.
412RW006
Legend
(1) Inner Shaft Bearing
(2) Inner Shaft
(3) Clutch Gear
420RS008
Inner Shaft Run–Out
With both end centers supported, rotate the shaft slowly
and measure deflection with a dial gauge.
Limit: 0.5 mm (0.02 in)
NOTE: Do not heat the shaft to correct its bend.
1. Inspect the inner shaft bearing for any signs of
deterioration, replace if uneven.
2. Insert the clutch gear and inspect the needle bearing.
3. Replace the needle bearing if found to be uneven.
Sleeve Condition
Check for wear damage, or cracking in the sleeve.
NOTE: Close inspection of the groove and inner gear are
required because those are important parts.
4C–62
DRIVE SHAFT SYSTEM
Sleeve Function
Clutch Gear Function
412RY00039
Test the sleeve for smoothness by sliding it between the
inner shaft and the clutch gear, replace the sleeve if its
difficult to slide.
NOTE: Gear oil should be applied to the contact surface
of gear.
Check the width of sleeve center groove.
Limit: 7.1 mm (0.28 in)
412RY00038
Test the sleeve for smoothness by sliding it across the
clutch gear, replace the clutch gear if its difficult to slide.
NOTE: When inspecting, gear oil should be applied to the
contact surface of gear.
Clutch Gear Journal Diameter
Make sure of the size illustrated.
Limit: 36.98 mm (1.456 in)
412RW022
412RY00037
Clutch Gear Condition
Check for wear, damage, crack or any other deterioration
in the clutch gear.
Actuator
Check for damage, cracking, or other abnormality.
DRIVE SHAFT SYSTEM
4C–63
NOTE: Be careful not to permit the entry of water or dust
into of the actuator.
Functional Check
Dimentional Check
Measure illustrated sizes 1, 2, and 3.
412RY00041
412RY00010
Limit
1=64.3 mm (2.53 in)
2=6.7 mm (0.26 in)
3=6.7 mm (0.26 in)
Reassembly
1. Install the new oil seal which has been immersed in
differential gear oil, by using an oil seal installer
J–41693 and grip J–8092.
412RY00009
Verify functionality by applying voltage (12V) to terminals
3 and 4 and set the tester to terminal 1 and 2 according to
the table bellow.
State
Trminal 3
Trminal 4
Electric
circuit
between
terminal 1
&2
A
+12V
Ground
OK
2WD
B
Ground
+12V
NONE
4WD
Function
If there is an abnormality, replace the actuator as an
assembly.
412RW034
4C–64
DRIVE SHAFT SYSTEM
2. Install a new needle bearing into inner shaft by using a
Installer J–41694 and grip J–8092.
NOTE: Be sure to install the snap ring properly.
412RW017
412RS051
3. Place a new snap ring(internal) in inner shaft.
Install a new inner shaft bearing into the inner shaft.
7. Apply differential gear oil to clutch gear, then install
clutch gear.
8. Apply differential gear oil to sleeve, then install
sleeve.
9. Clean contact surface with the front axle and actuator
mounting surface. Apply liquid gasket to the contact
surface on the front axle case, then install in the
housing.
412RS044
4. Install snap ring(external).
NOTE: Be careful not to damage the inner shaft.
5. Clean the housing contact surface of the front axle
case and insert inner shaft assembly into the front
axle case.
NOTE: Be careful not to damage seal.
6. Install snap ring internal in the groove of front axle
case.
412RW023
10. Tighten bolts to specified torque.
Torque: 75N·m(55 lb ft)
11. Clean the actuator contact surface with the housing
then Install and tighten shift position switch to the
specified torque.
Torque: 39N·m (29 lb ft)
DRIVE SHAFT SYSTEM
12. Apply liquid gasket to the contact surface on the
actuator side.
412RW012
13. Align shift arm with the groove of sleeve and install the
actuator.
14. Tighten bolts to specified torque.
Torque: 9N·m(78 lb in)
15. Install front axle drive shaft and mounting bracket.
Tighten fitting bolts to specified torque.
Torque: 116N·m (85 lb ft)
16. Pour specified amount of differential gear oil to filler
plug.
Front Differential
Oil Capacity: 1.25lit (1.32US qt)
Actuator Housing
Oil Capacity: 0.12lit(0.13US qt)
17. Install filler plug through gasket and tighten to
specified torque.
Torque: 78N·m (58lb ft)
4C–65
4C–66
DRIVE SHAFT SYSTEM
Main Data and Specifications
General Specifications
Front drive axle oil capacity
1.25 liter (1.32 US qt)(Differential)
0.12 liter (0.13 US qt)(Actuator Housing:Shift on the fly)
Type of lubricant
Axle shaft type
GL–5 (75W–90) Refer to chart in General Information
Constant velocity joint(Birfield joint type and double offset joint)
Torque Specifications
412RY00040
DRIVE SHAFT SYSTEM
4C–67
E04R200004
4C–68
DRIVE SHAFT SYSTEM
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION
TOOL NO.
TOOL NAME
J–39378
Remover and Installer;
Front Axle mount
bushing
J–36830
Installer; Oil seal
J– 26941
Remover; Bearing
needle
J–35910
Pliers; Band bellows,
drive shaft
J–2619–01
Hammer; Sliding
J–41693
Installer; Oil seal
J–41694
Installer; Bearing needle
J–8092
Grip
DRIVE SHAFT SYSTEM
4C–69
Propeller Shaft
General Description
401RX002
Legend
(1) Front Propeller Shaft
(2) Rear Propeller Shaft;
Aluminum Tube with Spline Yoke Type
Torque is transmitted from the transmission to the axle
through the propeller shaft and universal joint assembles.
All propeller shafts are the balanced tubular type. A
splined slip joint is provided in some drivelines.
B Since the propeller shaft is balanced carefully,
welding or any other modification is not permitted.
(3) Rear Propeller Shaft;
Aluminum Tube with Flange Yoke Type
(4) Rear Propeller Shaft;
Steel Tube Type (for 4×4, 6VD1, A/T model)
B Alignment marks should be applied to each propeller
shaft before removal.
B Park, turn the engine off and apply the parking brake
to secure the vehicle.
B Carefully attach the propeller shaft to the vise, do not
overtighten the vise when securing the propeller
shaft, this may cause deformation.
4C–70
DRIVE SHAFT SYSTEM
Phasing
The propeller shaft is designed and built with the yoke
lugs (ears) in line with each other. This design produces
the smoothest running shaft possible, called
phasing.Vibration can be caused by an out–of–phase
propeller shaft.The propeller shaft will absorb vibrations
from speeding up and slowing down each time the
universal joint spins.This vibration would be the same as
a person snapping a rope and watching the ”wave”
reaction flow to the end.A propeller shaft working in phase
would be similar to two persons snapping a rope at the
same time, and watching the ”waves” meet and cancel
each other out.In comparison, this would be the same as
the universal joints on a propeller shaft.A total
cancellation of vibration produces a smooth flow of power
in the driveline.It is very important to apply a reference
mark to the propeller shaft before removal, to assure
installation alignment.
Universal Joint
401RW015
Legend
(1) Spider
(2) Yoke
A universal joint consists of two Y-shaped yokes
connected by a crossmember called a spider.
The spider is shaped like a cross. Universal joints are
designed to handle the effects of various loadings and
front or rear axle windup during acceleration. Within the
designed angle variations, the universal joint will operate
efficiently and safely. When the design angle is changed
or exceeded the operational life of the joint may decrease.
The bearings used in universal joints are of the needle
roller type. The needle rollers are held in place on the
trunnions by round bearing cups. The bearing cups are
held in the yokes by snap rings.
DRIVE SHAFT SYSTEM
4C–71
Diagnosis of Propeller Shaft and
Universal Joint
Condition
Possible cause
Universal Joint Noise.
Correction
Worn universal joint bearings.
Replace.
Improper lubrication.
Lubricate as directed.
Loose flange bolts.
Tighten to specifications.
Ping, Snap, or Click in Drive Line
(Usually Heard on Initial Load after
the Transmission is in Forward or
Reverse Gear)
Loose bushing bolts on the rear
springs or upper and lower control
arms.
Tighten the bolts to specified torque.
Loose or out-of-phase end yoke.
Remove end yoke, turn 180 degrees
from its original position, lubricate the
splines and reinstall. Tighten the
bolts and pinion nut to specified
torque.
Knocking or Clanking Noise in the
Driveline when in High or Neutral
Gear at 16km/h(10mph)
Worn or damaged universal joint
Replace the universal joint.
Squeak
Lack of lubricant.
Lubricate joints and splines. Also
check for worn or brinelled parts.
Loose or missing bolts at the flanges.
Replace or tighten bolts to specified
torque.
Incorrectly set front joint angle.
Install shim under the transmission
support mount to change the front
joint angle.
Worn universal joint.
Replace.
Incorrect shaft runout.
Replace.
Shaft out of balance.
Adjust.
Transmission rear housing bushing,
transfer case housing bushing worn.
Replace.
Yoke spline jammed.
Replace.
Rough surface on splined yoke;
burred nicked or worn.
Replace the seal. Minor burrs can be
Smoothed by careful use of crocus
cloth or fine stone honing. Replace
the yoke if badly burred.
Defective transmission rear oil seal.
Replace the transmission rear oil
seal and replenish the transmission
oil.
Shudder
Speed)
on
Acceleration
(Low
Vibration
Excessive Leak at the Front Spline
Yoke of Rear Propeller Shaft
4C–72
DRIVE SHAFT SYSTEM
Front Propeller Shaft
Front Propeller Shaft and Associated Parts
401RW093
Legend
(1) Bolt, Nut and Washer (Front Axle Side)
(2) Front Propeller Shaft
(3) Bolt, Nut and Washer (Transfer Side)
2. Remove bolt, nut and washer (Front axle side).
3. Remove bolt, nut and washer (Transfer side).
4. Remove front propeller shaft.
Removal
1. Raise the vehicle on a hoist.
NOTE: Apply alignment marks on the flange at the front
propeller shaft both front and rear side.
Installation
NOTE: Never install the shaft assembly backwards.
Never insert bar between yoke lugs when tightening or
removing bolts. Completely remove the black paint from
the connecting surface of flange coupling on each end of
propeller shaft. Clean so that no foreign matter will be
caught in between.
1. Align the mark which is applied at removal. Install
front propeller shaft and tighten the bolts to the
specified torque.
Torque: 63 N·m (46 lb ft)
401RS020
DRIVE SHAFT SYSTEM
4C–73
Disassembly
401RW032
(3) Boot
(4) Clamp
(5) Tube Assembly
Legend
(1) Sleeve Yoke
(2) Clamp
1. Lay the shaft horizontally on a bench and secure.
2. Indicate the original assembled position (1) by
marking the phasing of the shaft prior to disassembly.
401RW037
3. Using the flat blade of a screwdriver, pry the loose end
of the boot clamp upwards and away from the
propeller shaft boot. Be careful not to damage the
boot.
4. When boot clamps becomes loose, remove by hand.
5. Repeat for the other boot clamp.
6. Remove the slip yoke assembly from the driveshaft,
by securing the boot with one hand and pulling on the
slip yoke.
7. Remove the boot from the shaft assembly.
4C–74
DRIVE SHAFT SYSTEM
Universal Joint Disassembly
401RW031
Legend
(1) Flange Yoke
(2) Snap Ring
(3) Spider
(4) Needle Roller Bearing
1. Using a soft drift, tap the outside of the bearing cup
assembly to loosen snap ring. Tap bearing only hard
enough to break assembly away from snap ring.
Remove snap ring from yoke. Turn joint over, tap
bearing away from snap ring, then remove opposite
snap ring.
Apply alignment marks (1) on the yokes of the
universal joint, then remove snap ring.
401RW018
DRIVE SHAFT SYSTEM
4C–75
2. Set the yoke in the arbor press with a piece of tube
stock beneath it.
Place a solid plug on the upper bearing assembly and
press it through to release the lower bearing
assembly.
401RW038
Propeller shaft run–out
401RW020
3. If the bearing assembly will not pull out by hand after
pressing, tap the base of the lug near the bearing
assembly to dislodge it.
4. To remove the opposite bearing, turn the yoke over
and straighten the spider in the open hole. Then
carefully press on the end of the spider so the
remaining bearing moves straight out of the bearing
spider hole. If the spider or bearing are cocked, the
bearing will score the walls of the spider hole and ruin
the yoke.
5. Repeat this procedure on the remaining bearing to
remove the spider from the yoke.
6. Make sure of proper position for reinstallation by
applying setting marks, then remove spider .
Support the propeller shaft on V-blocks (2) and check for
run-out by holding the probe of a dial indicator (1) in
contact with the shaft.
Static run-out limit:
0.13 mm (0.005 in)
TIR on the neck of the slip tube shaft (with a
boot).
0.25 mm (0.010 in)
TIR on the ends of the tubing 3 inch from the
welds.
0.38 mm (0.015 in)
TIR at the linear center of the tube.
0.38 mm (0.015 in)
TIR for the full length of tube with 30” or less of
tubing.
(TIR : Total Indicator Reading)
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition is
found through inspection.
NOTE: When any part of the journal assembly (spider,
needle roller bearing) requires replacement, be sure to
replace the entire assembly.
Check the following parts for wear, damage, noise or any
other abnormal conditions.
1. Spider
2. Needle roller bearing
3. Yoke
4. Flange
5. Boot
Spider pin for wear
Spider pin should be smooth and free from fretting or
galling. Visible signs of needle presence is normal, but
wear should not be felt.
401RS027
4C–76
DRIVE SHAFT SYSTEM
Spline
Universal Joint Reassembly
The nylon-coated spline should be free from nicks and
dings and the underlying steel spline should not be visible.
After cleaning the nylon coating spline, the coating should
exhibit only slight indicator of wear.
Grease volume is approximately 10 grams of grease in
total. Grease should be evenly applied to both the female
and the male slip splines using a small brush. After
assembly of the slip joint, the sliding joint should be fully
worked from the full collapsed to the full extended
position.
Play in the universal joint
Limit: Less than 0.15 mm (0.006 in)
1. Install spider to flange yoke. Be sure to install the
spider by aligning the setting marks made during
disassembly.
2. Pack the four grease cavities of the spider with a high
quality, extreme pressure N.L.G.I. Grade 2 grease.
Do not add additional grease to the bearing cup
assembly.
3. Move one end of the spider to cause a trunnion to
project through the spider hole beyond the outer
machined face of the yoke lug. Place a bearing over
the trunnion diameter and align it to the spider hole.
Using an arbor press, hold the trunnion in alignment
with the spider hole and place a solid plug on the
upper bearing. Press the bearing into the spider hole
enough to install a snap ring.
401RW023
Preload of the universal joint
401RW020
Preload should be 0 to 49 N(0 to11.0 lb). Joints should
rotate smoothly and freely and should exhibit no rough or
ratchety movement.
4. Install a snap ring.
Be sure the snap rings are properly seated in the
grooves.
5. Repeat steps 3 and 4 to install the opposite bearing. If
the joint is stiff, strike the yoke ears with a soft
hammer to seat needle bearings.
401RW019
DRIVE SHAFT SYSTEM
4C–77
6. Align setting marks (1) and join the yokes.
401RW018
7. Install snap ring.
Reassembly
401RW032
Legend
(1) Sleeve Yoke
(2) Clamp
(3) Boot
(4) Clamp
(5) Tube Assembly
4C–78
DRIVE SHAFT SYSTEM
1. Apply grease evenly to both the female and male
splines.
2. Apply a small amount of grease by finger to the outer
lips of the boot.
3. Slide the boot onto the yoke shaft being careful not to
damage the spline coating or boot.
4. Insert the yoke shaft spline into the sleeve being
careful to maintain proper phasing. The spider holes
should be in line and as per originally marked prior to
disassembly.
5. Position boot onto sleeve and yoke shaft in final
position over boot grooves.
6. Attach boot clamps and secure using pliers.
7. Be sure clamp is properly seated and secure.
Main Data and Specifications
General Specifications
Transmission
Length (between two spiders
center)
M/T
A/T
367.2 mm (14.81 in)
542.2 mm (21.35 in)
Torque Specifications
401RX001
DRIVE SHAFT SYSTEM
4C–79
Rear Propeller Shaft
Rear Propeller Shaft and Associated Parts
401RX003
Legend
(1) Bolt, Nut and Washer (Transfer Side)
Removal
1. Raise the vehicle on a hoist.
NOTE: Apply alignment marks on the flange at the rear
propeller shaft both front and rear side.
2. Remove transfer side bolt, nut and washer (except
spline yoke type).
3. Remove rear axle side bolt, nut and washer.
4. Remove rear propeller shaft.
NOTE: Plug the hole of the transmission rear end to
prevent oil leakage (spline yoke type only).
(2) Rear Propeller Shaft
(3) Bolt, Nut and Washer (Rear Axle Side)
Installation
NOTE: Never install the shaft assembly backwards.
Never insert bar between yoke lugs when tightening or removing bolts.
Completely remove the dust or foreign matter from the
connecting surface of flange coupling on each end of the
propeller shaft.
1. Align the mark which is applied at removal.
2. Install rear propeller shaft and tighten the bolts to the
specified torque.
Torque: 63 N·m(46 lb ft)
4C–80
DRIVE SHAFT SYSTEM
Slip Joint Disassembly
401RX00001
Legend
(1) Spline Yoke and Universal Joint Assembly
(2) Clamp
1. Lay the shaft horizontally on a bench and secure.
2. Indicate the original assembled position by marking
the phasing of the shaft prior to disassembly.
3. Using the flat blade of a screwdriver, pry the loose end
of the boot clamp upwards and away from the
propeller shaft boot. Be careful not to damage the
boot.
(3) Boot
(4) Clamp
(5) Tube and Universal Joint Assembly
4. When boot clamps becomes loose, remove by hand.
5. Repeat for the other boot clamp.
6. Remove the slip yoke assembly from the driveshaft,
by securing the boot with one hand and pulling on the
slip yoke.
7. Remove the boot from the shaft assembly.
DRIVE SHAFT SYSTEM
4C–81
Universal Joint Disassembly
401RX00007
Legend
(1) Spline Yoke
(2) Spider
(3) Propeller Shaft Assembly
(4) Spider
NOTE: Aluminum is softer than steel. Care must be
taken not to remove excessive material or damage
bearing holes.
If the vehicle has aluminum tube type propeller shaft,
flange yoke, boot kit, journal kit can be replaced. If other
parts are damaged, replace propeller shaft as assembly.
(5)
(6)
(7)
(8)
Flange Yoke
Bearing
Snap Ring
Flange Yoke
4C–82
DRIVE SHAFT SYSTEM
1. Apply alignment marks on the yokes of the universal
joint, then remove the snap ring.
2. Set the yoke in the arbor press with a piece of tube
stock beneath it.
Place a solid plug on the upper bearing and press it
through to release the lower bearing.
401RW024
If the snap ring is stuck in position, remove paint from
the hole in the yoke or tap around the edge of the
bearing lightly with a soft drift.
401RW027
3. If the bearing will not pull out by hand after pressing,
tap the base of the lug near the bearing to dislodge it.
4. To remove the opposite bearing, turn the yoke over
and straighten the spider in the open spider hole.
Then carefully press on the end of the spider so the
remaining bearing moves straight out of the bearing
spider hole. If the spider or bearing are cocked, the
bearing will score the walls of the spider hole and ruin
it.
401RW025
401RW026
5. Repeat this procedure on the remaining bearing to
remove the spider from the yoke.
DRIVE SHAFT SYSTEM
4C–83
Inspection
B Propeller shaft for run-out Aluminum tube type.
Static run-out limit : 1.0 mm(0.04 in)
TIR full length of tubing maximum.
(TIR : Total Indicator Reading)
B Propeller shaft for runout (Steel tube type).
Static runout limit : 0.13 mm(0.005 in)
TIR on the neck of the slip tube shaft (with a
boot).
0.25 mm(0.010 in)
TIR on the ends of the tubing 3 inch from the
welds.
0.38 mm(0.015 in)
TIR at the linear center of the tube.
401RW028
0.38 mm(0.015 in)
TIR for the full length of tube with 30” or less of
tubing.
(TIR: Total Indicator Reading)
401RW017
B Play in universal joint.
Limit: Less than 0.15 mm(0.006 in)
B Spider pin should be smooth and free from fretting or
galling.
Visible signs of needle presence is normal, but wear
should not be felt.
B Preload of the universal joint.
Preload should be 0 to 49 N (0 to 11.0 lb).
Joints should rotate smoothly and freely and should
exhibit no rough or ratchety movement.
401RW019
B Inspect splines of slip joint for wear.
The nylon-coated spline should be free from nicks
and dings and the underlying steel spline should not
be visible.
After cleaning the nylon coating spline, the coating
should exhibit only slight indication of wear.
Grease volume is approximately 10 grams of grease
in total. Grease should be evenly applied to both the
female and the male slip splines using a small brush.
After assembly of the slip joint, the sliding joint should
be fully worked from the full collapsed to the full
extended position.
4C–84
DRIVE SHAFT SYSTEM
B Aluminum tube type only: Inspect the aluminum
tubing for surface scratches and dents. These
scratches may not exceed 0.2 mm (0.008 in) in depth.
Universal Joint Reassembly
1. Pack the four grease cavities of the spider with a high
quality, extreme pressure N.L.G.I. Grade 2 grease.
Do not add additional grease to bearing cup
assembly.
2. Move one end of the spider to cause a trunnion to
project through the spider hole beyond the outer
machined face of the yoke lug. Place a bearing over
the trunnion diameter and align it to the spider hole.
Using an arbor press, hold the trunnion in alignment
with the spider hole and place a solid plug on the
upper bearing. Press the bearing into the spider hole
enough to install snap ring.
401RW022
B Aluminum tube type only: Visually inspect the circle
welds and fittings for any signs of cracks or signs of
deterioration. If there are any cracks that exceed 0.2
mm (0.008 in) in depth, the assembly must be
replaced.
B Aluminum tube type only: Check to be sure there are
no missing balance weights. If balance weights are
missing and void has occurred in the aluminum tubing
greater than 0.2 mm (0.008 in), the assembly must be
replaced.
401RW026
3. Install a snap ring.
NOTE: Be sure the snap rings are properly seated in the
grooves.
4. Repeat steps 2 and 3 to install the opposite bearing. If
the joint is stiff, strike the yoke ears with a soft
hammer to seat the bearing.
5. Align the setting marks and join the yokes.
DRIVE SHAFT SYSTEM
4C–85
Slip Joint Reassembly
401RX00001
Legend
(1) Spline Yoke and Universal Joint Assembly
(2) Clamp
1. Apply grease evenly to both the female and male
splines.
2. Apply a small amount of grease by finger to the outer
lips of the boot.
3. Slide the boot (smaller diameter side) onto the spline
yoke shaft being careful not to damage the spline
coating or boot.
4. Insert the spline yoke shaft spline into the tube
assembly being careful to maintain proper phasing.
The spider holes should be in line as originally marked
prior to disassembly.
5. Position boot onto tube and yoke shaft in its
assembled position.
6. Attach boot clamps and secure using pliers.
(3) Boot
(4) Clamp
(5) Tube and Universal Joint Assembly
7. Be sure clamp is properly seated and secure.
CAUTION: Only use a similar type or same as the
original type clamp. Using any other clamp may
create an imbalanced shaft or lead to grease leakage.
4C–86
DRIVE SHAFT SYSTEM
Main Data and Specifications
General Specifications
2WD Model
Engine
4WD Model
Y22SE
Transmission
6VD1
6VD1
M/T
A/T
M/T
A/T
M/T
A/T
Type (See illustration)
1
2
1
2
2
3
Length
between two spiders
center)
1314.4mm
(51.75in)
1334.7mm
(52.55in)
1298.4mm
(51.12in)
1323.0mm
(52.09in)
1191.2mm
(46.9in)
1021.2mm
(40.21in)
Universal joint type
Cardan type
Torque Specifications
401R100001
SECTION
TRANSFER CASE (TOD)
4D2–1
AXIOM
DRIVELINE/AXLE
TRANSFER CASE (TOD)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . .
General Description . . . . . . . . . . . . . . . . . . . . .
Removal and Installation of Tfansfer Case
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Rear Oil Seal . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOD Control Unit . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly and Reassembly of Major
Components . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Cover Assembly . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
4D2–1
4D2–2
4D2–3
4D2–4
4D2–4
4D2–6
4D2–6
4D2–6
4D2–8
4D2–8
4D2–8
4D2–9
4D2–9
4D2–10
4D2–10
4D2–13
4D2–13
4D2–14
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.
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Pack and Clutch Cam
(Transfer Case Assembly) . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Chain, Sprocket and Mechanical Lock
(Transfer Case Assembly) . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case Assembly . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair
(Transfer Case Assembly) . . . . . . . . . . . . . .
Main Data and Specification . . . . . . . . . . . . . .
General Specification . . . . . . . . . . . . . . . . . .
Torque Specifications . . . . . . . . . . . . . . . . . .
Torque Specifications (Cont’d) . . . . . . . . . . .
Torque Specifications (Cont’d) . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . .
4D2–15
4D2–16
4D2–16
4D2–18
4D2–20
4D2–21
4D2–22
4D2–24
4D2–24
4D2–26
4D2–28
4D2–32
4D2–32
4D2–33
4D2–34
4D2–35
4D2–36
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.
4D2–2 TRANSFER CASE (TOD)
General Description
A04R200003
The
Torque-On-Demand
(TOD)
is
electronically-controlled torque-split 4-wheel
system with the following features.
an
drive
Shifting Between High and Low Ranges
The shifting mechanism consists of the cam and shaft rail
assembly, the high/low shift motor and the encoder. The
encoder is built-in to the motor.
The encoder senses high/low range shift motor rotation
position and sends this data to the TOD control unit.
Based on this data, the TOD control unit adjusts motor
rotation speed or stops the motor.
The shifting between the high and low ranges using the
TOD switch only is possible. The vehicle must be stopped
or nearly stopped (vehicle speed less than 2 km/h (1.2
mph) and engine speed less than 1,500 rpm), the
automatic transmission selector level must be in the
neutral (N) position, and the brakes must be applied.
Electronically-controlled Wet-type Multiple
Disc Clutch
The clutch automatically provides the optimum drive
power to the front wheels of the vehicle in response to
varying road surface conditions when the vehicle is
operated in the TOD mode. The delivered power ranges
from 0% to 100% of power train output. Superior
operational stability is maintained over a wide range of
operating conditions.
Front Output Drive
Front output drive is provided by a chain. This reduces the
loud noise associated with 4-wheel drive operation.
Oil Pump Lubrication
An oil pump is used to lubricate the transfer. This ensures
stable multiple-disc clutch operation and maintains the
lubricating oil at a constant temperature.
TRANSFER CASE (TOD)
4D2–3
Removal and Installation of Tfansfer Case Assembly
F07R200001
Legend
(1) Transfer Protector
(2) Front Propeller Shaft Assembly
(3) Speedometer Sensor Harness Connector
(4) Rear Propeller Shaft Assembly
(5)
(6)
(7)
(8)
Center Exhaust Pipe
Transfer Case Bolt
Transfer Case Assembly
Transfer Case Harness Connector
4D2–4 TRANSFER CASE (TOD)
Removal
1. Disconnect the battery ground cable.
2. Remove the transfer protector.
3. Disconnect the rear propeller shaft assembly from the
transfer case.
4. Disconnect the front propeller shaft assembly from
the transfer case.
5. Remove the center exhaust pipe.
6. Disconnect the speedometer sensor harness
connector from the speedometer sensor, and remove
the harness clamp from the connector bracket of the
transfer case.
7. Disconnect the engine harness connector from the
transfer harness connector.
8. Support the transfer case with a transmission jack.
9. Remove the transfer bolts.
10. Remove the transfer case assembly.
Installation
1. Apply grease (Besco L2 or its equivalent) to the input
shaft spline.
260RY00011
2. Install the transfer case assembly to the transmission
assembly.
3. Install the transfer bolts to the specified torque (Refer
to next page).
Torque: 46 N·m (34 lb ft)
4. Connect the engine harness connector to the transfer
harness connector.
5. Install the breather hose up to bottom of the transfer
case breather and clip them firmly.
6. Securely insert the breather hose into the cutout
portion of the transfer case.
260R200001
TRANSFER CASE (TOD)
4D2–5
7. Install the speedometer harness clamp to the
connector bracket of the transfer case, and then
connect the harness connector to the speedometer
sensor.
261R200008
8. Install the center exhaust pipe.
Torque: 43 N·m (32 lb ft)
9. Connect the front and rear propeller shaft assembly
to the transfer case.
Torque: 63 N·m (46 lb ft)
10. Install the transfer protector.
Torque: 37 N·m (27 lb ft)
11. Connect the battery ground cable.
4D2–6 TRANSFER CASE (TOD)
Transfer Rear Oil Seal
261R200002
Legend
(1) Transfer Rear Oil Seal
(2) End Nut, Washer, Oil Seal and Rear
Companion Flange
(3) Rear Propeller Shaft Assembly
Removal
1. Disconnect the rear propeller shaft assembly from the
transfer case.
2. Using the flange holder J–8614–11, remove the end
nut.
3. Using the universal puller, remove the companion
flange, washer and oil seal.
4. Remove the transfer rear oil seal from the transfer
case.
Installation
1. Apply oil to the circumference of the transfer rear oil
seal.Fill the oil seal lip with grease (Besco L2 or its
equivalent).
2. Using the oil seal installer J–42804, install the transfer
rear oil seal to the transfer case.
261RY00017
TRANSFER CASE (TOD)
NOTE: When installing the oil seal, pay attention to the
direction.
4D2–7
5. Securely stake the end nut at one spot.
NOTE: Be sure to confirm that there is no clack at the
staked portion of the end nut after staking.
261RW006
Legend
(1) Inside
(2) Outside
266RY00003
3. Install the companion flange.
4. Install the oil seal and washer, and using the flange
holder J–8614–11, install the new end nut to the
specified torque.
Torque: 167 N·m (123 lb ft)
266R200004
6. Connect the rear propeller shaft assembly to the
transfer case.
Torque: 63 N·m (46 lb ft)
4D2–8 TRANSFER CASE (TOD)
TOD Control Unit
826R200006
Legend
(1) Bracket
(2) TOD Control Unit
Removal
1. Disconnect the battery ground cable.
2. Disconnect the harness connector from the TOD
control unit.
3. Remove the bracket retaining nuts (3 pieces) and the
bracket with TOD control unit.
4. Remove the TOD control unit from the bracket.
Installation
1. Install the TOD control unit to the bracket.
2. Install the bracket with TOD control unit to the
chassis.
3. Connect the harness connector to the TOD control
unit.
4. Connect the battery ground cable.
TRANSFER CASE (TOD)
4D2–9
Unit Repair
Disassembly and Reassembly of Major Components
266R200002
Legend
(1) Front Companion Flange, Oil Seal, Washer,
and End Nut
(2) 4H and 4L Switch
(3) Harness Assembly
(4) Harness Bracket
(5) Shift Motor Assembly
(6) Rear Companion Flange, Oil Seal, Washer and
End Nut
(7)
(8)
(9)
(10)
(11)
(12)
Speedometer Sensor and Driven Gear
Plate and Bracket
Connector Bracket
Breather Hose
Transfer Case Assembly
Transfer Cover Assembly
4D2–10 TRANSFER CASE (TOD)
Disassembly
1. Remove the drain plug from the transfer case and
drain the oil.
2. Remove the speedometer sensor and driven gear.
3. Remove the front and rear speed sensor of the
harness assembly from the transfer cover assembly.
6. Remove the 4H and 4L switch from the transfer case.
7. Remove the shift motor assembly from the transfer
cover.
8. Using the flange holder J–8614–11, remove the end
nut.
Remove the washers, oil seals, front and rear
companion flange.
NOTE: Use care to prevent damage to speed sensor
when removing speed sensor.
4. Disconnect the clutch solenoid coil, 4H and 4L switch
harness connector.
B Remove the harness bracket from the transfer
cover.
262RY00012
9. Remove the transfer cover retaining bolts and the
transfer cover assembly from the transfer case
assembly.
NOTE: When removing the transfer cover assembly, use
care to prevent damage to oil seal.
261RY00009
5. Remove the connector bracket from the transfer
case.
B Remove the harness assembly and shift motor
harness connector from the connector bracket.
10. Remove the breather hose from the transfer case.
Reassembly
1. Apply recommended liquid gasket (LOCTITE 598 or
its equivalent) uniformly to the transfer case and
cover fitting surface.
261RY00010
261RY00011
TRANSFER CASE (TOD) 4D2–11
2. Install the plate, bracket, connector bracket and
ground cable of the harness assembly, and tighten
the transfer cover retaining bolts (16 pieces) to
specified torque.
5. Securely stake the end nut at one spot.
NOTE: Be sure to confirm that there is no clack at the
staked portion of the end nut after staking.
Torque: 31 N·m (23 lb ft)
266RY00003
261RY00035
266R200004
261RY00037
3. Install the front and rear companion flange.
4. Install the oil seal and washer, and using the flange
holder J–8614–11, install the new end nut to the
specified torque.
Torque: 167 N·m (123 lb ft)
4D2–12 TRANSFER CASE (TOD)
6. Apply recommended liquid gasket (LOCTITE 598 or
its equivalent) to the transfer cover and shift motor
assembly fitting surface.
12. Install the driven gear and speedometer sensor to the
transfer case.
Torque: 25 N·m (19 lb ft)
261R200003
7. Install the shift motor assembly to the transfer cover
assembly.
Torque: 10 N·m (87 lb in)
8. Install the 4H and 4L switch.
261RY00034
13. Remove the filler plug and fill the transfer case with
ATF DEXRON–II or III.
14. Wind the sealing tape around the filler plug thread and
tighten the plug to the specified torque.
Torque: 25 N·m (19 lb ft)
Torque: 24 N·m (17 lb ft)
9. Install the harness assembly and shift motor harness
connector to the connector bracket.
10. Install the front and rear speed sensors to the transfer
cover.
Torque: 5 N·m (43 lb in)
11. Connect the harness assembly connector to the
clutch solenoid coil harness connector and 4H and 4L
switch.
B Fix the harness with harness bracket.
261RY00026
15. Install the breather hose to the transfer case.
261RY00009
TRANSFER CASE (TOD) 4D2–13
Transfer Cover Assembly
261RY00032
Legend
(1) Coil Assembly
(2) Snap Ring
(3) Ball Bearing
(4)
(5)
(6)
(7)
Speed Gear and Tone Wheel
Ball Bearing
Transfer Cover (With Oil Seal)
Oil Drain Plug and Oil Filler Plug
Disassembly
1. Using a precision screwdriver or a suitable tool, push
down the lock to unlatch the terminal for the coil
assembly, and pull the terminal out.
NOTE: Use care to prevent damage to harness terminal
and connector.
261RY00013
4D2–14 TRANSFER CASE (TOD)
2. Remove the coil assembly set nuts (3 pieces) and coil
assembly from the transfer cover.
4. Strike the speed gear and tone wheel with a rod or
other appropriate tool from the rear side of the
transfer cover assembly, and remove the ball bearing,
speed gear and tone wheel.
NOTE: Use care to prevent damage to the speed gear
teeth.
261RW030
3. Using snap ring pliers, remove the snap ring from the
transfer cover.
261RY00012
5. Using the bearing remover J–42805 and slide
hammer J–2619–01, remove the ball bearing of the
front output shaft from the transfer cover.
261RW047
261RY00027
Inspection and Repair
Refer to “Inspection and Repair (Transfer Case
Assembly)” in this section.
TRANSFER CASE (TOD) 4D2–15
Reassembly
Transfer cover oil seal replacement
1. Remove the oil seal from the transfer cover assembly.
2. Apply oil to the circumference of the new oil seal and
fill the lip with grease (BESCO L2 or its equivalent).
3. Using the oil seal installer J–42804, install the oil seal
to the transfer cover assembly.
7. Install the ball bearing of the front output shaft to the
transfer cover.
8. Install the speed gear and tone wheel.
9. Install the ball bearing to the transfer cover.
10. Using snap ring pliers, install the snap ring to the
transfer cover.
NOTE: The snap ring must be fully inserted into the
transfer cover snap ring groove.
261RY00017
Shift shaft oil seal replacement
4. Remove the oil seal from the transfer cover assembly.
5. Apply oil the circumference of the new oil seal.
6. Using the oil seal installer J–33951, install the oil seal
to the transfer cover assembly.
The drive in depth must be 9.4 ∼ 10.4 mm (0.370 ∼
0.409 in). The knurled end of the installer (indicated
by the arrow) must be flush with the oil seal
installation surface.
261RY00018
11. Install the coil assembly to the transfer cover and
tighten the set nuts (3 pieces) to the specified torque.
Torque: 10 N·m (87 lb in)
12. Install the connector to the harness terminal of the coil
assembly.
NOTE: Use care to prevent tilt to oil seal when installing
oil seal to the case.
261RY00013
261R200009
4D2–16 TRANSFER CASE (TOD)
Clutch Pack and Clutch Cam (Transfer Case Assembly)
266RY00015
Legend
(1) Transfer Case Assembly
(2) Snap Ring
(3) Wave Spring
(4) Cam Pulley
(5) Cam Ball
(6)
(7)
(8)
(9)
(10)
(11)
Cam and Coil Housing Assembly
Thrust Bearing
Armature Plate
Insulator Washer
Clutch Pack Assembly
Lockup Fork Spring
Disassembly
1. Remove the lockup fork spring.
2. Remove the thrust bearing and cam and coil housing
assembly from the output shaft.
NOTE: When the cam and coil housing assembly is
removed, the cam balls may be detached together with
the housing. Pay attention not to lose the ball.
261RY00020
TRANSFER CASE (TOD) 4D2–17
3. Remove the cam ball (3 pieces).
4. Remove the cam pulley.
6. Using snap ring pliers, remove the snap ring.
NOTE: Use care to prevent damage to snap ring.
266RY00005
266RY00007
5. Remove the wave spring.
7. Remove the armature plate, insulator washer and
clutch pack assembly as a package.
266RY00006
266RY00008
4D2–18 TRANSFER CASE (TOD)
3. Using snap ring pliers, install the snap ring to the
output shaft.
Reassembly
1. Install the clutch pack assembly which the multi clutch
plate is orderly installed to the output shaft.
NOTE:
B Install the clutch pack assembly while adjusting the
phase of both the clutch housing and drive sprocket.
B During installation, the plate of the clutch pack
assembly may slide out of this fixed position (the
correct position is shown in the illustration). If this
occurs, remove all of the clutch plates of the clutch
pack assembly and reinstall them to their correct
position.
266RY00007
4. Install the wave spring to the output shaft.
266RY00009
2. Install the insulator washer and armature plate to the
clutch pack assembly.
266RY00006
266RY00008
TRANSFER CASE (TOD) 4D2–19
5. Install the cam pulley.
6. Place a ball on each groove of the cam pulley.
266RY00005
7. Install the cam and coil housing to the output shaft.
8. Install the thrust bearing.
9. Install the lockup fork spring.
261RY00020
4D2–20 TRANSFER CASE (TOD)
Chain, Sprocket and Mechanical Lock (Transfer Case Assembly)
262RY00021
Legend
(1) Transfer Case Assembly
(2) Cam and Shaft Rail Assembly
(3) Front Output Shaft
(4) Chain
(5) Lower Drive Sprocket
(6) Front Tone Wheel
(7) Drive Sprocket
(8) Spacer
(9) Shift Fork and Rail Assembly
(10) Lockup Rail
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
Spring Pin
Shift Fork Assembly
Lockup Fork
Lockup Fork Spring
Reduction Hub
Rear Output Shaft
Oil Pump Assembly (with Strainer)
Thrust Washer
Lockup Hub
Lockup Collar Assembly
Magnet
TRANSFER CASE (TOD) 4D2–21
6. Remove the magnet from the strainer set position
together with the oil pump assembly.
Disassembly
1. Remove the spacer.
2. Remove the front tone wheel, lower drive sprocket,
drive sprocket and chain together from the front and
rear output shaft.
266RY00012
7. Remove the output shaft.
8. Remove the cam and shaft rail assembly.
266RY00010
3. Remove the lockup collar assembly and lockup fork
together.
262RY00015
266RY00011
4. Remove the lockup hub.
5. Remove the thrust washer.
9. Remove the shift fork and rail assembly, and
reduction hub.
10. Remove the spring pin from the shift fork and rail
assembly.
11. Remove the shift fork assembly from the lockup rail.
12. Remove the front output shaft from the transfer case.
4D2–22 TRANSFER CASE (TOD)
Reassembly
1. Apply ATF to the inside of the ball bearing.
2. Install the front output shaft to the transfer case.
7. Install the thrust washer.
8. Install the lockup hub.
9. Install the cam and shaft rail assembly.
266RY00012
262RY00019
3. Install the shift fork assembly to the lockup rail and fix
the assembly with the snap ring.
4. Install the shaft fork and rail assembly and reduction
hub to the transfer case.
10. Install the lockup collar assembly and lockup fork
together.
266RY00011
262RY00015
5. Install the output shaft to the transfer case.
6. Install the oil pump assembly to the output shaft and
attach the magnet to the strainer set position.
TRANSFER CASE (TOD) 4D2–23
11. Apply ATF to the chain and engage it to both
sprockets.
12. Mount the chain and sprocket assembly to both
output shafts.
NOTE: When installing chain, the copper colored ring of
the chain (indicated by the arrow) to be installed in
direction of rear.
13. Install the front torn wheel to the front output shaft.
14. Install the spacer to the drive sprocket assembly.
266RY00018
4D2–24 TRANSFER CASE (TOD)
Transfer Case Assembly
265RY00001
Legend
(1) Transfer Case (with Oil Seal)
(2) Ball Bearing
(3) Ring Gear
(4) Snap Ring
(5) Input Shaft and Carrier Assembly
(6) Snap Ring
(7) Ball Bearing
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Snap Ring
Circular Hub
Carrier Assembly
Snap Ring
Thrust Plate
Sun Gear
Input Shaft Assembly (with Bearing and
Bushing)
Disassembly
1. Using snap ring pliers, open the snap ring from the
gap on the carrier assembly.
While opening the snap ring, remove the input shaft
assembly, carrier assembly and thrust plate together
from the transfer case.
265RY00002
TRANSFER CASE (TOD) 4D2–25
2. Remove the snap ring from the transfer case.
4. Using the bearing remover J–22912–01, remove the
ball bearing from the input shaft.
265RY00003
3. Using snap ring pliers, remove the snap ring.
265R200001
5. Remove the circular hub.
6. Remove the snap ring from the carrier assembly.
265RW009
265RW006
7. Remove the thrust plate from the carrier assembly.
4D2–26 TRANSFER CASE (TOD)
8. Remove the snap ring before the ring gear.
10. Remove the ball bearing of the front output shaft from
the transfer case.
261RW025
9. Using the ring gear remover J–42806 and a bench
press, remove the ring gear from the transfer case.
261RY00021
Reassembly
Oil Seal Replacement
1. Remove the oil seal of the front output shaft and input
shaft from the transfer case.
2. Apply the circumference of the new oil seal and fill the
lip with grease (BESCO L2 or its equivalent).
3. Using the oil seal installer J–42807, install the front
output shaft oil seal to the transfer case.
261R200005
NOTE: Removing ring gear needs a high-load press.
This means the transfer case may be damaged.
To remove and replace the ring gear, it is recommended
that the transfer case assembly should be replaced.
266RY00013
TRANSFER CASE (TOD) 4D2–27
4. Using the oil seal installer J–42808, install the input
shaft oil seal to the transfer case.
6. Install the snap ring.
7. Install the thrust plate to the carrier assembly.
Attach the snap ring to the carrier assembly.
8. Install the carrier assembly to the input shaft.
9. With care the direction of circular hub, mount it to the
input shaft.
261RY00031
5. Using the ring gear installer J–42809 and a bench
press, install the ring gear to the transfer case.
NOTE: Pay attention to the following points.
B Identify the correct direction of gear.
265RW008
10. Press the ball bearing to the input shaft so that the
snap ring will be attached to the input shaft.
B Do not damage the gear.
B Do not press-fit the ring gear slantingly.
B Press-fit the ring gear to the innermost.
B Remove burrs generated by press-fitting.
B If the transfer case has serrations, match them with
those of the gear and press-fit the gear.
265RY00004
11. Install the snap ring to the input shaft.
12. Install the ball bearing of the front output shaft to the
transfer case.
261R200007
4D2–28 TRANSFER CASE (TOD)
13. Install the snap ring of the input shaft bearing to the
transfer case.
Chain
B Check whether the face that contacts the sprocket is
free from excessive wear or damage. If defects are
observed, replace the part.
B If the chain interference mark is found on the inside
wall of the transfer cover or the chain is so slack that a
skipped engagement occurs between the chain and
sprocket, replace the chain.
Sprocket
B Check whether the sprocket tooth surface is
excessively worn or damaged, and there is evidence
of burrs, chipping, wear, or damage on the gear
spline. Remove minor flaws or scratches with oil
stone. If excessive wear or damage is observed,
replace the part.
B If excessive wear or damage is observed on the
sprocket inside sliding surface, replace the part.
Gear
265RY00003
14. Using snap ring pliers, open the snap ring from the
gap on the carrier assembly.
While opening the snap ring, securely attach the input
shaft and carrier assembly to the transfer case.
B Check whether the gear tooth surface is excessively
worn or damaged, and there is evidence of burrs,
chipping, wear, or damage on the gear spline.
Remove minor flaws or scratches with oil stone. If
excessive wear or damage is observed, replace the
part.
Thickness of Reduction Hub
B Measure the thickness with a micrometer.
B If the measurement exceeds the limit, replace the
reduction hub.
Standard : 3.05–3.30 mm (0.120–0.130 in)
Allowable limit : 2.5 mm (0.098 in)
265RY00002
Inspection and Repair (Transfer Case
Assembly)
When wear, damage, or any other defects are observed
during the inspection, the part or parts must be repaired or
replaced. Wash all the parts with clean detergent, and
check that old oil, metallic particles, dirt, or foreign
materials are completely removed. Blow the air into oil
holes and grooves to remove foreign materials or residual
detergent.
265RW005
TRANSFER CASE (TOD) 4D2–29
Lockup Collar Assembly
B Install the lockup hub, drive sprocket assembly, and
lockup collar assembly to the output shaft.
B If the lockup collar assembly does not move
smoothly, replace the lockup collar assembly.
NOTE: Apply ATF to the rear engaging the gear.
Width of Lockup Collar
B Using calipers, measure the lockup collar groove for
width of wear.
B If the measurement exceeds the limit, replace the
lockup collar assembly.
Standard : 7.16–7.32 mm (0.282–0.288 in)
Allowable limit : 7.9 mm (0.311 in)
262RY00016
Lockup Fork and Rail
B Check the lockup fork and rail for wear, distortion, and
scratches. If defects are observed, replace the parts.
Thickness Lockup Fork
If the measurement exceeds the limit, replace the lockup
fork.
Standard : 6.99–7.09 mm (0.275–0.279 in)
Allowable limit : 6.3 mm (0.248 in)
262RY00018
Shift Fork and Rail Assembly
Check the shift fork and rail for wear, distortion, and
scratches. If defects are observed, replace the parts.
Thickness of Shift Fork
B If the measurement exceeds the limit, replace the
shift fork.
Standard : 3.41–3.79 mm (0.134–0.149 in)
Allowable limit : 4.4 mm (0.173 in)
262RY00017
4D2–30 TRANSFER CASE (TOD)
Bearing
Check the profile of the needle, roller, ball, and thrust
bearings. Wash the bearings with clean detergent
completely, and dry with air.
NOTE: If the bearing is rotated excessively, the rollers
may be damaged. So, rotate the bearing slowly with your
hand. Apply grease to the bearing, and check the
smoothness of the bearing while slowly rotating the race
with your hand.
Allowable limit : 0.23 mm (0.009 in)
Legend
(1) Clutch Housing
(2) Clutch Plate
(3) Insulator Washer
(4) Armature Plate
Coil Assembly
B Check the resistance of the coil with a tester. If
defects are observed, replace the coil assembly.
Standard : 1.7±0.3W (at ordinary temperature)
Allowable limit : 1.0∼5.0W
226RW143
Lockup Fork Spring
Check the lockup fork spring for distortion, cracking, and
wear. If defects are observed, replace the part.
Multi Plate Disk Clutch
B If the burned, mirror-surfaced clutch facing, or
scraping is observed on the clutch plates, clutch
housing, armature plate, and insulator washer,
replace the parts.
261RY00022
Cam Pulley, Cam Ball, and Cam & Coil
Housing
B Check the cam balls and cam for excessive wear or
damage. If defective, replace the parts.
266RW016
266R200003
TRANSFER CASE (TOD) 4D2–31
4H and 4L Switch
Shift Motor Assembly
B Check the continuity of 4H and 4L switch.
If defects are observed, replace the 4H and 4L switch.
B Check the resistance of the shift motor assembly
(between terminal 4 to 7) with a tester.
If defects are observed, replace the shift motor
assembly.
Standard : 0.63±0.2W (at ordinary temperature)
261R200006
8–6
261RW049
Switch
Stroke
4H Switch
Signal
4L Switch
Signal
The
corresponding
g
position of
TOD
switch
Terminal 2 to
Switch Body
Terminal
1 to 3
1
Open
Open
2H, TOD
2
Open
Close
4L
3
Close
Close
Neutral
261RY00023
Oil Pump
B Remove foreign materials from the strainer. If the
strainer is damaged, replace it.
B If the area into which the shaft is inserted is
excessively worn or damaged, replace the oil pump
assembly.
4D2–32 TRANSFER CASE (TOD)
Main Data and Specification
General Specification
Type
Electronically controlled torque split four wheel drive with two wheel
drive.
2WD: Rear two wheel drive
TOD: Electronically controlled torque split four wheel drive.
4L: Low speed mechanical lockup four wheel drive.
Rear drive: Direct drive
Front drive: Chain drive
Low range deceleration: Planetary gear drive
Control system
Switch control
Gear ratio
High: 1.000
Low: 2.480
Lubrication system
Built-in oil pump
Forced lubrication
Type of lubricant
ATF DEXRON–II or III
Oil capacity
1.35 liters. (1.43 US.quart)
Clutch discs number
13
Planetary gear teeth number
Sun gear: 58
Pinion gear: 15
Ring gear: 86
TRANSFER CASE (TOD) 4D2–33
Torque Specifications
E04R200001
4D2–34 TRANSFER CASE (TOD)
Torque Specifications (Cont’d)
E04R200002
TRANSFER CASE (TOD) 4D2–35
Torque Specifications (Cont’d)
E04R200003
4D2–36 TRANSFER CASE (TOD)
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION
TOOL NO.
TOOL NAME
J–8614–11
Flange Holder
J–42806
Ring Gear Remover
J–42804
Rear Oil Seal Installer
J–42807
Front Output Shaft Oil
Seal Installer
J–33951
Shift Shaft Oil Seal
Installer
J–42808
Input Shaft Oil Seal
Installer
J–42805
Bearing Remover
J–42809
Ring Gear Installer
J–2619–01
Slide Hammer
J–22912–01
Bearing Remover
SECTION
BRAKE CONTROL SYSTEM
5A–1
AXIOM
BRAKES
CONTENTS
Brake Control System . . . . . . . . . . . . . . . . . . . .
Anti–lock Brake System . . . . . . . . . . . . . . . . . .
Power–assisted Brake System . . . . . . . . . . . .
Parking Brakes (4x4 Model) . . . . . . . . . . . . . .
Parking Brakes (4x2 Model) . . . . . . . . . . . . . .
5A–1
5B–1
5C–1
5D1–1
5D2–1
Brake Control System
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . .
General Description . . . . . . . . . . . . . . . . . . . . .
Functional Description . . . . . . . . . . . . . . . . .
System Components . . . . . . . . . . . . . . . . . . .
Electronic Hydraulic Control Unit (EHCU) .
ABS Warning Light . . . . . . . . . . . . . . . . . . . .
Wheel Speed Sensor . . . . . . . . . . . . . . . . . .
G-Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Normal and Anti-lock Braking . . . . . . . . . . .
Brake Pedal Travel . . . . . . . . . . . . . . . . . . . .
Acronyms and Abbreviations . . . . . . . . . . . .
General Diagnosis . . . . . . . . . . . . . . . . . . . . . . .
General Information . . . . . . . . . . . . . . . . . . . .
ABS Service Precautions . . . . . . . . . . . . . . .
Computer System Service Precautions . . .
General Service Precautions . . . . . . . . . . . .
Note on Intermittents . . . . . . . . . . . . . . . . . . .
Test Driving ABS Complaint Vehicles . . . . .
“ABS” Warning Light . . . . . . . . . . . . . . . . . . .
Normal Operation . . . . . . . . . . . . . . . . . . . . .
Tech 2 Scan Tool . . . . . . . . . . . . . . . . . . . . . .
DATA LIST . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACTUATOR TEST . . . . . . . . . . . . . . . . . . . . .
Tech 2 Service Bleed . . . . . . . . . . . . . . . . . .
Basic Diagnostic Flow Chart . . . . . . . . . . . .
Basic Inspection Procedure . . . . . . . . . . . . .
EHCU Connector Pin-out Checks . . . . . . . . .
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . .
Connector List . . . . . . . . . . . . . . . . . . . . . . . .
Part Location . . . . . . . . . . . . . . . . . . . . . . . . .
Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . .
Chart A-1 ABS Works Frequently But
Vehicle Does Not Decelerate . . . . . . . . . . .
Chart TA-1 ABS Works Frequently But
Vehicle Does Not Decelerate
(Use TECH 2) . . . . . . . . . . . . . . . . . . . . . . . .
Chart A-2 Uneven Braking Occurs While
ABS Works . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart TA-2 Uneven Braking Occurs While
ABS Works (Use TECH 2) . . . . . . . . . . . . .
5A–2
5A–3
5A–4
5A–10
5A–10
5A–10
5A–10
5A–10
5A–10
5A–10
5A–11
5A–11
5A–11
5A–11
5A–11
5A–11
5A–11
5A–12
5A–12
5A–12
5A–13
5A–16
5A–17
5A–21
5A–22
5A–23
5A–24
5A–25
5A–28
5A–29
5A–30
5A–30
5A–31
5A–31
5A–31
Chart A-3, TA-3 The Wheels Are Locked .
Chart A-4 Brake Pedal Feed Is Abnormal .
Chart A-5, TA-5 Braking Sound
(From EHCU) Is Heard While Not Braking
Diagnostic Trouble Codes . . . . . . . . . . . . . . . .
Diagnosis By “ABS” Warning Light
Illumination Pattern . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Codes (DTCs) . . . . . . .
Chart B-1 With the key in the ON position
(Before starting the engine). Warning light
(W/L) is not activated. . . . . . . . . . . . . . . . . .
Chart B-2 CPU Error (DTC 14 (Flash out) /
C0271, C0272, C0273, C0284 (Serial
communications)) . . . . . . . . . . . . . . . . . . . . .
Chart B-3 Low or High Ignition Voltage
(DTC 15 (Flash out) / C0277, 0278 (Serial
communications)) . . . . . . . . . . . . . . . . . . . . .
Chart B-4 Excessive Dump Time (DTC 17
(Flash out) / C0269 (Serial
communications)) . . . . . . . . . . . . . . . . . . . . .
Chart B-5 Excessive Isolation Time
(DTC 18 (Flash out) / C0274
(Serial communications)) . . . . . . . . . . . . . . .
Chart B-6 G-Sensor Output Failure
(DTC 21 (Flash out) / C0276
(Serial communications)) . . . . . . . . . . . . . . .
Chart B-7 Brake Switch Failure
(DTC 22 (Flash out) / C0281
(Serial communications)) . . . . . . . . . . . . . . .
Chart B-8 2WD Controller in 4WD Vehicle
Controller (DTC 13 (Flash out) / C0285
(Serial communications)), 4WD State Input
Signal Failure (DTC 24 (Flash out) / C0282
(Serial communications)) . . . . . . . . . . . . . . .
Chart B-9 Pump Motor Failure
(DTC 32 (Flash out) / C0267, C0268
(Serial communications)) . . . . . . . . . . . . . . .
Chart B-10 EHCU Valve Relay Failure
(DTC 35 (Flash out) / C0265, C0266
(Serial communications)) . . . . . . . . . . . . . . .
Chart B-11 FL Isolation Solenoid Coil Failure
(DTC 41 (Flash out) / C0245, C0247
(Serial communications)) . . . . . . . . . . . . . . .
Chart B-12 FL Dump Solenoid Coil Failure
(DTC 42 (Flash out) / C0246, C0248
(Serial communications)) . . . . . . . . . . . . . . .
5A–32
5A–32
5A–33
5A–34
5A–36
5A–37
5A–39
5A–39
5A–40
5A–40
5A–40
5A–41
5A–41
5A–42
5A–42
5A–43
5A–43
5A–43
5A–2
BRAKE CONTROL SYSTEM
Chart B-13 FR Isolation Solenoid Coil Failure
(DTC 43 (Flash out) / C0241, C0243
(Serial communications)) . . . . . . . . . . . . . . .
5A–44
Chart B-14 FR Dump Solenoid Coil Failure
(DTC 44(Flash out) / C0242, C0244
(Serial communications)) . . . . . . . . . . . . . . .
5A–44
Chart B-15 Rear Isolation Solenoid Coil
Failure (DTC 45 (Flash out) / C0251, C0253
(Serial communications)) . . . . . . . . . . . . . . .
5A–44
Chart B-16 Rear Dump Solenoid Coil Failure
(DTC 46 (Flash out) / C0252, C0254
(Serial communications)) . . . . . . . . . . . . . . .
5A–45
Chart B-17 FL Speed Sensor Open or Shorted
(DTC 51 (Flash out) / C0225
(Serial communications)) . . . . . . . . . . . . . . .
5A–45
Chart B-18 FR Speed Sensor Open or Shorted
(DTC 52 (Flash out) / C0221
(Serial communications)) . . . . . . . . . . . . . . .
5A–46
Chart B-19 Rear Speed Sensor Open or
Shorted (DTC 53 (Flash out) / C0235
(Serial communications)) . . . . . . . . . . . . . . .
5A–47
Chart B-20 FL Speed Sensor Missing Signal
(DTC 61 (Flash out) / C0226, C0227
(Serial communications)) . . . . . . . . . . . . . . .
5A–48
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.
Chart B-21 FR Speed Sensor Missing Signal
(DTC 62 (Flash out) / C0222, C0223
(Serial communications)) . . . . . . . . . . . . . . .
Chart B-22 Rear Speed Sensor Missing Signal
(DTC 63 (Flash out) / C0236, C0237
(Serial communications)) . . . . . . . . . . . . . . .
Chart B-23 Simultaneous Drop-out of Front
Speed Sensor Signal (DTC 64 (Flash out) /
C0229 (Serial communications)) . . . . . . . .
Chart B-24 Wheel Speed Input Abnormality
(DTC 65 (Flash out) / C0238 (Serial
communications)) . . . . . . . . . . . . . . . . . . . . .
Unit Inspection Procedure . . . . . . . . . . . . . . . .
Chart C-1-1 FL Sensor Output Inspection
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart C-1-2 FR Sensor Output Inspection
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart C-1-3 Rear Sensor Output Inspection
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart TC-1 Sensor Output Inspection
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . .
5A–49
5A–50
5A–51
5A–52
5A–53
5A–53
5A–54
5A–54
5A–55
5A–56
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
5A–3
General Description
The Anti-lock Brake System (ABS) works on all four
wheels. A combination of wheel speed sensor and
Electronic Hydraulic Control Unit (EHCU) can determine
when a wheel is about to stop turning and adjust brake
pressure to maintain best braking.
This system helps the driver maintain greater control of
the vehicle under heavy braking conditions.
NOTE: The Electronic Hydraulic Control Unit (EHCU)
comprises the Hydraulic Unit (H/U) and the coil Integrated
Module.
C05RW004
Legend
(1) Electronic Line
(2) Hydraulic Line
(3) Hydraulic Unit (H/U)
(4)
(5)
(6)
(7)
Coil Integrated Module
Front Wheel Speed Sensor
Rear Wheel Speed Sensor
Proportioning and Bypass (P&B) Valve
5A–4
BRAKE CONTROL SYSTEM
Functional Description
Hydraulic Unit (H/U)
Solenoid Valve
C05RW012
Legend
(1) Isolation Valve
(2) Dump valve
BRAKE CONTROL SYSTEM
5A–5
Normal Braking
During normal (non anti-lock) braking, the solenoid valves
has current flow. The dump valve is closed and the
isolation valve is opened due to spring force.
Brake fluid travels through the centre of the isolation valve
(normally open) around the dump valve (normally closed)
then to the brake pistons.
C05RW010
Legend
(1) Brake
(2) Master Cylinder
5A–6
BRAKE CONTROL SYSTEM
Pressure Isolation (Pressure Maintain)
The electro-hydraulic control unit is activated when the
brakes are applied.
If the information from the wheel speed sensors indicates
excessive wheel deceleration (imminent lockup), the first
step in the anti-lock sequence is to isolate the brake
pressure being applied by the brake pedal.
The microprocessor in the coil integrated module sends a
voltage to the coil to energize and close the isolation
valve. This prevents any additional fluid pressure applied
by the brake pedal from reaching the wheel. With the
isolation valves closed, unnecessary increase in the
brake pressure is prevented.
C05RW011
Legend
(1) Brake
(2) Master Cylinder
BRAKE CONTROL SYSTEM
5A–7
Pressure Reduction
Once the brake pressure is isolated, it must be reduced to
allow the wheels to unlock. This is accomplished by
dumping a portion of the brake fluid pressure into a low
pressure accumulator.
The microprocessor activates the normally closed dump
valve to open, allowing fluid from the wheels to be
dumped into the accumulator. This is done with very short
activation pulses opening and closing the dump valve
passageway. Brake pressure is reduced at the wheel and
allows the wheel to begin rotating again. The fluid from the
brake piston is stored in the accumulator against spring
pressure and a portion of this fluid also primes the pump.
The dump valves are operated independently to control
the deceleration of the wheel.
C05RW009
Legend
(1) Brake
(2) Master Cylinder
5A–8
BRAKE CONTROL SYSTEM
Pressure Increase (Re-apply)
The re-apply sequence is initiated to achieve optimum
braking. The isolation valve is momentarily opened to
allow master cylinder and pump pressure to reach the
brakes. This controlled pressure rise continues until the
wheel is at optimum brake output or until the brake
pressure is brought up to the master cylinder output
pressure.
If more pressure is required, more fluid is drawn from the
master cylinder and applied to the brakes. The driver may
feel slight pedal pulsations, or pedal drop, this is normal
and expected.
As fluid is re-applied to the brakes, the wheel speed will
reduce. If the wheels approach imminent lockup again,
the module will isolate, dump and re-apply again. This
cycle occurs in millisecond intervals, allowing several
cycles to occur each second. It is a much faster and more
controlled way of “pumping the pedal”.
C05RW014
Legend
(1) Brake
(2) Master Cylinder
BRAKE CONTROL SYSTEM
5A–9
Brake Release
At the end of the anti-lock stop, when the brake pedal is
released, the pump will remain running for a short time to
help drain any fluid from the accumulators. As this fluid
returns into the system, the spring forces the piston back
to its original position.
The isolation valve opens and fluid may return to the
master cylinder. Conventional braking is then resumed.
C05RW013
Legend
(1) Brake
(2) Master Cylinder
5A–10
BRAKE CONTROL SYSTEM
System Components
Electronic Hydraulic Control Unit (EHCU), three Wheel
Speed Sensors, Warning Light, and G-sensor.
Electronic Hydraulic Control Unit (EHCU)
The EHCU consists of ABS control circuits, fault detector,
and a fail-safe. The signal received from each sensor
activates the hydraulic unit accordingly and cancels the
ABS to return to normal braking if a malfunction occurs in
the ABS system.
The EHCU has a self-diagnosing function which can
indicate faulty circuits during diagnosis.
The EHCU is mounted on the engine compartment rear
right side. It consists of a Motor, Plunger Pump, Solenoid
Valves.
Solenoid Valves: Reduces or holds the caliper fluid
pressure for each front disc brake or both rear disc brakes
according to the signal sent from the EHCU.
Reservoir: Temporarily holds the brake fluid that returns
from the front and rear disc brake caliper so that pressure
of front disc brake caliper can be reduced smoothly.
Plunger Pump: Feeds the brake fluid held in the reservoir
to the master cylinder.
Motor: Drives the pump according to the signal from
EHCU.
Check Valve: Controls the brake fluid flow.
ABS Warning Light
If the “ABS” light stays “ON” after the ignition switch is
turned to the “ON” position, or comes “ON” and stays
“ON” while driving, the Anti-lock Brake System should be
inspected for a malfunction according to the diagnosis
procedure.
Wheel Speed Sensor
It consists of a sensor and a rotor. The sensor is attached
to the knuckle on the front wheels and to the rear axle
case on the rear differential.
The front sensor rotor is attached to the each brake rotor
by bolts.
The rear rotor is press-fit in the differential case.
The magnetic flux generated from electrodes magnetized
by a magnet in the sensor varies due to rotation of the
rotor, and the electromagnetic induction generates
alternating voltage in the coil. This voltage draws a “sine
curve” with the frequency proportional to rotor speed and
it allows detection of wheel speed.
G-Sensor
The G-sensor installed inside the EHCU detects the
vehicle deceleration speed and sends a signal to the
EHCU. In 4WD operation, all four wheels may be
decelerated in almost the same phase, since all wheels
are connected mechanically.
This tendency is noticeable particularly on roads with low
friction coefficient, and the ABS control is adversely
affected.
The G-sensor judges whether the friction coefficient of
road surface is low or high, and changes the EHCU’s
operating system to ensure ABS control.
Normal and Anti-lock Braking
821R200015
Vehicles equipped with the Anti-lock Brake System have
an amber “ABS” warning light in the instrument panel.
The “ABS” warning light will illuminate if a malfunction in
the Anti-lock Brake System is detected by the Electronic
Hydraulic Control Unit (EHCU).In case of an electronic
malfunction, the EHCU will turn “ON” the “ABS” warning
light and disable the Anti-lock braking function.
The “ABS” light will turn “ON” for approximately three
seconds after the ignition switch is turned to the “ON”
position.
Under normal driving conditions, the Anti-lock Brake
System functions the same as a standard power assisted
brake system. However, with the detection of wheel
lock-up, a slight bump or kick-back will be felt in the brake
pedal. This pedal “bump” will be followed by a series of
short pedal pulsations which occurs in rapid succession.
The brake pedal pulsation will continue until there is no
longer a need for the anti-lock function or until the vehicle
is stopped. A slight ticking or popping noise may be heard
during brake applications when the Anti-lock features is
being used.
When the Anti-lock feature is being used, the brake pedal
may rise even as the brakes are being applied. This is
also normal. Maintaining a constant force on the pedal
will provide the shortest stopping distance.
Brake Pedal Travel
Vehicles equipped with the Anti-lock Brake System may
be stopped by applying normal force to the brake pedal.
Although there is no need to push the pedal beyond the
point where it stops or holds the vehicle, by applying more
force the pedal will continue to travel toward the floor.
This extra brake pedal travel is normal.
BRAKE CONTROL SYSTEM
Acronyms and Abbreviations
Several acronyms and abbreviations are commonly used
throughout this section:
ABS
Anti-lock Brake System
CIM
Coil Integrated Module
CKT
Circuit
DLC
Data Link Connector
EHCU
Electronic Hydraulic Control Unit
FL
Front Left
FR
Front Right
GEN
Generator
H/U
Hydraulic Unit
MV
Millivolts
RR
Rear
RPS
Revolution per Second
VDC
DC Volts
VAC
AC Volts
W/L
Warning Light
WSS
Wheel Speed Sensor
General Diagnosis
General Information
ABS troubles can be classified into two types, those
which can be detected by the ABS warning light and those
which can be detected as a vehicle abnormality by the
driver.
In either case, locate the fault in accordance with the
“BASIC DIAGNOSTIC FLOWCHART” and repair.
Please refer to Section 5C for the diagnosis of
mechanical troubles such as brake noise, brake judder
(brake pedal or vehicle vibration felt when braking),
uneven braking, and parking brake trouble.
ABS Service Precautions
Required Tools and Items:
B Box Wrench
B Brake Fluid
B Special Tool
5A–11
Some diagnosis procedures in this section require the
installation of a special tool.
J-39200 High Impedance Multimeter
When circuit measurements are requested, use a circuit
tester with high impedance.
Computer System Service Precautions
The Anti-lock Brake System interfaces directly with the
Electronic Hydraulic Control Unit (EHCU) which is a
control computer that is similar in some regards to the
Powertrain Control Module. These modules are designed
to withstand normal current draws associated with
vehicle operation. However, care must be taken to avoid
overloading any of the EHCU circuits. In testing for opens
or shorts, do not ground or apply voltage to any of the
circuits unless instructed to do so by the appropriate
diagnostic procedure. These circuits should only be
tested with a high impedance multimeter (J-39200) or
special tools as described in this section. Power should
never be removed or applied to any control module with
the ignition in the “ON” position.
Before removing or connecting battery cables, fuses or
connectors, always turn the ignition switch to the “OFF”
position.
General Service Precautions
The following are general precautions which should be
observed when servicing and diagnosing the Anti-lock
Brake System and/or other vehicle systems. Failure to
observe these precautions may result in Anti-lock Brake
System damage.
B If welding work is to be performed on the vehicle using
an electric arc welder, the EHCU and valve block
connectors should be disconnected before the
welding operation begins.
B The EHCU and valve block connectors should never
be connected or disconnected with the ignition “ON” .
B If only the rear wheels are rotated using jacks or drum
tester, the system will diagnose a speed sensor
malfunction and the “ABS” warning light will
illuminate. But actually no trouble exists. After
inspection stop the engine once and re-start it, then
make sure that the “ABS” warning light does not
illuminate.
If the battery has been discharged
The engine may stall if the battery has been completely
discharged and the engine is started via jumper cables.
This is because the Anti-lock Brake System (ABS)
requires a large quantity of electricity. In this case, wait
until the battery is recharged, or set the ABS to a
non-operative state by removing the fuse for the ABS
(50A). After the battery has been recharged, stop the
engine and install the ABS fuse. Start the engine again,
and confirm that the ABS warning light does not light.
Note on Intermittents
As with virtually any electronic system, it is difficult to
identify an intermittent failure. In such a case duplicating
the system malfunction during a test drive or a good
description of vehicle behavior from the customer may be
helpful in locating a “most likely” failed component or
5A–12
BRAKE CONTROL SYSTEM
circuit. The symptom diagnosis chart may also be useful
in isolating the failure. Most intermittent problems are
caused by faulty electrical connections or wiring. When
an intermittent failure is encountered, check suspected
circuits for damage:
B Suspected harness damage.
B Poor mating of connector halves or terminals not fully
seated in the connector body (backed out).
B Improperly formed or damaged terminals.
Test Driving ABS Complaint Vehicles
In case of an intermittent ABS lamp illumination, see
“Diagnosis by ABS Warning Light illumination Pattern” or
go to 5A–37. In some cases, the vehicle may need to be
test driven by following the test procedure below.
1. Start the engine and make sure that the “ABS” W/L
goes OFF. If the W/L remains ON, it means that the
Diagnostic Trouble Code (DTC) is stored. Therefore,
read the code and locate the fault.
NOTE: The DTC cannot be cleared if the vehicle speed
does not exceed 12 km/h (8 mph) at DTC, even though
the repair operation is completed.
2. Start the vehicle and accelerate to about 30 km/h (19
mph) or more.
3. Slowly brake and stop the vehicle completely.
4. Then restart the vehicle and accelerate to about 40
km/h (25 mph) or more.
5. Brake at a time so as to actuate the ABS and stop the
vehicle.
6. Be cautious of abnormality during the test. If the W/L
is actuated while driving, read the DTC and locate the
fault.
7. If the abnormality is not reproduced by the test, make
best efforts to reproduce the situation reported by the
customer.
8. If the abnormality has been detected, repair in
accordance with the “SYMPTOM DIAGNOSIS” .
NOTE:
B Be sure to give a test drive on a wide, even road with a
small traffic.
B If an abnormality is detected, be sure to suspend the
test and start trouble diagnosis at once.
“ABS” Warning Light
When ABS trouble occurs to actuate “ABS” warning light,
the trouble code corresponding to the trouble is stored in
the EHCU. Only ordinary brake is available with ABS
being unactuated. Even when “ABS” warning light is
actuated, if the starter switch is set ON after setting it OFF
once, the EHCU checks up on the entire system and, if
there is no abnormality, judges ABS to work currently and
the warning light is lit normally even though the trouble
code is stored.
NOTE: Illumination of the “ABS” warning light indicates
that anti-lock braking is no longer available. Power
assisted braking without anti-lock control is still available.
Normal Operation
“ABS” Warning Light
When the ignition is first moved from “OFF” to “RUN” , the
amber “ABS” warning light will turn “ON” . The “ABS”
warning light will turn “ON” during engine starting and will
usually stay “ON” for approximately three seconds after
the ignition switch is returned to the “ON” position. The
warning light should remain “OFF” at all other times.
BRAKE CONTROL SYSTEM
5A–13
Tech 2 Scan Tool
From 98 MY, Isuzu dealer service departments are
recommended to use Tech 2. Please refer to Tech 2 scan
tool user guide.
901RW257
Legend
(1) PCMCIA Card
(2) SAE 16/19 Adaptor
(3) DLC Cable
(4) Tech–2
5A–14
BRAKE CONTROL SYSTEM
Getting Started
B Before operating the Isuzu PCMCIA card with the
Tech 2, the following steps must be performed:
1. The Isuzu 98 System PCMCIA card (1) inserts into
the Tech 2 (4).
2. Connect the SAE 16/19 adapter (2) to the DLC cable
(3).
3. Connect the DLC cable to the Tech 2 (4).
4. Make sure the vehicle ignition is off.
5. Connect the Tech 2 SAE 16/19 adapter to the vehicle
DLC.
Operating Procedure
The power up screen is displayed when you power up the
tester with the Isuzu systems PCMCIA card. Follow the
operating procedure below.
826R200011
6. The vehicle ignition turns on.
7. Power up the Tech 2.
8. Verify the Tech 2 power up display.
060R100102
060RW009
BRAKE CONTROL SYSTEM
060R200078
5A–15
5A–16
BRAKE CONTROL SYSTEM
DATA LIST
The data displayed by DATA LIST are as follows:
Display
Content
OK/NG Criteria for Data
Front Left Wheel Speed
Front Right Wheel Speed
Rear Wheel Speeds
km/h (MPH)
B Start the vehicle and make sure of linear change in
each wheel speed.
B Turn each wheel by hand and make sure that each
speed data change.
Warning Lamp
ON/OFF
B To be OFF usually
ABS State
ON/OFF
B To be OFF usually
ABS Relay
Active/Inactive
B To be Active usually
4 Wheel Drive
Active/Inactive
B 2WD: Inactive
B 4WD: Active
Brake Switch
Active/Inactive
B Inactive (Released)
B Active (Pressed)
Brake Fluid Level
Normal or not
B To be Normal usually
Return Pump
Active/Inactive
B To be Inactive usually
DRP (Dynamic Rear
Proportioning)
Active/Inactive
B To be Inactive usually
Rear Dump Valve Commanded
Active/Inactive
B To be Inactive usually
Active/Inactive
B To be Inactive usually
Active/Inactive
B To be Inactive usually
G–Sensor
Voltage
B 2.50V when vehicle is stopped
Battery Voltage
Voltage
B Between 10–16.9V
Rear Dump Valve Feedback
Rear Isolation Valve
Commanded
Rear Isolation Valve Feedback
FL Dump Valve Commanded
FL Dump Valve Feedback
FL Isolation Valve Commanded
FL Isolation Valve Feedback
FR Dump Valve Commanded
FR Dump Valve Feedback
FR Isolation Valve
Commanded
FR Isolation Valve Feedback
BRAKE CONTROL SYSTEM
5A–17
ACTUATOR TEST
This mode is used to exercise the ABS actuators and
make sure they operate normally. Prior to the test, pay
attention to the cautions below. (When checking the
solenoid valve system, be sure to jack up the vehicle.)
CAUTION:
B Before testing, be sure that the brakes work normally.
B Make sure that the battery is fully charged.Conduct
the test by two persons (A TECH 2 operator and a
vehicle checker).
B Be sure to start ACTUATOR TEST with the engine
stopped.
B Before testing, make sure that electrical trouble, if
any, has been completely repaired. Conducting tests
of ABS solenoid with electrical circuit problem
remaining uncorrected could damage the control unit.
F05R200001
5A–18
BRAKE CONTROL SYSTEM
F05R200002
BRAKE CONTROL SYSTEM
5A–19
F05R200003
5A–20
BRAKE CONTROL SYSTEM
F05R200004
BRAKE CONTROL SYSTEM
5A–21
Tech 2 Service Bleed
F05R200005
5A–22
BRAKE CONTROL SYSTEM
F05R200006
Basic Diagnostic Flow Chart
Step
1
Action
Verify DTC through: “F0: Diagnostic Trouble Codes.”
Is the DTC stored in the EHCU?
3
1. Repair of faulty part.
2. Clear DTC.
3. Inspection of “ABS” W/L Illumination pattern with ignition SW
“ON”.
4. Test drive.
Does trouble repeat?
4
Go to Step 2
Go to Step 4
Clear code and
check for
repeatability.
Go to Step 3
Go to Step 5
Repeat the
diagnosis it the
symptom or DTC
appears again
Go to Step 1
Go to Step 5
Clear code and
check for
repeatability
Go to Step 3
Trouble diagnosis
based on
symptom (Refer
to Symptom
Diagnosis)
Go to Step 3
Finished
Go to Step 5
Verify DTC through: “F0: Diagnostic Trouble Codes.”
Is the DTC stored in the EHCU?
5
No
1. Verify complaint with the customer.
2. Questioning to customer.
3. Basic inspection (Refer to Basic inspection procedure)
Using TECH 2?
2
Yes
1. Reconnect all components. Ensure that all component are
properly mounted.
2. Clear diagnostic trouble code.
Was this step finished?
BRAKE CONTROL SYSTEM
5A–23
Basic Inspection Procedure
1. Basic Inspection of Service Brake
Step
1
2
3
4
5
Action
Yes
No
Go to Step 2
Replenish with
fluid
Go to Step 2
Repair
Go to Step 3
Go to Step 3
Go to Step 4
Repair
Go to Step 4
Go to Step 5
Repair
Go to Step 5
Finished
Go to Step 5
Yes
No
Go to Step 2
Repair
Go to Step 2
Finished
Go to Step 2
Is the fluid level normal?
Does fluid leak?
Is the booster functioning properly?
Is the pad and rotor within specs?
Reconnect all components. Ensure all component are properly
mounted.
Was this step finished?
2. Ground Inspection
Step
1
2
Action
Is there good contact with the ABS ground points?
Reconnect all components. Ensure that all component are
properly mounted.
5A–24
BRAKE CONTROL SYSTEM
EHCU Connector Pin-out Checks
B Disconnect Electronic Hydraulic Control Module.
B Perform checks with high impedance digital
multimeter J-39200 or equivalent.
No.
Circuit to be Tested
Ignition
Switch
Position
Multimeter
Scale/Range
Measure
between Pin
Number
Nominal Value
1
Power supply
OFF
20DCV
1 (C–5)
2 (C–5)
11.5V to 14.5V
2
Ignition enable
OFF
20DCV
1 (C–6)
7 (C–6)
0V to 0.1V
ON
20DCV
1 (C–6)
7 (C–6)
11.5V to 14.5V
Note
3
Stoplamp switch
OFF
20DCV
13 (C–6)
7 (C–6)
10.5V to 14.5V
4
Ground connection
OFF
200W
7 (C–6)
Ground
Less than 2W
OFF
1W
2 (C–5)
Ground
Less than 0.2W
OFF
2kW
2 (C–6)
10 (C–6)
2.0kW to 2.8kW
OFF
200kW
2 (C–6)
7 (C–6)
more than
100kW
Insulation Resistance
OFF
200mACV
2 (C–6)
10 (C–6)
more than
200mV
Turn wheel at 1RPS
OFF
2kW
3 (C–6)
11 (C–6)
2.0kW to 2.8kW
Internal Resistance
OFF
200kW
3 (C–6)
7 (C–6)
more than
100kW
Insulation Resistance
OFF
200mACV
3 (C–6)
11 (C–6)
more than
200mV
Turn wheel at 1RPS
OFF
2kW
4 (C–6)
12 (C–6)
1.2kW to 2.0kW
Internal Resistance
OFF
200kW
4 (C–6)
7 (C–6)
more than
100kW
Insulation Resistance
OFF
200mACV
4 (C–6)
12 (C–6)
more than
200mV
Turn wheel at 1RPS
5
6
7
FL speed sensor
FR speed sensor
RR speed sensor
Press brake pedal
Internal Resistance
BRAKE CONTROL SYSTEM
5A–25
Circuit Diagram
D05R200004
5A–26
BRAKE CONTROL SYSTEM
D05R200002
BRAKE CONTROL SYSTEM
5A–27
D05R200003
5A–28
BRAKE CONTROL SYSTEM
Connector List
No.
Connector face
No.
B-15
H-5
C-1
C-28
H-8
C-5
C-6
C-10
C-16
E-23
C-27
C-37
H-14
H-16
H-20
I-18
I-23
C-39
I-24
F-4
X-15
Connector face
BRAKE CONTROL SYSTEM
5A–29
Part Location
810R200002
Legend
(1) Battery
(2) Fuse & Relay Box
(3) C–16
(4) C–5
(5) C–6
(6) H–8, 14
(7) I–18
(8) Starter Switch
(9)
(10)
(11)
(15)
(16)
(17)
(19)
(21)
I–24
C–39
F–4
C–10
C–28
H–5
E–23
C–1
5A–30
BRAKE CONTROL SYSTEM
Symptom Diagnosis
The symptoms that cannot be indicated by warning light
can be divided in the following five categories:
1. ABS works frequently but vehicle does not
decelerate.
2. Uneven braking occurs while ABS works.
3. The wheels lock during braking.
4. Brake pedal feel is abnormal.
5. Braking sound (from EHCU) is heard while not
braking.
These are all attributed to problems which cannot be
detected by EHCU self-diagnosis. Use the customer
complaint and test to determine which symptom is
present. Then follow the appropriate flow chart listed
below.
No
No.
Symptom
Sym
tom
Diagnostic Flow Charts
Without TECH 2
With TECH 2
1
ABS works frequently but vehicle does not decelerate.
Chart A-1
Chart TA-1
2
Uneven braking occurs while ABS works.
Chart A-2
Chart TA-2
3
The wheels are locked.
Chart A-3
Chart TA-3
4
Brake pedal feel is abnormal.
Chart A-4
—
5
Braking sound (from EHCU) is heard while not braking.
Chart A-5
Chart TA-5
Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate
Step
Action
1
Is braking force distribution normal between front and rear of
vehicle?
2
3
4
5
6
7
Yes
No
Go to Step 2
Repair brake
parts.
Go to Step 7
Go to Step 3
Repair axle parts.
Go to Step 7
Repair wheel
speed sensor.
Go to Step 7
Go to Step 4
Replace or repair
sensor or sensor
ring.
Go to Step 7
Go to Step 5
Go to Step 6
Replace wheel
speed sensor or
repair harness.
Go to Step 7
Go to Step 7
Replace TOD
control unit or
repair harness.
Go to Step 7
Repeat the “Basic
diagnostic flow
chart”
Go to Step 7
Are axle parts installed normally?
Is there play in each or any wheel speed sensor?
Is there damage, or powdered iron sticking to each or any wheel
speed sensor/sensor ring?
Is the output of each wheel speed sensor normal? (Refer to Chart
C-1 or TC-1)
Is the input of TOD control unit normal?
Reconnect all components, ensure all components are properly
mounted.
Was this step finished?
BRAKE CONTROL SYSTEM
5A–31
Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)
Step
1
Action
Go to Step 2
Replace wheel
speed sensor.
Go to Step 3
Go to Step 3
Go to Step 2
Repeat the “Basic
diagnostic flow
chart”
Go to Step 3
Yes
No
Repair.
Go to Step 5
Go to Step 2
Repair.
Go to Step 5
Go to Step 3
Go to Step 4
Replace sensor
or repair harness.
Go to Step 5
Replace H/U.
Go to Step 5
Reconnect brake
pipe correctly.
Go to Step 5
Repeat the “Basic
diagnostic flow
chart”
Go to Step 5
Return to Chart A-1.
Was the Chart A-1 finished?
3
No
1. Connect TECH 2.
2. Make sure of the output conditions of each sensor.
Is the output of each sensor normal?
2
Yes
Reconnect all components, ensure all components are properly
mounted.
Was this step finished?
Chart A-2 Uneven Braking Occurs While ABS Works
Step
1
2
3
4
5
Action
Is there play in each or any sensor?
Damage or powdered iron sticking to each or any sensor/sensor
ring?
Is the output of each sensor normal? (Refer to Chart C-1 or TC-1)
Is brake pipe connecting order correct?
Reconnect all components, ensure all components are properly
mounted.
Was this step finished?
Chart TA-2 Uneven Braking Occurs While ABS Works (Use TECH 2)
Step
1
Action
Check piping by TECH 2 ACTUATOR TEST
Is the piping normal?
3
Go to Step 2
Go to Step 3
Replace EHCU.
Go to Step 4
Repair the pipe.
Go to Step 4
Go to Step 4
Go to Step 3
Repeat the “Basic
diagnostic flow
chart”
Go to Step 4
Repair and check the wheel speed sensor (Refer to Chart B-20 to
B-23 , C-1 or TC-1).
Was the each chart finished?
4
No
1. Connect TECH 2.
2. Make sure of the output conditions of each sensor.
Is the output of each sensor normal?
2
Yes
Reconnect all components, ensure all components are properly
mounted.
Was this step finished?
5A–32
BRAKE CONTROL SYSTEM
Chart A-3, TA-3 The Wheels Are Locked
Step
Action
Yes
No
1
Is ABS working?
Go to Step 2
Go to Step 4
2
Is vehicle speed under 10 km/h (6mph)?
Go to Step 3
Normal.
3
Is sensor output normal? (Chart C-1 or TC-1)
Go to Step 4
Replace sensor
or repair harness.
Go to Step 6
Go to Step 5
Replace TOD
control unit or
repair harness.
Go to Step 6
Replace EHCU.
Go to Step 6
Repair.
Go to Step 6
Repeat the “Basic
diagnostic flow
chart”
Go to Step 6
Yes
No
Go to Step 2
Go to Step 3
Go to Step 4
Harness NG
between brake
SW and EHCU.
Go to Step 6
Go to Step 5
Replace stop light
fuse.
Go to Step 6
Go to Step 6
Repair body
grounded
harness.
Go to Step 6
Repair stop light
harness.
Go to Step 6
Replace brake
SW.
Go to Step 6
Repeat the “Basic
diagnostic flow
chart”
Go to Step 6
4
Is front TOD control unit normal?
5
Is hydraulic unit grounded properly?
6
Reconnect all components, ensure all components are properly
mounted.
Was this step finished?
Chart A-4 Brake Pedal Feed Is Abnormal
Step
Action
1
Is the stop light actuated when the brake pedal is depressed?
2
1. Turn the ignition switch off.
2. Disconnected EHCU connector.
Is the check voltage EHCU connector terminals 13 to 7 when
brake pedal is depressed than battery voltage?
3
4
Is stop light fuse normal?
Is the check continuity between EHCU connector terminals, 7 to
body grounded?
5
Is brake SW normal?
6
Reconnect all components, ensure all components are properly
mounted.
Was this step finished?
BRAKE CONTROL SYSTEM
5A–33
Chart A-5, TA-5 Braking Sound (From EHCU) Is Heard While Not Braking
Step
1
2
3
Action
Is this the first vehicle start after engine start?
Is vehicle speed under 10 km/h (6 mph)?
Check for the following condition:
B At the time of shift down or clutch operation.
B At the time of low road friction drive (ice or snow road) or rough
road drive.
B At the time of high-speed turn.
B At the time of passing curb.
B At the time of operating electrical equipment switches.
B At the time of racing the engine (over 5000 rpm).
Did it occur under any one condition above?
4
5
6
7
Is there play in each or any sensor/wheel speed sensor rings?
Damage or powdered iron sticking to each or any sensor/wheel
speed sensor ring?
Is each sensor output normal? (Refer to Chart C-1 or TC-1).
Reconnect all components, ensure all components are properly
mounted.
Was this step finished?
Yes
No
Normal.
(It is self
checking sound.)
Go to Step 2
Normal.
(It is self
checking sound.)
Go to Step 3
ABS may
sometimes be
actuated even
when brake pedal
is not applied.
Go to Step 4
Repair.
Go to Step 7
Go to Step 5
Repair.
Go to Step 7
Go to Step 6
Check harness/
connector for
suspected
disconnection
If no
disconnection is
found, replace
Coil integrated
module.
Go to Step 7
Repair.
Go to Step 7
Repeat the “Basic
diagnostic flow
chart”
Go to Step 7
5A–34
BRAKE CONTROL SYSTEM
Diagnostic Trouble Codes
Choose and trace an appropriate flowchart by the
numbers listed below to find fault and repair.
Code
Flash out
Serial
Communications
Diagnosis
Item
Chart
No.
12
—
—
—
—
13
C0285
2 WD Controller in 4WD Vehicle Controller
Wiring
B-8
14
C0271
RAM read/write error
C0272
ROM checksum error
C0270
ALU function error
B-2
C0273
Inoperative isolation item
Coil
Integrated
M d l
Module
C0284
Loop time overrun
C0277
Low ignition voltage
C0278
High ignition voltage
Wiring
B-3
C0269
Excessive dump time
15
17
18
C0274
Excessive isolation time
21
C0276
G-Sensor Failure
22
C0281
Brake switch Failure
24
C0282
Open or shorted 4×4 input signal (4WD only)
32
C0267
Open motor circuit or shorted ECU output
C0268
Stalled motor or open ECU output
C0265
Open relay circuit
C0266
Shorted relay circuit
C0245
FL Open isolation solenoid or shorted ECU output
C0247
FL Shorted isolation solenoid or open ECU output
C0246
FL Open dump solenoid or shorted ECU output
C0248
FL Shorted dump solenoid or open ECU output
C0241
FR Open isolation solenoid or shorted ECU output
C0243
FR Shorted isolation solenoid or open ECU output
C0242
FR Open dump solenoid or shorted ECU output
C0244
FR Shorted dump solenoid or open ECU output
C0251
Rear Open isolation solenoid or shorted ECU output
C0253
Rear Shorted isolation solenoid or open ECU output
C0252
Rear Open dump solenoid or shorted ECU output
C0254
Rear Shorted dump solenoid or open ECU output
35
41
42
43
44
45
46
B-4
Coil
Integrated
Module
B-5
B-6
B-7
Wiring
B-8
Motor
B-9
Relay
B-10
B-11
B-12
B-13
Solenoid
B-14
B-15
B-16
BRAKE CONTROL SYSTEM
Code
Diagnosis
Item
5A–35
Chart
No.
Flash out
Serial
Communications
51
C0225
FL Open or shorted sensor
B-17
52
C0221
FR Open or shorted sensor
B-18
53
C0235
Rear Open or shorted sensor
B-19
61
C0226
FL Missing sensor signal
C0227
FL Sensor signal dropout
C0222
FR Missing sensor signal
C0223
FR Sensor signal dropout
C0236
Rear Missing sensor signal
C0237
Rear Sensor signal dropout
64
C0229
Simultaneous dropout of front sensor signal
65
C0238
Wheel speed error
—
C0286
Shorted indicator lamp
62
63
B-20
Sensor or
Wiring
B-21
B-22
B-23
Vehicle or
Sensor
B-24
Wiring
—
5A–36
BRAKE CONTROL SYSTEM
Diagnosis By “ABS” Warning Light
Illumination Pattern
In the event that there is abnormality in the “ABS” warning
light illumination pattern while the key is in the ON position
or if the warning light is actuated while driving, refer to the
flow chart below for the correct diagnostic procedure.
No.
Condition
“ABS” Warning Light Illumination Pattern
Diagnostic
1
Warning light is
actuated normally
Normal
2
Warning light is not lit
Warning light lighting circuit
trouble→Go to Chart B-1
3
Warning light remains
ON
Diagnostic trouble codes are
stored.
Display diagnostic trouble
codes and diagnose on a
code basis according to the
flow charts.
4
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.
5
Warning light goes at
12 km/h (8 mph) or
higher (After repairing
the faulty part)
Even after repairing the
faulty part the warning light
(W/L) dose not go out if
vehicle is at a stop.
Turn the ignition switch to the
ON position and drive the
vehicle at 12 km/h (8 mph) or
higher to make sure that the
warning light goes out.
BRAKE CONTROL SYSTEM
Diagnostic Trouble Codes (DTCs)
When the warning light in the meter remains ON, the
EHCU stores the fault identification and disables the
ABS.
How to display and erase DTCs:
NOTE:
B DTCs can be displayed also by TECH 2. Use
“Diagnostic Trouble Codes” mode.
5A–37
1. How to start DTC display:
B Confirm that the vehicle has come to a complete
stop (with the wheels standing still) and that the
brake pedal is not depressed. (Unless these two
condition are satisfied, DTC display cannot be
started.)
B With IGN OFF, connect #12 terminal with #4
terminal or # 5 terminal (GND) . Then turn IGN ON.
The DLC is located behind the driver side kick panel
350R200001
B Keep #12 terminal connected with #4 terminal or # 5
terminal (GND) during DTC display. (If #12 terminal
is separated from #4 terminal or # 5 terminal (GND)
during display, display will stop.)
2. DTC display:
B DTC is displayed by blinking warning light.
B Double-digit display.
B First, normal DTC 12 is displayed three times and
then any other DTCs are displayed three times. (If
no other DTCs have been stored, the display of DTC
12 will be repeated.)
3. How to erase code:
B Conduct brake switch ON/OFF operation 6 or more
times within 3 seconds of self-diagnosis startup.
B The code cannot be erased if more than 3 seconds
have passed since self-diagnosis startup, or if
self-diagnosis has started with brake switched on
(brake pedaled).
B05RW005
5A–38
BRAKE CONTROL SYSTEM
4. Notes
B If the following should occur during Diagnostic
Trouble Code (DTC) display, the display will be
discontinued. After initial check, the status that is
under the control of ABS will be returned :
– The vehicle starts (The wheels turn) or the brake
pedal is depressed.
B Up to 3 different codes can be stored.
B If the ABS should turn OFF due to an intermittent
defect, the system will be restored at the next key
cycle, if the initial check finds no abnormality (when
IGN is switched from OFF to ON).
5. An example of DTC display
B05R100001
After displaying DTC 12 three times, one DTC after
another is displayed, starting with the most recent
one. (However, display is discontinued after about 5
minutes.)
B05R100002
The DTC 12 is displayed repeatedly. (display is
discontinued after about 5 minutes after)
BRAKE CONTROL SYSTEM
5A–39
Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L)
is not activated.
Step
1
2
3
Action
Is W/L fuse disconnected?
Is W/L burnt out?
5
No
Replace fuse.
Go to Step 5
Go to Step 2
Replace W/L
bulb.
Go to Step 5
Go to Step 3
Go to Step 4
Repair harness
and connector.
Go to Step 5
Check harness
for suspected
disconnection
No fault found:
Replace EHCU.
Go to Step 5
Repair harness
and connector.
Go to Step 5
Repeat the “Basic
diagnostic flow
chart”
Go to Step 5
1. Turn the key off.
2. Disconnect coil integrated module connector (C-6).
3. Turn the key ON.
Is the check voltage between coil integrated module connector
(C-6) terminals 6 and 7 the battery voltage?
4
Yes
Is there the continuity between coil integrated module connector
(C-6) terminals, 1 and 7 and body ground.
Reconnect all components, ensure all components are properly
mounted.
Was this step finished?
Chart B-2 CPU Error (DTC 14 (Flash out) / C0271, C0272, C0273, C0284 (Serial
communications))
Step
1
Action
1.
2.
3.
4.
Go to Step 2
Repair the body
ground harness.
Go to Step 3
Replace EHCU.
Go to Step 3
Inspect in
accordance with
the DTC
displayed.
Repeat the “Basic
diagnostic flow
chart”
Go to Step 3
Turn the key off, connect the coil integrated module connector.
Erase the trouble code.
Turn Ignition off, then on, to perform system self-check.
If warning light remains on, display trouble codes once again.
Is the trouble code the DTC 14 (Flash out) / C0271, C0272,
C0273, C0284 (Serial communications)?
3
No
1. Turn the key off.
2. Disconnected coil integrated module connector.
3. Inspect coil integrated module ground.
Is there the continuity between the coil integrated module
connector terminals, 2 (C-5) and 7 (C-6) and body ground?
2
Yes
1. Reconnect all components, ensure all components are
properly mounted.
2. Clear diagnostic trouble code.
Was this step finished?
5A–40
BRAKE CONTROL SYSTEM
Chart B-3 Low or High Ignition Voltage (DTC 15 (Flash out) / C0277, 0278 (Serial
communications))
Step
1
2
Action
No
Go to Step 2
Charge or
replace battery.
Go to Step 2
Check harness
connector for
suspected
disconnection
Fault found:
Repair, and
perform system
self-check
No fault found:
replace EHCU.
Go to Step 3
Repair harness or
connector.
Go to Step 3
Repeat the “Basic
diagnostic flow
chart”
Go to Step 3
Is the battery voltage normal? (Battery capacity check)
1. Turn the key off.
2. Disconnect coil integrated module connector.
3. Turn the key on.
Is the voltage between coil integrated module connector (C-6)
terminals 1 and 7, higher than 10V?
3
Yes
1. Reconnect all components, ensure all components are
properly mounted.
2. Clear diagnostic trouble code.
Was this step finished?
Chart B-4 Excessive Dump Time (DTC 17 (Flash out) / C0269 (Serial communications))
Step
Action
1
Check for anything causing extended ABS activation, such as
locked brakes or an erratic speed sensor signal.
Was a problem found?
2
1. The key turned off.
2. Replace EHCU.
3. Reconnect all components, ensure all components are
properly mounted.
Was this step finished?
Yes
No
Repair or
Replace
Go to Step 2
Repeat the “Basic
diagnostic flow
chart”
Go to Step 2
Chart B-5 Excessive Isolation Time (DTC 18 (Flash out) / C0274 (Serial communications))
Step
Action
1
Check for anything causing extended ABS activation, such as
locked brakes or an erratic speed sensor signal.
Was a problem found?
2
1. The key turned off.
2. Replace EHCU.
3. Reconnect all components, ensure all components are
properly mounted.
Was this step finished?
Yes
No
Repair or
Replace
Go to Step 2
Repeat the “Basic
diagnostic flow
chart”
Go to Step 2
BRAKE CONTROL SYSTEM
5A–41
Chart B-6 G-Sensor Output Failure (DTC 21 (Flash out) / C0276 (Serial communications))
Step
Action
1
1. Turn the key off.
2. Replace EHCU.
3. Reconnect all components, ensure all components are
properly mounted.
Was this step finished?
Yes
No
Repeat the “Basic
diagnostic flow
chart”
Go to Step 1
Chart B-7 Brake Switch Failure (DTC 22 (Flash out) / C0281 (Serial communications))
Step
Action
1
Is the stop light actuated when the brake pedal is depressed?
2
1. Turn the key off.
2. Disconnected coil integrated module connector.
Is the check voltage between coil integrated module connector
(C-6) terminals 13 to 7 when brake pedal is depressed the battery
voltage?
3
4
5
6
Is the check that pins C-5 connector 2, and C-6 connector 7 have
good ground?
Yes
No
Go to Step 2
Go to Step 4
Go to Step 3
Harness between
brake SW and
coil integrated
module is faulty.
Go to Step 6
Check harness /
connector for
disconnection
Fault found:
Repair, and
perform system
self-check.
No fault found:
replace EHCU.
Go to Step 6
Repair.
Go to Step 6
Go to Step 5
Replace.
Go to Step 6
Abnormal
harness in stop
light circuit.
Repair the
harness.
Go to Step 6
Replace.
Go to Step 6
Repeat the “Basic
diagnostic flow
chart”
Go to Step 6
Is stop light fuse normal?
Is brake SW normal?
1. Reconnect all components, ensure all components are
properly mounted.
2. Clear diagnostic trouble code.
Was this step finished?
5A–42
BRAKE CONTROL SYSTEM
Chart B-8 2WD Controller in 4WD Vehicle Controller (DTC 13 (Flash out) / C0285 (Serial
communications)), 4WD State Input Signal Failure (DTC 24 (Flash out) / C0282 (Serial
communications))
Step
1
Action
3
No
Go to Step 2
Repair.
Go to Step 3
Replace EHCU.
Go to Step 3
Replace TOD
control unit.
Go to Step 3
Repeat the “Basic
diagnostic flow
chart”
Go to Step 3
Remove coil integrated module connector.
Is the coil integrated module connector (C-6) terminal 8 line
normally?
2
Yes
Is the TOD control unit normally?
1. Reconnect all components, ensure all components are
properly mounted.
2. Clear diagnostic trouble code.
Was this step finished?
Chart B-9 Pump Motor Failure (DTC 32 (Flash out) / C0267, C0268 (Serial
communications))
Step
Action
1
1. Turn the key off.
2. Disconnect coil integrated module connector.
3. Measure the voltage between terminal 1 of the coil integrated
module connector (C-5) and body ground.
Yes
No
Go to Step 2
Repair
fuse/harness
between battery
and coil
integrated
module connector
(C-5) terminal 1.
Go to Step 5
Go to Step 3
Connect to the
connector.
Go to Step 3
Go to Step 4
Replace EHCU.
Go to Step 5
Replace EHCU.
Go to Step 5
Replace EHCU.
Go to Step 5
Repeat the “Basic
diagnostic flow
chart”
Go to Step 5
Is the voltage equal to the battery voltage?
2
3
Is the harness from the hydraulic unit connected to the coil
integrated module connector?
Is the hydraulic unit harness in good condition?
4
Is the resistance of hydraulic unit connector terminals 1 and 2
between 0.2 and 1.0 ohms?
5
1. Reconnect all components, ensure all components are
properly mounted.
2. Clear diagnostic trouble code.
Was this step finished?
BRAKE CONTROL SYSTEM
5A–43
Chart B-10 EHCU Valve Relay Failure (DTC 35 (Flash out) / C0265, C0266 (Serial
communications))
Step
Action
1
1. Turn the key off.
2. Disconnect coil integrated module connector.
3. Measure the voltage between terminal 1 of the coil integrated
module connector (C-5) and body ground.
Is the voltage equal to the battery voltage?
2
1. Reconnect all components, ensure all components are
properly mounted.
2. Clear diagnostic trouble code.
Was this step finished?
Yes
No
Replace EHCU.
Go to Step 2
Repair fuse and
harness between
coil integrated
module connector
(C-5) terminal 1
and battery.
Go to Step 2
Repeat the “Basic
diagnostic flow
chart”
Go to Step 2
Chart B-11 FL Isolation Solenoid Coil Failure (DTC 41 (Flash out) / C0245, C0247 (Serial
communications))
Step
1
2
Action
No
Go to Step 2
Go to “EHCU
Connector
Pin–out Checks.”
Go to Step 3
Repair the
connector.
Repeat the “Basic
Diagnostic Flow
Chart.”
Repeat the “Basic
diagnostic flow
chart”
Go to Step 3
Was the “EHCU Connector Pin–out Checks” performed?
1. Turn the key switch to off.
2. Disconnect the 2–way EHCU connector (C–5) from the
EHCU.
3. Inspect the connector for damage or corrosion.
Is the connector free from damage or corrosion?
3
Yes
1. Replace the Coil Integrated Module.
2. Reconnect all components, ensure all components are
properly mounted.
Was this step finished?
Chart B-12 FL Dump Solenoid Coil Failure (DTC 42 (Flash out) / C0246, C0248 (Serial
communications))
Step
1
2
Action
No
Go to Step 2
Go to “EHCU
Connector
Pin–out Checks.”
Go to Step 3
Repair the
connector.
Repeat the “Basic
Diagnostic Flow
Chart.”
Repeat the “Basic
diagnostic flow
chart”
Go to Step 3
Was the “EHCU Connector Pin–out Checks” performed?
1. Turn the key switch to off.
2. Disconnect the 2–way EHCU connector (C–5) from the
EHCU.
3. Inspect the connector for damage or corrosion.
Is the connector free from damage or corrosion?
3
Yes
1. Replace the Coil Integrated Module.
2. Reconnect all components, ensure all components are
properly mounted.
Was this step finished?
5A–44
BRAKE CONTROL SYSTEM
Chart B-13 FR Isolation Solenoid Coil Failure (DTC 43 (Flash out) / C0241, C0243 (Serial
communications))
Step
1
2
Action
No
Go to Step 2
Go to “EHCU
Connector
Pin–out Checks.”
Go to Step 3
Repair the
connector.
Repeat the “Basic
Diagnostic Flow
Chart.”
Repeat the “Basic
diagnostic flow
chart”
Go to Step 3
Was the “EHCU Connector Pin–out Checks” performed?
1. Turn the key switch to off.
2. Disconnect the 2–way EHCU connector (C–5) from the
EHCU.
3. Inspect the connector for damage or corrosion.
Is the connector free from damage or corrosion?
3
Yes
1. Replace the Coil Integrated Module.
2. Reconnect all components, ensure all components are
properly mounted.
Was this step finished?
Chart B-14 FR Dump Solenoid Coil Failure (DTC 44(Flash out) / C0242, C0244 (Serial
communications))
Step
1
2
Action
No
Go to Step 2
Go to “EHCU
Connector
Pin–out Checks.”
Go to Step 3
Repair the
connector.
Repeat the “Basic
Diagnostic Flow
Chart.”
Repeat the “Basic
diagnostic flow
chart”
Go to Step 3
Was the “EHCU Connector Pin–out Checks” performed?
1. Turn the key switch to off.
2. Disconnect the 2–way EHCU connector (C–5) from the
EHCU.
3. Inspect the connector for damage or corrosion.
Is the connector free from damage or corrosion?
3
Yes
1. Replace the Coil Integrated Module.
2. Reconnect all components, ensure all components are
properly mounted.
Was this step finished?
Chart B-15 Rear Isolation Solenoid Coil Failure (DTC 45 (Flash out) / C0251, C0253 (Serial
communications))
Step
1
2
Action
No
Go to Step 2
Go to “EHCU
Connector
Pin–out Checks.”
Go to Step 3
Repair the
connector.
Repeat the “Basic
Diagnostic Flow
Chart.”
Repeat the “Basic
diagnostic flow
chart”
Go to Step 3
Was the “EHCU Connector Pin–out Checks” performed?
1. Turn the key switch to off.
2. Disconnect the 2–way EHCU connector (C–5) from the
EHCU.
3. Inspect the connector for damage or corrosion.
Is the connector free from damage or corrosion?
3
Yes
1. Replace the Coil Integrated Module.
2. Reconnect all components, ensure all components are
properly mounted.
Was this step finished?
BRAKE CONTROL SYSTEM
5A–45
Chart B-16 Rear Dump Solenoid Coil Failure (DTC 46 (Flash out) / C0252, C0254 (Serial
communications))
Step
1
2
Action
No
Go to Step 2
Go to “EHCU
Connector
Pin–out Checks.”
Go to Step 3
Repair the
connector.
Repeat the “Basic
Diagnostic Flow
Chart.”
Repeat the “Basic
diagnostic flow
chart”
Go to Step 3
Was the “EHCU Connector Pin–out Checks” performed?
1. Turn the key switch to off.
2. Disconnect the 2–way EHCU connector (C–5) from the
EHCU.
3. Inspect the connector for damage or corrosion.
Is the connector free from damage or corrosion?
3
Yes
1. Replace the Coil Integrated Module.
2. Reconnect all components, ensure all components are
properly mounted.
Was this step finished?
Chart B-17 FL Speed Sensor Open or Shorted (DTC 51 (Flash out) / C0225 (Serial
communications))
Step
Action
Yes
No
1
1. Turn the key off.
2. Disconnect coil integrated module connector.
3. Measure the resistance between coil integrated module
connector (C-6) terminals 2 and 10.
Check for faults
in harness
between speed
sensor and coil
integrated
module.
Fault found:
Repair, and
perform system
self-check.
No fault found:
Replace coil
integrated
module.
Go to Step 3
Go to Step 2
Repair harness
abnormality
between sensors
and coil
integrated
module.
Go to Step 3
Replace sensor.
Go to Step 3
Repeat the “Basic
diagnostic flow
chart”
Go to Step 3
Is the resistance between 2.0k and 2.8k ohms?
2
Measure the FL speed sensor resistance at the sensor connector.
Is the resistance between 2.0k and 2.8k ohms?
3
1. Reconnect all components, ensure all components are
properly mounted.
2. Clear diagnostic trouble code.
Was this step finished?
5A–46
BRAKE CONTROL SYSTEM
Chart B-18 FR Speed Sensor Open or Shorted (DTC 52 (Flash out) / C0221 (Serial
communications))
Step
Action
Yes
No
1
1. Turn the key off.
2. Disconnect coil integrated module connector.
3. Measure the resistance between coil integrated module
connector (C-6) terminals 3 and 11.
Check for faults
in harness
between speed
sensor and coil
integrated
module.
Fault found:
Repair, and
perform system
self-check.
No fault found:
Replace coil
integrated
module.
Go to Step 3
Go to Step 2
Repair harness
abnormality
between sensors
and coil
integrated
module.
Go to Step 3
Replace sensor.
Go to Step 3
Repeat the “Basic
diagnostic flow
chart”
Go to Step 3
Is the resistance between 2.0k and 2.8k ohms?
2
Measure the FR speed sensor resistance at the sensor
connector.
Is the resistance between 2.0k and 2.8k ohms?
3
1. Reconnect all components, ensure all components are
properly mounted.
2. Clear diagnostic trouble code.
Was this step finished?
BRAKE CONTROL SYSTEM
5A–47
Chart B-19 Rear Speed Sensor Open or Shorted (DTC 53 (Flash out) / C0235 (Serial
communications))
Step
Action
Yes
No
1
1. Turn the key off.
2. Disconnect coil integrated module connector.
3. Measure the resistance between coil integrated module
connector (C-6) terminals 4 and 12.
Check for faults
in harness
between speed
sensor and coil
integrated
module.
Fault found:
Repair, and
perform system
self-check.
No fault found:
Replace EHCU.
Go to Step 3
Go to Step 2
Repair harness
abnormality
between sensors
and coil
integrated
module.
Go to Step 3
Replace sensor.
Go to Step 3
Repeat the “Basic
diagnostic flow
chart”
Go to Step 3
Is the resistance between 1.0k and 1.7k ohms?
2
Measure the Rear speed sensor resistance at the sensor
connector.
Is the resistance between 1.0k and 1.7k ohms?
3
1. Reconnect all components, ensure all components are
properly mounted.
2. Clear diagnostic trouble code.
Was this step finished?
5A–48
BRAKE CONTROL SYSTEM
Chart B-20 FL Speed Sensor Missing Signal (DTC 61 (Flash out) / C0226, C0227 (Serial
communications))
Step
Action
1
1. Turn the key off.
2. Disconnect coil integrated module connector.
3. Measure the FL speed sensor resistance between coil
integrated module connector (C-6) terminals 2 and 10.
2
3
Yes
No
Is the resistance between 2.0k and 2.8k ohms?
Go to Step 2
Go to Step 3
Is there play sensor/sensor rotor?
Repair.
Go to Step 6
Go to Step 4
Repair harness
abnormality
between sensors
and coil
integrated
module.
Go to Step 6
Replace sensor.
Go to Step 6
Repair.
Go to Step 6
Go to Step 5
Check for faults
in harness
between speed
sensor and coil
integrated
module.
Fault found:
repair, and
perform system
self-check.
No fault found:
replace EHCU.
Go to Step 6
Replace sensor.
Go to Step 6
Repeat the “Basic
diagnostic flow
chart”
Go to Step 6
Measure the FL speed sensor resistance at the sensor connector.
Is the resistance between 2.0k and 2.8k ohms?
4
5
6
Damage and powdered iron sticking to sensor/sensor ring?
Is sensor output normal? (Chart C-1-1 or TC-1)
1. Reconnect all components, ensure all components are
properly mounted.
2. Clear diagnostic trouble code.
Was this step finished?
NOTE: Even after repairing the faulty part the warning
light (W/L) does not go out if the vehicle is at a stop. Turn
the ignition switch to the ON position and drive the vehicle
at 12 km/h (8 mph) or higher to make sure that the
warning light goes out.
BRAKE CONTROL SYSTEM
5A–49
Chart B-21 FR Speed Sensor Missing Signal (DTC 62 (Flash out) / C0222, C0223 (Serial
communications))
Step
Action
1
1. Turn the key off.
2. Disconnect coil integrated module connector.
3. Measure the FR speed sensor resistance between coil
integrated module connector (C-6) terminals 3 and 11.
2
3
Yes
No
Is the resistance between 2.0k and 2.8k ohms?
Go to Step 2
Go to Step 3
Is there play sensor/sensor rotor?
Repair.
Go to Step 6
Go to Step 4
Repair harness
abnormality
between sensors
and coil
integrated
module.
Go to Step 6
Replace sensor.
Go to Step 6
Repair.
Go to Step 6
Go to Step 5
Check for faults
in harness
between speed
sensor and coil
integrated
module.
Fault found:
repair, and
perform system
self-check.
No fault found:
replace EHCU.
Go to Step 6
Replace sensor.
Go to Step 6
Repeat the “Basic
diagnostic flow
chart”
Go to Step 6
Measure the FR speed sensor resistance at the sensor
connector.
Is the resistance between 2.0k and 2.8k ohms?
4
5
6
Damage and powered iron sticking to sensor/sensor ring?
Is sensor output normal? (Chart C-1-2 or TC-1)
1. Reconnect all components, ensure all components are
properly mounted.
2. Clear diagnostic trouble code.
Was this step finished?
NOTE: Even after repairing the faulty part the warning
light (W/L) does not go out if the vehicle is at a stop. Turn
the ignition switch to the ON position and drive the vehicle
at 12 km/h (8 mph) or higher to make sure that the
warning light goes out.
5A–50
BRAKE CONTROL SYSTEM
Chart B-22 Rear Speed Sensor Missing Signal (DTC 63 (Flash out) / C0236, C0237 (Serial
communications))
Step
Action
1
1. Turn the key off.
2. Disconnect coil integrated module connector.
3. Measure the Rear speed sensor resistance between coil
integrated module connector (C-6) terminals 4 and 12.
2
3
Yes
No
Is the resistance between 1.0k and 1.7k ohms?
Go to Step 2
Go to Step 3
Is there play sensor/sensor rotor?
Repair.
Go to Step 6
Go to Step 4
Repair harness
abnormality
between sensors
and coil
integrated
module.
Go to Step 6
Replace sensor.
Go to Step 6
Repair.
Go to Step 6
Go to Step 5
Check for faults
in harness
between speed
sensor and coil
integrated
module.
Fault found:
repair, and
perform system
self-check.
No fault found:
replace EHCU.
Go to Step 6
Replace sensor.
Go to Step 6
Repeat the “Basic
diagnostic flow
chart”
Go to Step 6
Measure the rear speed sensor resistance at the sensor
connector.
Is the resistance between 1.0k and 1.7k ohms?
4
5
6
Damage and powered iron sticking to sensor/sensor ring?
Is sensor output normal? (Chart C-1-3 or TC-1)
1. Reconnect all components, ensure all components are
properly mounted.
2. Clear diagnostic trouble code.
Was this step finished?
NOTE: Even after repairing the faulty part the warning
light (W/L) does not go out if the vehicle is at a stop. Turn
the ignition switch to the ON position and drive the vehicle
at 12 km/h (8 mph) or higher to make sure that the
warning light goes out.
BRAKE CONTROL SYSTEM
5A–51
Chart B-23 Simultaneous Drop-out of Front Speed Sensor Signal (DTC 64 (Flash out) /
C0229 (Serial communications))
Step
Action
1
1. Turn the key off.
2. Disconnect coil integrated module connector.
3. Measure the FL speed sensor resistance between coil
integrated module connector (C-6) terminals 2 and 10.
Is the resistance between 2.0k and 2.8k ohms?
2
Measure the FL speed sensor resistance at the sensor connector.
Is the resistance between 2.0k and 2.8k ohms?
4
Measure the FR speed sensor resistance at the sensor
connector.
Is the resistance between 2.0k and 2.8k ohms?
5
6
7
8
No
Go to Step 2
Go to Step 3
Go to Step 5
Go to Step 4
Repair harness
abnormality
between sensors
and coil
integrated
module.
Go to Step 2
Replace sensor.
Go to Step 2
Repair harness
abnormality
between sensors
and coil
integrated
module.
Go to Step 5
Replace sensor.
Go to Step 5
Repair.
Go to Step 6
Go to Step 6
Repair.
Go to Step 7
Go to Step 7
Check for faults
in harness
between speed
sensor and coil
integrated
module.
Fault found:
repair, and
perform system
self-check.
No fault found:
replace EHCU.
Go to Step 8
Replace sensor.
Go to Step 8
Repeat “Basic
diagnostic flow
chart”
Go to Step 8
Measure the FR speed sensor resistance between coil integrated
module connector (C-6) terminals 3 and 11.
Is the resistance between 2.0k and 2.8 k ohms?
3
Yes
Damage and powered iron sticking to sensor/sensor ring?
Is there play sensor/sensor rotor?
Is sensor output normal? (Chart C-1-1&C-1-2 or TC-1)
1. Reconnect all components, ensure all components are
properly mounted.
2. Clear diagnostic trouble code.
Was this step finished?
NOTE: Even after repairing the faulty part the warning
light (W/L) does not go out if the vehicle is at a stop. Turn
the ignition switch to the ON position and drive the vehicle
at 12 km/h (8 mph) or higher to make sure that the
warning light goes out.
5A–52
BRAKE CONTROL SYSTEM
Chart B-24 Wheel Speed Input Abnormality (DTC 65 (Flash out) / C0238 (Serial
communications))
Step
Action
1
Using TECH 2?
2
1. Connect TECH 2.
2. Select Snap shot manual trigger.
3. With wheel speed data displayed, run the vehicle when speed
has arrived at 30 km/h (18 mph).
4. Check speed data on each wheel (refer to the criterion given
below). * 1
Is the abnormal sensor condition found?
3
4
5
6
7
8
Is there play in sensor/sensor ring?
Is there powdered iron sticking to sensor/sensor ring?
Is there a broken tooth or indentation in sensor ring?
Is there play in wheel bearing?
Yes
No
Go to Step 2
Go to Step 3
Replace.
Go to Step 8
Go to Step 3
All the sensors
should follow the
following
flowchart (without
using TECH 2).
Repair.
Go to Step 8
Go to Step 4
Repair.
Go to Step 8
Go to Step 5
Replace sensor
ring.
Go to Step 8
Go to Step 6
Adjust or repair.
Go to Step 8
Go to Step 7
Replace EHCU.
Go to Step 8
Repair, and
perform system
self-check.
Go to Step 8
Repeat ‘Basic
diagnostic flow
chart”
Go to Step 8
Is the check wiring between sensor and coil integrated module
normal?
1. Reconnect all components, ensure all components are
properly mounted.
2. Clear diagnostic trouble code.
Was this step finished?
Sensor Signal Abnormality Criteria using TECH 2
1. While driving, the speed of one or two wheels is 25%
or more higher or lower than that of the other wheels.
2. The speed of one or two wheels is 10 km/h (6 mph) or
more higher or lower than that of the other wheels.
3. During steady driving, wheel speed changes abruptly.
*1 The vehicle must run on a level paved road.
NOTE: Even after repairing the faulty part the warning
light (W/L) does not go out if the vehicle is at a stop.
Turn the ignition switch to the ON position and drive the
vehicle at 12 km/h (8 mph) or higher to make sure that the
warning light goes out.
It is important to verify that the correct tires are installed
on vehicle.
BRAKE CONTROL SYSTEM
5A–53
Unit Inspection Procedure
This section describes the following inspection
procedures referred to during Symptom Diagnosis and
Diagnosis By “ABS” Warning Light Illumination Pattern
Sensor Output Inspection
without TECH 2
with TECH 2
Chart C-1-1 to C-1-3
Chart TC-1
Chart C-1-1 FL Sensor Output Inspection Procedure
Step
Action
1
1. Turn the key off.
2. Disconnect coil integrated module connector.
3. Jack up the vehicle with all four wheels off the ground.
Measure the AC voltage between coil integrated module
connector terminals while turning FL wheel at a speed of 1
RPS:
Is the voltage between coil integrated module connector (C-6)
terminals 2 and 10 less than 200 mV?
2
1. Disconnect the wheel speed sensor.
2. Measure resistance between the wheel speed sensor
connector terminals 1 and 2.
Is the check between connector (C-28) terminals 1 and 2 within
2.0k - 2.8k ohms?
3
Reconnect all components, ensure all components are properly
mounted.
Was this step finished?
Yes
No
Go to Step 2
OK.
Go to Step 3
Connector is
faulty, or open or
short circuit of
harness between
wheel speed
sensor connector
and coil
integrated
module.
Inspect and
correct the
connector or
harness.
Go to Step 3
Wheel speed
sensor is faulty.
Replace the
wheel speed
sensor.
Go to Step 3
Repeat the “Basic
diagnostic flow
chart”
Go to Step 3
5A–54
BRAKE CONTROL SYSTEM
Chart C-1-2 FR Sensor Output Inspection Procedure
Step
Action
1
1. Turn the key off.
2. Disconnect coil integrated module connector.
3. Jack up the vehicle with all four wheels off the ground.
Measure the AC voltage between coil integrated module
connector terminals while turning FR wheel at a speed of 1
RPS:
Is the voltage between coil integrated module connector (C-6)
terminals 3 and 11 less than 200 mV?
2
1. Disconnect the wheel speed sensor.
2. Measure resistance between the wheel speed sensor
connector terminals 1 and 2.
Is the check between connector (C-1) terminals 1 and 2 within
2.0k - 2.8k ohms?
3
Reconnect all components, ensure all components are properly
mounted.
Was this step finished?
Yes
No
Go to Step 2
OK.
Go to Step 3
Connector is
faulty, or open or
short circuit of
harness between
wheel speed
sensor connector
and coil
integrated
module.
Inspect and
correct the
connector or
harness.
Go to Step 3
Wheel speed
sensor is faulty.
Replace the
wheel speed
sensor.
Go to Step 3
Repeat the “Basic
diagnostic flow
chart”
Go to Step 3
Yes
No
Go to Step 2
OK.
Go to Step 3
Connector is
faulty, or open or
short circuit of
harness between
wheel speed
sensor connector
and coil
integrated
module.
Inspect and
correct the
connector or
harness.
Go to Step 3
Wheel speed
sensor is faulty.
Replace the
wheel speed
sensor.
Go to Step 3
Repeat the “Basic
diagnostic flow
chart”
Go to Step 3
Chart C-1-3 Rear Sensor Output Inspection Procedure
Step
Action
1
1. Turn the key off.
2. Disconnect coil integrated module connector.
3. Jack up the vehicle with all four wheels off the ground measure
the AC voltage between coil integrated module connector
terminals while turning Rear wheel at a speed of 1 RPS:
Is the check between coil integrated module connector (C-6)
terminals 4 and 12 than under 200 mV?
2
1. Disconnect the wheel speed sensor.
2. Measure resistance between the wheel speed sensor
connector terminals 1 and 2.
Is the check between connector (F-4) terminals 1 and 2 within
1.0k - 1.7k ohms?
3
Reconnect all components, ensure all components are properly
mounted.
Was this step finished?
BRAKE CONTROL SYSTEM
5A–55
Chart TC-1 Sensor Output Inspection Procedure
Step
1
Action
Check the sensor harness for suspected disconnection (check
while shaking harness/connector).
Is the sensor harness connection normal?
3
Check the sensor rotor.
Is the sensor rotor normal?
5
Go to Step 6
Go to Step 2
Replace speed
sensor.
Go to Step 4
Repair.
Go to Step 3
Go to Step 6
Go to Step 4
Replace speed
sensor.
Go to Step 5
Replace sensor
rotor.
Go to Step 5
Go to Step 6
Repair harness or
connector
between coil
integrated
module and
speed sensor.
Go to Step 6
Repeat the “Basic
diagnostic flow
chart”
Go to Step 6
Check the wheel speed of each sensor by Data List.
Is the vehicle speed normal?
4
No
1. Connect TECH 2.
2. Check the wheel speed of each sensor by Data List.
Is the vehicle speed normal?
2
Yes
Check the harness between coil integrated module and speed
sensor.
Is the harness connection normal?
6
Reconnect all components, ensure all components are properly
mounted.
Was this step finished?
5A–56
BRAKE CONTROL SYSTEM
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
J–35616
Connector test adapter
kit
J–39200
High impedance
multimeter
7000086–ISU
Tech 2 Set
(1) PCMCIA Card
(2) SAE 16/19 Adapter
(3) DLC Cable
(4) Tech 2
SECTION
ANTI–LOCK BRAKE SYSTEM
5B–1
AXIOM
BRAKES
ANTI-LOCK BRAKE SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . .
Electronic Hydraulic Control Unit . . . . . . . . . .
Electronic Hydraulic Control Unit and
Associated Parts . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Wheel Speed Sensor . . . . . . . . . . . . . . .
5B–1
5B–2
5B–2
5B–2
5B–3
5B–3
5B–3
5B–3
5B–4
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.
Front Wheel Speed Sensor and Associated
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Wheel Speed Sensor . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5B–4
5B–4
5B–4
5B–4
5B–5
5B–5
5B–5
5B–5
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.
5B–2
ANTI–LOCK BRAKE SYSTEM
Electronic Hydraulic Control Unit
Electronic Hydraulic Control Unit and Associated Parts
350R100003
Legend
(1) EHCU
(2) Bolt
(3) Bracket
(4) Bolt and Nut
Removal
1. Remove brake pipes.
B After disconnecting brake pipe, cap or tape the
openings of the brake pipe to prevent the entry of
foreign matter.
2. Remove three bracket fixing bolts.
3. Disconnect red clip from harness connector.
350RW018
ANTI–LOCK BRAKE SYSTEM
4. Remove harness connector.
5. Remove EHCU ASM.
6. Remove EHCU.
5B–3
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
Torque
Hydraulic unit fixing nuts : 22 N·m (16 lb ft)
Ground cable : 14 N·m (10 lb ft)
Brake pipe (joint bolts) : 16 N·m (12 lb ft)
B After installing the hydraulic unit, bleed brakes
completely. See Section 5A “Hydraulic Brakes”.
Disassembled View
350RW025
Legend
(1) Fixing Bolts
(2) Coil Integrated Module
(3) Hydraulic Unit (H/U)
Disassembly
1. Remove fixing bolts from EHCU.
2. Remove coil integrated module from hydraulic unit.
Reassembly
To reassembly, follow the disassembly steps in the
reverse order, noting the following points:
Torque
Fixing bolts: 4.4 N·m (39 lb in)
5B–4
ANTI–LOCK BRAKE SYSTEM
Front Wheel Speed Sensor
Front Wheel Speed Sensor and Associated Parts
350RS033
Legend
(1) Speed Sensor Connector
(2) Sensor Cable Fixing Bolt (Upper side)
Removal
1. Remove speed sensor connector.
2. Remove sensor cable fixing bolt (Upper side).
3. Remove sensor cable fixing bolt (Lower side).
4. Remove the speed sensor cable fixing bolt.
5. Remove speed sensor.
Inspection and Repair
1. Check the speed sensor pole piece for presence of
foreign materials; remove any dirt, etc.
2. Check the pole piece for damage; replace speed
sensor if necessary.
3. Check the speed sensor cable for short or open
circuit, and replace with a new one if necessary.
To check for cable short or open, bend or stretch the
cable while checking for continuity.
4. Check the sensor ring for damage including tooth
chipping, and if damaged, replace the sensor ring
assembly. Refer to removal of the sensor ring in
Section 4C “Front hub and disc”.
(3) Sensor Cable Fixing Bolt (Lower side)
(4) Sensor Cable Fixing Bolt (Sensor side)
(5) Speed Sensor
Installation
1. Install speed sensor and take care not to hit the speed
sensor pole piece during installation.
2. Install speed sensor fixing bolt and tighten the fixing
bolt to the specified torque.
Torque: 11 N·m (95 lb in)
3. Install speed sensor cable fixing bolt (Lower side) and
tighten the fixing bolt to the specified torque.
Torque : 24 N·m (17 lb ft)
4. Install speed sensor cable fixing bolt (Upper side) and
tighten the fixing bolt to the specified torque.
Torque : 6 N·m (52 lb in)
NOTE: Confirm that a white line marked on the cable is
not twisted when connecting the speed sensor cable.
5. Install speed sensor connector.
ANTI–LOCK BRAKE SYSTEM
5B–5
Rear Wheel Speed Sensor
Removal
Installation
1. Disconnect harness connector (1).
2. Remove sensor fixing bolt (2) .
3. Remove speed sensor (3).
1. Install speed sensor (3).
2. Tighten the sensor fixing bolt (2) to the specified
torque.
Torque : 24 N·m (17 lb ft)
3. Connect harness connector (1).
350R100004
Inspection and Repair
1. Check speed sensor pole piece for presence of
foreign materials; remove any dirt, etc.
2. Check the pole piece for damage, and replace speed
sensor if necessary.
3. Check speed sensor cable for short or open, and
replace with a new one if necessary. To check for
cable short or open, bend or stretch the cable while
checking for continuity.
4. Check the sensor ring for damage including tooth
chipping, and if damaged, replace the axle shaft
assembly. Refer to removal of the sensor ring in
Section 4A2 “Differential (Rear)”.
350R100004
SECTION
POWER–ASSISTED BRAKE SYSTEM
5C–1
AXIOM (Vehicles Produced Before July/31/2001)
BRAKES
POWER-ASSISTED BRAKE SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . .
General Description . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Diagnosis . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Brakes . . . . . . . . . . . . . . . . . . . . . . . .
Filling Master Cylinder Reservoir . . . . . . . .
Deterioration of Brake Fluid . . . . . . . . . . . . .
Leakage of Brake Fluid . . . . . . . . . . . . . . . . .
Bleeding Brake Hydraulic System . . . . . . . .
Flushing Brake Hydraulic System . . . . . . . .
Brake Pipes and Hoses . . . . . . . . . . . . . . . .
Brake Hose Inspection . . . . . . . . . . . . . . . . .
Front Caliper Brake Hose . . . . . . . . . . . . . . . .
Front Caliper Brake Hose and Associated
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Axle Brake Hose . . . . . . . . . . . . . . . . . . .
Rear Axle Brake Hose and Associated
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P & B (Proportioning and Bypass) Valve . . . .
P & B (Proportioning and Bypass) Valve
Sectional View . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications . . . . . . . . . . . . .
Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Pedal Height . . . . . . . . . . . . . . . . .
Checking Pedal Travel . . . . . . . . . . . . . . . . .
Brake Pedal and Associated Parts . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stoplight Switch . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Location . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications . . . . . . . . . . . . .
Fluid Reservoir Tank . . . . . . . . . . . . . . . . . . . . .
Fluid Reservoir Tank and Associated Parts
5C–2
5C–2
5C–6
5C–7
5C–10
5C–10
5C–10
5C–10
5C–10
5C–11
5C–11
5C–11
5C–12
5C–12
5C–12
5C–12
5C–13
5C–13
5C–13
5C–13
5C–14
5C–14
5C–14
5C–15
5C–15
5C–15
5C–15
5C–16
5C–17
5C–17
5C–17
5C–18
5C–18
5C–18
5C–19
5C–19
5C–19
5C–19
5C–20
5C–21
5C–21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Cylinder Assembly . . . . . . . . . . . . . . . .
Master Cylinder Assembly and Associated
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . .
Vacuum Booster Assembly . . . . . . . . . . . . . . .
Vacuum Booster Assembly and Associated
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exterior Components . . . . . . . . . . . . . . . . . . . .
Exterior Components and Associated Parts
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vacuum Booster Overhaul . . . . . . . . . . . . . . . .
Vacuum Booster . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Disc Brake Pads . . . . . . . . . . . . . . . . . . .
Front Disc Brake Pads Inspection . . . . . . . .
Front Disc Brake Pads and Associated
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Disc Brake Rotor . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Brake Rotors . . . . . . . . . . . . . . . .
Refinishing Brake Rotors . . . . . . . . . . . . . . .
Front Disc Brake Caliper Assembly . . . . . . . .
Front Disc Brake Caliper Assembly and
Associated Parts . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Disc Brake Caliper . . . . . . . . . . . . . . . . .
Front Disc Brake Caliper Disassembled
View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
5C–21
5C–21
5C–22
5C–22
5C–22
5C–22
5C–23
5C–24
5C–24
5C–25
5C–25
5C–25
5C–26
5C–26
5C–28
5C–28
5C–28
5C–29
5C–29
5C–29
5C–29
5C–30
5C–31
5C–32
5C–32
5C–32
5C–33
5C–33
5C–35
5C–35
5C–35
5C–35
5C–36
5C–36
5C–37
5C–37
5C–39
5C–39
5C–39
5C–2
POWER–ASSISTED BRAKE SYSTEM
Inspection and Repair . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications . . . . . . . . . . .
Rear Disc Brake Pads (4×4 Model) . . . . . . . .
Brake Pads Inspection . . . . . . . . . . . . . . . . .
Brake Pads and Associated Parts . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Disc Brake Rotor (4×4 Model) . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Brake Rotors . . . . . . . . . . . . . . . .
Refinishing Brake Rotors . . . . . . . . . . . . . . .
Rear Drum (In Disc) Inside Diameter Check
Rear Disc Brake Caliper Assembly
(4×4 Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Disc Brake Caliper Assembly and
Associated Parts . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Disc Brake Caliper (4×4 Model) . . . . . .
Rear Disc Brake Caliper Disassembled
View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5C–40
5C–40
5C–42
5C–43
5C–43
5C–43
5C–44
5C–44
5C–46
5C–46
5C–46
5C–46
5C–47
5C–48
5C–48
5C–48
5C–49
5C–50
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications (4×4 Model)
Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Lining and Associated Parts . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Lining Inspection . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drum Brake Adjustment (4×2 Model) . . . . .
Servicing The Brake Drum . . . . . . . . . . . . . .
Wheel Cylinder Assembly (4×2 Model) . . . . .
Wheel Cylinder Assembly and Associated
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications . . . . . . . . . . .
5C–51
5C–51
5C–51
5C–53
5C–54
5C–54
5C–54
5C–55
5C–55
5C–56
5C–56
5C–57
5C–57
5C–57
5C–57
5C–58
5C–58
5C–58
5C–58
5C–60
5C–50
Service Precaution
General Description
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.
Master Cylinder Assembly
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.
330RS001
POWER–ASSISTED BRAKE SYSTEM
The master cylinder contains two pistons that supply the
hydraulic pressure for a dual–circuit braking system. The
primary piston provides the fluid pressure to the front
brakes, while the secondary piston provides the fluid
pressure to the rear brakes. If the pressure is lost from
either system, the remaining system will function to stop
the vehicle.
5C–3
CAUTION:
1. The master cylinder is not repairable. If found
defective, it must be replaced as a complete
assembly.
2. If any hydraulic component is removed or
disconnected, it may be necessary to bleed all or
part of the brake system. (Refer to Bleeding Brake
Hydraulic System in this section.)
3. The torque values specified
unlubricated fasteners.
are
for
dry,
4. Perform service operations on a clean bench free
from all mineral oil materials.
Brake Booster
331RS001
This booster is a tandem vacuum unit with a diaphragm
effective diameter 205mm (8.072 in) + 230mm (9.056 in).
In normal operating mode, with the service brakes in the
released position, the tandem vacuum booster operates
with vacuum on both sides of its diaphragms. When the
brakes are applied, air at atmospheric pressure is
admitted to both sides of the diaphragm to provide the
power assist. When the service brake is released, the
atmospheric air is shut off from both sides of the
diaphram. The air is then drawn from the booster through
the vacuum check valve to the vacuum source.
CAUTION:
1. If any hydraulic component is removed or
disconnected, it may be necessary to bleed all or
part of the brake system.
2. The torque values specified
unlubricated fasteners.
are
for
dry,
3. The vacuum booster is not repairable and must be
replaced as complete assembly.
5C–4
POWER–ASSISTED BRAKE SYSTEM
Disc Brake
Front Disc Brake
A05RW001
Rear Disc Brake (4×4 Model)
A05RW002
The disc brake assembly consists of a caliper, piston,
rotor, pad assembly and support bracket. The caliper
assembly has a single bore and is mounted to the support
bracket with two mounting bolts. The support bracket
allows the caliper to move laterally against the rotor. The
caliper is a one–piece casting with the inboard side
containing the piston bore. A square cut rubber seal is
located in a groove in the piston bore which provides the
hydraulic seal between the piston and the cylinder wall.
NOTE:
1. Replace all components included in repair kits used to
service this caliper.
2. Lubricate rubber parts with clean brake fluid to ease
assembly.
3. If any hydraulic component is removed or
disconnected, it may be necessary to bleed all or part
of the brake system.
4. Replace pads in axle sets only.
5. The torque values specified are for dry, unlubricated
fasteners.
6. Perform the service operation on a clean bench free
from all mineral oil materials.
Operation
Hydraulic pressure, created by applying the brake pedal,
is converted by the caliper to a stopping force. This force
creates a clamping action of the piston pressing towards
the rotors (outward) and the caliper slides inward toward
the vehicle. This clamping action forces the linings
against the rotor, creating friction to stop the vehicle.
POWER–ASSISTED BRAKE SYSTEM
5C–5
Leading/Trailing Drum Brakes (4×2 Model)
A05RS003
This drum brake assembly is a leading/trailing shoe
design. Both brake shoes are held against the wheel
cylinder pistons by the upper return spring and to the fixed
anchor plate by the lower return spring. When the brakes
are applied, the wheel cylinder pistons expand pushing
both shoes out contact the drum.
With forward wheel rotation, the forward brake shoe will
wrap into the drum and becomes self-energized.
With reverse wheel rotation, the rear brake shoe is
self-energized. Force from the brake shoes is transferred
to the anchor plate through the braking plate to the axle
flange. Adjustment is automatic and occurs on any
service brake application. Also, with leading/trailing
brakes, it is normal for the front shoe to wear at a faster
rate than the rear shoe.
5C–6
POWER–ASSISTED BRAKE SYSTEM
Diagnosis
Road Testing The Brakes
Brake Test
Brakes should be tested on a dry, clean, reasonably
smooth and level roadway. A true test of brake
performance cannot be made if the roadway is wet,
greasy or covered with loose dirt where all tires do not grip
the road equally. Testing will also be adversely affected if
the roadway is crowned so as to throw the weight of the
vehicle toward wheels on one side or if the roadway is so
rough that wheels tend to bounce. Test the brakes at
different vehicle speeds with both light and heavy pedal
pressure; however, avoid locking the wheels and sliding
the tires. Braking without locking the tires will stop the
vehicle in less distance than braking to a skid (which has
no brake efficiency). More tire to road friction is present
while braking without locking the tires than braking to a
skid.
The standard brake system is designed and balanced to
avoid locking the wheels except at very high deceleration
levels.
It is designed this way because the shortest stopping
distance and best control is achieved without brake
lock–up.
Because of high deceleration capability, a firmer pedal
may be felt at higher deceleration levels.
External Conditions That Affect Brake Performance
1. Tires: Tires having unequal contact and grip on the
road will cause unequal braking. Tires must be
equally inflated, identical in size, and the thread
pattern of right and left tires must be approximately
equal.
2. Vehicle Loading: A heavily loaded vehicle requires
more braking effort.
3. Wheel Alignment: Misalignment of the wheels,
particularly in regard to excessive camber and caster,
will cause the brakes to pull to one side.
Brake Fluid Leaks
With engine running at idle and the transmission in
“Neutral”, depress the brake pedal and hold a constant
foot pressure on the pedal. If pedal gradually falls away
with the constant pressure, the hydraulic system may be
leaking.
Check the master cylinder fluid level. While a slight drop in
the reservoir level will result from normal lining wear, an
abnormally low level in reservoir indicates a leak in the
system. The hydraulic system may be leaking internally
as well as externally. Refer to Master Cylinder Inspection.
Also, the system may appear to pass this test but still
have slight leakage. If fluid level is normal, check the
vacuum booster push rod length. If an incorrect length
push rod is found, adjust or replace the push rod. Check
the brake pedal travel and the parking brake adjustment.
When checking the fluid level, the master cylinder fluid
level may be lower than the “MAX” mark if the front and
rear linings are worn. This is normal.
Warning Light Operation
When the ignition switch is in the START position, the
“BRAKE” warning light should turn on and go off when the
ignition switch returns to the ON position.
The following conditions will activate the “BRAKE” light:
1. Parking brake applied. The light should be on
whenever the parking brake is applied and the ignition
switch is on.
2. Low fluid level. A low fluid level in the master cylinder
will turn the “BRAKE” light on.
3. During engine cranking the “BRAKE” light should
remain on. This notifies the driver that the warning
circuit is operating properly.
POWER–ASSISTED BRAKE SYSTEM
5C–7
General Diagnosis
Condition
Possible cause
Brake Pull
Brake Roughness
(Pulsates)
Excessive Pedal Effort
or
Chatter
Correction
Tire inflation pressure is unequal.
Adjust
Front wheel alignment is incorrect.
Adjust
Unmatched tires on same axle.
Tires with approx. the same amount
of tread should be used on the same
axle.
Restricted brake pipes or hoses.
Check for soft hoses and damaged
lines. Replace with new hoses and
new double“walled steel brake
piping.
Water or oil on the brake pads.
Clean or replace.
Brake pads hardened.
Replace
Brake pads worn excessively.
Replace
Brake rotor worn or scored.
Grind or replace.
Disc brake caliper malfunctioning.
Clean or replace.
Front hub bearing preload incorrect.
Adjust or replace.
Loose suspension parts.
Check all suspension mountings.
Loose calipers.
Check and tighten the bolts to
specifications.
Excessive lateral runout.
Check per instructions. If not within
specifications, replace or machine
the rotor.
Parallelism not within specifications.
Check per instructions. If not within
specifications, replace or machine
the rotor.
Wheel bearings not adjusted.
Adjust wheel bearings to correct
specifications
Pad reversed (steel against iron).
Replace the brake pad and machine
rotor to within specifications.
Malfunctioning vacuum booster.
Check the vacuum booster operation
and repair, if necessary.
Partial system failure.
Check the front and rear brake
system for failure and repair. Also,
check the brake warning light. If a
failed system is found, the light
should indicate failure.
Excessively worn pad.
Check and replace pads in sets.
Piston in caliper stuck or sluggish.
Remove caliper and rebuild.
Fading brakes due to incorrect pad.
Remove and replace with original
equipment pad or equivalent.
Vacuum leak to vacuum booster.
Check for ruptured or loose hose.
Check the direction of check valve
within vacuum hose.
Correct vacuum hose direction.
Grease on the brake pads.
Replace or clean.
5C–8
POWER–ASSISTED BRAKE SYSTEM
Condition
Excessive Brake Pedal Travel
Brake Drag
Grabbing or Uneven Braking Action
(All conditions listed under “Pulls”)
Brake Noisy
Possible cause
Correction
Air in hydraulic circuit.
Bleed the hydraulic circuit.
Level of brake fluid in the reservoir
too low.
Replenish brake fluid reservoir to
specified level and bleed hydraulic
circuit as necessary.
Master cylinder push rod clearance
excessive.
Adjust
Leakage in hydraulic system.
Correct or replace defective parts.
Master cylinder pistons not returning
correctly.
Adjust the stop light switch and
vacuum booster push rod. If
necessary, rebuild.
Restricted brake pipes or hoses.
Check for soft hoses or damaged
pipes, and replace with new hoses
and new double–walled steel brake
piping.
Parking brake maladjusted.
Adjust
Parking brake
insufficient.
Adjust
lining
clearance
Brake pedal free play insufficient.
Adjust the brake pedal height or
power cylinder operating rod.
Piston in the master cylinder sticking.
Replace
Piston in the disc brake caliper
sticking.
Replace piston seals.
Brake pads sticking in caliper.
Clean
Return spring weakened.
Replace
Parking brake binding.
Overhaul the parking brakes and
correct.
Front hub bearing preload incorrect.
Adjust or replace.
Parking brake shoes not returning.
Correct or replace the brake back
plate and brake shoe as necessary.
Obstructions in hydraulic circuit.
Clean
Rotor warped excessively.
Grind or replace.
Rear brake drum distorted.
Grind or replace.
Parking cable sticking.
Grind or replace.
Malfunctioning vacuum booster.
Check operation and correct as
necessary.
Binding brake pedal mechanism.
Check and lubricate, if necessary.
Corroded caliper assembly.
Clean and lubricate.
Brake pads are worn.
Replace
Brake pads are hardened.
Replace
Brake pads are in poor contact with
rotor.
Correct
Brake disc(s) warped, worn or
damaged.
Grind or replace.
Disc brake
fatigued.
Replace
anti–squeak
shims
Front hub bearings are loose or
preload is incorrect.
Adjust or replace.
Brake disc is rusted.
Grind or replace.
POWER–ASSISTED BRAKE SYSTEM
Condition
Poor Brake Action
Possible cause
Correction
Master cylinder faulty.
Correct or replace.
Vacuum booster faulty.
Correct or replace.
Level of brake fluid in reservoir too
low.
Replenish and bleed.
Air in hydraulic circuit.
Bleed
Disc brake caliper faulty.
Clean or replace.
Water or oil on brake pads.
Clean or replace.
Brake pads in poor contact with the
rotor.
Correct
Brake pads worn.
Replace
Brake disc rusted.
Grind or replace.
Check valve in vacuum hose faulty.
Correct or replace.
5C–9
5C–10 POWER–ASSISTED BRAKE SYSTEM
Hydraulic Brakes
Filling Master Cylinder Reservoir
CAUTION: Use only specified brake fluid. Do not
use any fluid which contains a petroleum base. Do
not use a container which has been used for
petroleum based fluids or a container which is wet
with water. Petroleum based fluid will cause swelling
and distortion of rubber parts in the hydraulic brake
system. Water mixed with brake fluid lowers the fluid
boiling point. Keep all fluid containers capped to
prevent contamination.
Always fill the master cylinder reservoir when the engine is cold.
Never allow the brake fluid to come in contact with
the painted surfaces.
The master cylinder reservoir must be kept properly
filled to ensure adequate reserve and to prevent air
and moisture from entering the hydraulic system.
However, because of expansion due to heat absorbed from the brakes and the engine, the reservoir
must not be overfilled. The brake fluid reservoir is on
the master cylinder, which is located under the hood
on the left side of the cowl. Thoroughly clean reservoir cap before removal to avoid getting dirt into reservoir. Remove the diaphragm. Add fluid as required
to bring level to the “MAX” mark on the reservoir
tank. Use “DOT 3” Hydraulic Brake Fluid. If the fluid
cap diaphragm is stretched, return it to the original
position before installing.
Deterioration of Brake Fluid
Using any other brake fluid than specified or brake fluid
with mineral oil or water mixed in will drop the boiling point
of brake fluid. It may, in turn, result in vapor lock or
deteriorated rubber parts of the hydraulic system. Be sure
to change the brake fluid at specified intervals.
If the rubber parts are deteriorated, remove all the system
parts and clean them with alcohol. Prior to reassembly,
dry the cleaned parts with air to remove the alcohol.
Replace all the hoses and rubber parts of the system.
Leakage of Brake Fluid
With engine idling, set shift lever in the neutral position
and continue to depress brake pedal at a constant pedal
application force.
Should the pedal stroke become deeper gradually,
leakage from the hydraulic pressure system is possible.
Perform visual inspection for any signs of leakage.
Bleeding Brake Hydraulic System
A bleeding operation is necessary to remove air from the
hydraulic brake system whenever air is introduced into
the hydraulic system. It may be necessary to bleed the
hydraulic system at all four brakes if air has been
introduced through a low fluid level or by disconnecting
brake pipes at the master cylinder. If a brake pipe is
disconnected at one wheel, only that wheel
cylinder/caliper needs to be bled. If the pipes are
disconnected at any fitting located between the master
cylinder and brakes, then the brake system served by the
disconnected pipe must be bled.
1. For 4–Wheel Antilock Brake System (ABS) equipped
vehicle, be sure to remove the ABS main fuse 60A
located at the relay and fuse box before bleeding air. If
you attempt to bleed air without removing the main
fuse, air cannot be let out thoroughly, and this may
cause damage to the hydraulic unit. After bleeding air,
be sure to replace the ABS main fuse back to its
original position.
2. Set the parking brake completely, then start the
engine.
NOTE: The vacuum booster will be damaged if the
bleeding operation is performed with the engine off.
3. Remove the master cylinder reservoir cap.
4. Fill the master cylinder reservoir with brake fluid.
Keep the reservoir at least half full during the air
bleeding operation
5. Always use new brake fluid for replenishment.
6. When replenishing the brake fluid reservoir, carefully
pour in the brake fluid to prevent air bubbles from
entering the brake system.
When the master cylinder is replaced or overhauled,
first bleed the air from the master cylinder, then from
each wheel cylinder and caliper following the
procedures described below.
Bleeding the Master Cylinder
7. Disconnect the rear wheel brake pipe (1) from the
master cylinder.
Check the fluid level and replenish as necessary. If
replenished, leave the system for at least one minute.
8. Depress the brake pedal slowly once and hold it
depressed.
9. Completely seal the delivery port of the master
cylinder with your finger, where the pipe was
disconnected then release the brake pedal slowly.
10. Release your finger from the delivery port when the
brake pedal returns completely.
11. Repeat steps 8 through 10 until the brake fluid comes
out of the delivery port during step 8.
NOTE: Do not allow the fluid level in the reservoir to go
below the half–way mark.
12. Reconnect the brake pipe (1) to the master cylinder
and tighten the pipe.
13. Depress the brake pedal slowly once and hold it
depressed.
14. Loosen the rear wheel brake pipe (1) at the master
cylinder.
15. Retighten the brake pipe, then release the brake
pedal slowly.
16. Repeat steps 13 through 15 until no air comes out of
the port when the brake pipe is loosened
NOTE: Be very careful not to allow the brake fluid to come
in contact with painted surfaces.
POWER–ASSISTED BRAKE SYSTEM
5C–11
28. After the bleeding operation is completed on the each
individual wheel, check the level of the brake fluid in
the reservoir and replenish up to the “MAX” level as
necessary.
29. Attach the reservoir cap.
If the diaphragm inside the cap is deformed, reform
it and install.
30. Stop the engine.
Flushing Brake Hydraulic System
330RW012
17. Bleed the air from the front wheel brake pipe
connection (2) by repeating steps 7 through 16.
Bleeding the Caliper
18. Bleed the air from each wheel in the order listed
below:
B Right rear caliper or wheel cylinder
B Left rear caliper or wheel cylinder
B Right front caliper
B Left front caliper
Conduct air bleeding from the wheels in the above
order. If no brake fluid comes out, it suggests that air
is mixed in the master cylinder. In this case, bleed air
from the master cylinder in accordance with steps 7
through 17, and then bleed air from the caliper or
wheel cylinder.
19. Place the proper size box end wrench over the
bleeder screw.
20. Cover the bleeder screw with a transparent tube, and
submerge the free end of the transparent tube in a
transparent container containing brake fluid.
21. Pump the brake pedal slowly three (3) times
(once/sec), then hold it depressed.
22. Loosen the bleeder screw until fluid flows through the
tube.
23. Retighten the bleeder screw.
24. Release the brake pedal slowly.
25. Repeat steps 21 through 24 until the air is completely
removed.
It may be necessary to repeat the bleeding procedure
10 or more times for front wheels and 15 or more
times for rear wheels.
26. Go to the next wheel in the sequence after each wheel
is bled.
Be sure to monitor reservoir fluid level.
27. Depress the brake pedal to check if you feel
“sponginess” after the air has been removed from all
wheel cylinders and calipers.
If the pedal feels “spongy”, the entire bleeding
procedure must be repeated.
It is recommended that the entire hydraulic system be
thoroughly flushed with clean brake fluid whenever new
parts are installed in the hydraulic system. Approximately
one quart of fluid is required to flush the hydraulic system.
The system must be flushed if there is any doubt as to the
grade of fluid in the system or if fluid has been used which
contains the slightest trace of mineral oil. All rubber parts
that have been subjected to a contaminated fluid must be
replaced.
Brake Pipes and Hoses
The hydraulic brake system components are
interconnected by special steel piping and flexible hoses.
Flexible hoses are used between the frame and the front
calipers, the frame and rear axle case and the rear axle
and the rear calipers.
When the hydraulic pipes have been disconnected for
any reason, the brake system must be bled after
reconnecting the pipe. Refer to Bleeding the Brake
Hydraulic System in this section.
Brake Hose Inspection
The brake hose should be inspected at least twice a year.
The brake hose assembly should be checked for road
hazard, cracks and chafing of the outer cover, and for
leaks and blisters. Inspect for proper routing and
mounting of the hose. A brake hose that rubs on
suspension components will wear and eventually fail. A
light and mirror may be needed for an adequate
inspection. If any of the above conditions are observed on
the brake hose, adjust or replace the hose as necessary.
CAUTION: Never allow brake components such as
calipers to hang from the brake hoses, as damage to
the hoses may occur.
5C–12 POWER–ASSISTED BRAKE SYSTEM
Front Caliper Brake Hose
Front Caliper Brake
Associated Parts
Hose
and
Installation
To install, follow the removal steps in the reverse order,
noting the following points.
1. Tighten the brake pipes to the specified torque
Torque: 19 N·m (14 lb ft)
2. Tighten the bolt to the specified torque.
Torque: 35 N·m (26 lb ft)
NOTE: Always use new gaskets and be sure to put the
hooked edge of the flexible hose end into the anti–rotation
cavity.
After installing the brake hoses, bleed the brakes as
described in this section.
352RW001
Legend
(1) Bolt and Gasket
(2) Clip
(3) Hose
(4) Brake Pipe
Removal
1. Raise the vehicle and support it with suitable safety
stands.
2. Remove the wheel and tire assembly.
3. Clean dirt, grease, and other foreign material off the
hose fittings at both ends.
4. Disconnect brake pipe.
5. Remove clip.
6. Remove bolt and gasket.
7. Remove hose.
POWER–ASSISTED BRAKE SYSTEM
5C–13
Rear Axle Brake Hose
Rear Axle Brake Hose and Associated
Parts
Installation
To install, follow the removal steps in the reverse order,
noting the following points.
1. Tighten the brake pipes to the specified torque
Torque: 19 N·m (14 lb ft)
2. Tighten the bolt to the specified torque.
Torque: 15 N·m (11 lb ft)
After installing the brake hoses, bleed the brakes as
described in this section.
352RW002
Legend
(1) Brake Pipe
(2) Clip
(3) Bolt
(4) Brake Pipe
(5) Hose
Removal
1. Raise the vehicle and support it with suitable safety
stands.
2. Remove wheel and tire assembly.
3. Clean dirt, grease, and other foreign material off the
hose fittings at both ends.
4. Disconnect brake pipe.
5. Remove clip.
6. Remove brake pipe.
7. Remove bolt.
8. Remove hose.
5C–14 POWER–ASSISTED BRAKE SYSTEM
Brake Pipe
Removal
Installation
1. Raise the vehicle and support it with suitable safety
stands.
2. Remove wheel and tire assembly as necessary.
3. Clean dirt, grease, and other foreign material off the
pipe fittings at both ends.
4. Remove brake pipe (1).
To install, follow the removal steps in the reverse order,
noting the following points.
1. Tighten the brake pipes to the specified torque.
Master cylinder and Proportioning and Bypass
valve sides
Torque: 15 N·m (11 lb ft)
Others
Torque: 16 N·m (12 lb ft)
After installing the brake pipes, bleed the brakes as
described in this section.
330RW011
5. Remove plastic clip (2).
330RW002
POWER–ASSISTED BRAKE SYSTEM
5C–15
P & B (Proportioning and Bypass) Valve
P & B (Proportioning and Bypass)
Valve Sectional View
Removal
1. The P&B valve is not repairable and must be replaced
as a complete assembly. Care must be taken to
prevent brake fluid from contacting any painted
surface.
2. Remove hydraulic pipes (1) and plug the pipes (1) to
prevent the loss of fluid or the entrance of dirt.
3. Remove bolt (3).
4. Remove P&B valve (2).
350RW014
Legend
(1) Master Cylinder (Secondary)
(2) Master Cylinder (Primary)
(3) Rear Brake
(4) Front Brake
The P&B valve contains two sections, each serving a
different function.
The proportioning section of the P&B valve proportions
outlet pressure to the rear brakes after a predetermined
rear input pressure has been reached. This is done to
prevent rear wheel lock up on the vehicles with light rear
wheel loads. The valve has a by–pass feature which
assures full system pressure to the rear brakes in the
event of front brake system malfunction. Also full front
pressure is retained in the event of rear brake
malfunction.
The P&B valve is not repairable and must be replaced as
complete assembly.
350RW026
Installation
1. Install P&B valve (2).
2. Install bolt (3) and tighten the bolt to the specified
torque.
Torque: 22 N·m (16 lb ft)
3. Install hydraulic pipes (1) and tighten the bolt to the
specified torque.
Torque: 15 N·m (11 lb ft)
4. After installing the brake pipes, bleed the brakes as
refer to Bleeding Brake Hydraulic System in this
section.
5C–16 POWER–ASSISTED BRAKE SYSTEM
Main Data and Specifications
Torque Specifications
E05R200001
POWER–ASSISTED BRAKE SYSTEM
5C–17
Brake Pedal
Checking Pedal Height
The push rod serves as the brake pedal stopper when the
pedal is fully released. Brake pedal height adjustment
should be performed as follows:
Adjust Brake Pedal
310RY00005
NOTE: While adjusting the stoplight switch, make sure
that the threaded part of the stoplight switch does not
push the brake pedal.
h. Tighten the stoplight switch lock nut.
i. Connect the stoplight switch connector.
310RY00004
1. Measure the brake pedal height after making sure the
pedal is fully returned by the pedal return spring.
Pedal height must be measured after starting the
engine and receiving it several times.
Checking Pedal Travel
Pedal Free Play: 6-10 mm (0.23-0.39 in)
Pedal Free Play: 173-185 mm (6.81-7.28 in)
NOTE: Pedal free play must be measured after turning
off the engine and stepping on the brake pedal firmly five
times or more.
2. If the measured value is not within the above range,
adjust the brake pedal as follows:
a. Disconnect the stoplight switch connector.
b. Loosen the stoplight switch lock nut.
c. Rotate the stoplight switch so that it moves away
from the brake pedal.
d. Loosen the lock nut (1) on the push rod.
e. Adjust the brake pedal to the specified height by
rotating the push rod in the appropriate direction.
f. Tighten the lock nut to the specified torque.
Torque: 20 N·m (15 lb ft)
g. Adjust the stoplight switch (2) to the specified
clearance (between the switch housing and the
brake pedal) by rotating the switch housing.
Clearance: 0.5–1.0 mm (0.02–0.04 in)
310RY00004
1. Pedal height must be measured after starting the
engine and revving it several times to apply vacuum
to the vacuum booster fully.
NOTE: Pedal height must be 95 mm (3.7 in) or more
when about 50 kg (110.25 lb) of stepping force is applied.
2. If the measured value is lower than the above range,
air may still be present in the hydraulic system
Perform the bleeding procedure.
5C–18 POWER–ASSISTED BRAKE SYSTEM
Brake Pedal and Associated Parts
310RY00006
Legend
(1) Brake Pedal Bracket Assembly
(2) Fulcrum Pin and Nut
(3) Connector
(4) Snap Pin
(5) Return Spring
Removal
1. Disconnect the battery “–” terminal cable, and wait at
least 5 minutes.
2. Disconnect the yellow 3 way SRS connector located
under the steering column.
3. Remove the engine hood opening lever.
4. Remove lower cover (8).
5. Remove driver knee bolster (10).
6. Disconnect the stop light switch connector (3).
Disconnect the anti-theft control module connector.
Refer to Body and Accessories section in this
Manual.
7. Remove snap pin (4) and push rod pin (7).
8. Remove the steering column shaft fixing bolt and nut
(9) on the steering wheel side, and lower the steering
column shaft.
9. Remove the brake pedal bracket assembly (1).
10. Remove return spring (5).
11. Remove fulcrum pin and nut (2).
(6)
(7)
(8)
(9)
(10)
Peadl Assembly
Push Rod Pin
Lower Cover
Bolts and Nut
Driver Knee Bolster
12. Remove pedal assembly (6).
Installation
1. Apply grease to the entire circumference of the
fulcrum pin.
2. Install pedal assembly (6) and fulcrum pin and nut (2).
Tighten the nut (2) to the specified torque.
Torque: 35 N·m (26 lb ft)
3. Install the brake pedal bracket assembly (1).
Tighten the bolts and nuts soecified torque.
Torque: 15 N·m (11 lb ft)
4. Install return spring (5).
5. Adjust pedal free travel.
Refer to Brake Pedal Adjustment in this section.
6. Tighten the steering column fixing bolt (9) (dash
panel) to the specified torque.
Torque: 20 N·m (14 lb ft)
POWER–ASSISTED BRAKE SYSTEM
7. Tighten the steering column fixing nut (9) (Cross
Beam) to the specified torque.
Torque: 17 N·m (12 lb ft)
8. Apply grease to the entire circumference of the Push
rod pin (7).
9. Install push rod pin (7).
10. Install snap pin (4).
11. Connect the anti-theft control module connector.
Refer to Body and Accessories section in this
manual.
5C–19
12. Connect the stop light switch connector (3).
13. Install driver knee bolster (10) and lower cover (8).
14. Install the engine hood opening lever.
15. Connect the yellow 3 way SRS connector located
under the steering column.
16. Connect the battery “–” terminal cable.
Stoplight Switch
Parts Location
Installation
1. Adjust the stop light switch to the specified clearance
(between switch housing and brake pedal) by rotating
the switch housing.
Clearance : 0-0.2 mm (0-0.08 in)
NOTE: Do not attempt to force the push rod into position
during the stop light switch installation and adjustment
procedure.
310RW008
Legend
(1) Connector
(2) Switch
(3) Lock Nut
Removal
1. Disconnect connector (1)
2. Remove lock nut (3).
3. Remove switch (2).
310RY00005
2. Connect connector (1).
3. Install lock nut (3).
5C–20 POWER–ASSISTED BRAKE SYSTEM
Main Data and Specifications
General Specifications
Pedal free play
6–10 mm (0.23 –0.39 in)
Pedal Height
173–185 mm (6.81–7.28 in)
Torque Specifications
310RY00007
POWER–ASSISTED BRAKE SYSTEM
5C–21
Fluid Reservoir Tank
Fluid Reservoir Tank and Associated Parts
330RW003
(3) O–ring
(4) Retainer
Legend
(1) Fluid Reservoir
(2) Electrical Connector
Removal
Installation
NOTE: Before removing the fluid reservoir, remove the
brake fluid from the fluid reservoir.
To install, follow the removal steps in the reverse order,
noting the following points:
1. O–ring (1) must be set onto the fluid reservoir (2),
before installing fluid reservoir.
1. Disconnect electrical connector.
2. Remove retainer (1).
330RW005
330RW004
3. Remove fluid reservoir and the fluid level sensor built
into the fluid reservoir. The fluid level sensor cannot
be removed for servicing.
4. Remove O–ring.
5C–22 POWER–ASSISTED BRAKE SYSTEM
Master Cylinder Assembly
Master Cylinder Assembly and Associated Parts
330RW010
Legend
(1) Electrical Connector
(2) Master Cylinder
(3) 2 attaching Nuts
Removal
CAUTION: When removing the master cylinder from
the vacuum booster, be sure to get rid of the internal
negative pressure of the vacuum booster (by, for
instance, disconnecting the vacuum hose) in
advance.
If any negative pressure remains in the vacuum
booster, the piston may possibly come out when the
master cylinder is being removed, letting the brake
fluid run out.
While removing the master cylinder, further, do not
hold the piston as it can be easily pulled out.
Outside surface of the piston is the surface on which
seals are to slide. Care should be taken to keep the
surface free of cuts and dents.
1. Disconnect electrical connector.
2. Remove brake pipes and after disconnecting the
brake pipe, cap or tape the openings of the brake pipe
to prevent the entry of foreign matter.
3. Remove 2 attaching nuts.
4. Remove P&B valve and bracket.
(4) P&B Valve and Bracket
(5) Brake Pipes
(6) Spacer and 2 gaskets
5. Remove master cylinder.
6. Remove spacer and the 2 gaskets.
Inspection and Repair
Master Cylinder
The master cylinder is not repairable and must be
replaced as a complete assembly if found defective.
Inspection
Excessive brake pedal travel, malfunction or dragging
brake suggests that the master cylinder is defective. In
such cases perform the following visual check:
Visual Check
Make parts replacement as required if wear, distortion,
nicks, cuts, corrosion, or other abnormal conditions are
found through the following parts inspection:
B Master cylinder body
B Fluid reservoir
B O–ring
POWER–ASSISTED BRAKE SYSTEM
5C–23
Functional Inspection of Master Cylinder
Piston
Push the primary piston (1) with your fingers to check that
it travels smoothly. If the motion is questionable, replace
the master cylinder as a complete assembly.
330RW009
NOTE: When checking the front (or primary) side, be
sure to mount the master cylinder plug in the rear (or
secondary) port.
“0” Line
330RW007
Functional Inspection of Master Cylinder
Inspect the master cylinder for functionality described
below. Replace if necessary.
Install the primary piston holder (3) J–39242 (including
the master cylinder attachment (5) and master cylinder
plug (7)) onto the master cylinder (4). Make sure the
spacer (2) (2 bolts) with its adjusting bolt is screwed in up
to the “0” line
“5” Line
Apply air
pressure to the
front and rear
ports
No pressure
rise.
Pressure
increase of 0.5
kg/cm2 or more
Remarks
Checks port
into the
atmospheric
pressure
chamber
Checks air
tightness of the
pressure chamber
NOTE:
1. Do not use an air compressor, as the air from the
compressor is mixed with compressor oil.
2. When installing the master cylinder onto the vacuum
booster, always adjust the vacuum booster push rod.
(Refer to Vacuum Booster in this section).
3. After the master cylinder is installed onto the vehicle,
check for leakage, pedal travel and pedal free play.
Installation
1. Install spacer and the 2 gaskets.
2. Install master cylinder.
When replacing the master cylinder or vacuum
booster or both, always measure the vacuum booster
push rod protrusion and adjust it as necessary (Refer
to Vacuum Booster in section).
330RW008
Connect the master cylinder attachment (5) J–39242 with
the end of the radiator cap tester (6) J–24460–01, and
apply air pressure with the cap tester. Make sure there is
no rise in pressure while adjusting the bolt to the “5” line.
There should be a pressure increase of 0.5 kg/cm2 or
more.
3. Install P&B valve and bracket.
4. Install 2 attaching nuts and tighten the attaching nuts
to the specified torque.
Torque: 13 N·m (113 lb in)
5C–24 POWER–ASSISTED BRAKE SYSTEM
5. Install brake pipes and tighten the brake pipe to the
specified torque.
Master cylinder and P&B valve sides
Special Tools
ILLUSTRATION
Torque: 15 N·m (11 lb ft)
TOOL NO.
TOOL NAME
Others
Torque: 16 N·m (12 lb ft)
J-39242
Primary Piston Holder
(including master
cylinder attachment and
master cylinder plug
6. Connect electrical connector.
Main Data and Specifications
General Specifications
Type
Dual–circuit
Piston bore
diameter
25.4 mm (1.000 in)
J-24460-01
Radiator Cap Tester
Torque Specifications
E05R200002
POWER–ASSISTED BRAKE SYSTEM
5C–25
Vacuum Booster Assembly
Vacuum Booster Assembly and Associated Parts
331RW005
Legend
(1) Pin
(2) Vacuum Booster Fixing Nut
(3) Vacuum Hose
Removal
1. Before removing the vacuum booster assembly,
disconnect and remove the brake pipes.
2. Remove master cylinder, refer to Master Cylinder
Removal in this section.
CAUTION: When removing the master cylinder from
the vacuum booster, be sure to get rid of the internal
negative pressure of the vacuum booster (by, for
instance, disconnecting the vacuum hose) in
advance.
If any negative pressure remains in the vacuum
booster, the piston may possibly come out when the
master cylinder is being removed, letting the brake
fluid run out.
Do not hold the piston while removing the master cyliner, the piston can be easily pulled out.
Outside surface of the piston is the surface on which
seals are to slide. Care should be taken to keep the
surface free of cuts and dents.
3. Remove vacuum hose.
(4) Master Cylinder
(5) Vacuum Booster
(6) Snap Pin
4. Disconnect the yoke clevis from the brake pedal.
5. Remove vacuum booster fixing nut.
6. Remove vacuum booster.
5C–26 POWER–ASSISTED BRAKE SYSTEM
Inspection and Repair
Installation
Vacuum Hose (The built in check valve)
1. Inspect the check valve (2), which is installed inside
the vacuum hose.
2. Air should pass freely from the vacuum booster (3) to
the engine (1).
3. Air should not pass from the engine (1) to the vacuum
booster (3). If it does, the check valve is inoperative
and the vacuum hose built in the check valve must be
replaced.
1. Perform vacuum booster and vacuum booster push
rod adjustment.
NOTE: When replacing either the master cylinder or
vacuum booster, be sure to measure push rod, and adjust
if required.
2. Remove retainer from vacuum booster front shell
using a small screwdriver. Then gently draw plate and
seal assembly out of the shell inside.
331RS003
360RY00004
3. Set push rod gauge J–39216 on vacuum booster, and
apply negative pressure by means of vacuum pump
J–23738–A so that the pressure in the vacuum
booster becomes 500 mm Hg.
NOTE: Be sure to apply NEGATIVE pressure after
installing a push rod gauge on the vacuum booster.
331RS004
POWER–ASSISTED BRAKE SYSTEM
4. Measure dimension (4).
Dimension (4) (Standard): –0.1–0.1 mm
(–0.0039–0.0039 in)
331RW002
5. If dimension (4) is out of the standard range, adjust
push rod using the Push Rod Support J–39241.
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: 15 N·m (11 lb ft)
8. Install yoke clevis.
9. Connect vacuum hose and make sure that the arrow
on the hose points in the direction of the engine.
10. Install master cylinder, refer to Master Cylinder
Installation in this section.
5C–27
5C–28 POWER–ASSISTED BRAKE SYSTEM
Exterior Components
Exterior Components and Associated Parts
331RW006
Legend
(1) Yoke Clevis
(2) Lock Nut
(3) Retaining Clip
(4) Valve Body Guard
(5) Silencer
(6)
(7)
(8)
(9)
(10)
(11)
Filter
2 Gaskets and Spacer
Vacuum Booster
Retainer
Plate and Seal Assembly
Master Cylinder
Removal
1. Remove master cylinder. Refer to Master Cylinder in
this section.
2. Remove vacuum booster. Refer to Vacuum Booster
in this section.
3. Remove yoke clevis.
4. Remove lock nut.
5. Remove retaining clip.
6. Remove valve body guard.
7. Remove silencer.
8. Remove filter.
9. Remove 2 gaskets and spacer.
10. Remove retainer, using a small screwdriver to pry out
the retainer. Gently pull out the plate and seal
assembly from the shell.
331RS003
POWER–ASSISTED BRAKE SYSTEM
Inspection and Repair
Visual Check
Make necessary parts replacement if cuts, nicks,
excessive wear, or other abnormal conditions are found
through inspection. Check the following parts:
B Yoke clevis
B Valve body guard
B Silencer
B Filter plate and seal assembly
Installation
1. Install plate and seal assembly.
2. Install retainer.
3. Install 2 gaskets and spacer.
4. Install filter.
5. Install silencer.
6. Install valve body guard.
7. Install retainer.
8. Install lock nut and yoke clevis and tighten to the
specified torque.
Torque: 20 N·m (15 lb ft)
9. Install vacuum booster, refer to Vacuum Booster in
this section.
10. Install master cylinder, refer to Master Cylinder in this
section and after installation, perform brake pedal
check and adjustment. Refer to Brake Pedal in this
section.
Vacuum Booster Overhaul
Vacuum Booster
The vacuum booster cannot be disassembled for repair.
Replace a defective vacuum booster with a new one.
5C–29
5C–30 POWER–ASSISTED BRAKE SYSTEM
Main Data and Specifications
General Specifications
Vacuum booster diaphragm diameter (Front)
205 mm (8.07 in)
Vacuum booster diaphragm diameter (Rear)
230 mm (9.06 in)
Push rod stroke
More than 32.0 mm (1.26 in)
Plunger diameter
10.25 mm (0.40 in)
Push rod diameter
27.4 mm (1.08 in)
Torque Specifications
330R200001
POWER–ASSISTED BRAKE SYSTEM
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
J-39216
Push Rod Gauge
J-23738-A
Vacuum Pump
J-39241
Push Rod Support
5C–31
5C–32 POWER–ASSISTED BRAKE SYSTEM
Front Disc Brake Pads
Front Disc Brake Pads Inspection
Check the outer pad by looking at each caliper from
above. Check the thickness on the inner pad by looking
down through the inspection hole on the top of the caliper.
Whenever the pad is worn to about the thickness of the
pad base, the pad should be removed for further
measurements. The pad should be replaced anytime the
pad thickness (1) is worn to within 1.00 mm (0.039 in) of
the pad itself.
Wear indicators are installed on disc brake pads, disc
brake pads need replacement when the wear indicator is
heard.
Minimum limit (1): 1.0 mm (0.039 in)
302RS002
Front Disc Brake Pads and Associated Parts
302RW003
Legend
(1) Lock Bolt
(2) Caliper Assembly
(3) Pad Assembly
(4) Clip
(5) Outer Side
POWER–ASSISTED BRAKE SYSTEM
Removal
5C–33
Installation
NOTE: If a squealing noise occurs from the front brake
while driving, check the pad wear indicator plate. If the
indicator plate contacts the rotor, the disc pad assembly
should be replaced.
1. Install clip.
B Draw out two–thirds of the brake fluid from the
reservoir.
B Raise the vehicle and support it with suitable safety
stands.
1. Remove wheel and tire assembly, refer to Wheels
and Tires System in Section 3E.
2. Remove lock bolt (1).
302RS005
2. Apply special grease (approximately 0.2 g) to both
contacting surfaces of the inner shims (2). Wipe off
extruded grease after installing. Install pad assembly
with shim.
302RW004
3. Rotate caliper assembly and support the caliper
assembly so that the brake hose is not stretched or
damaged.
4. Remove pad assembly with shim.
5. Remove Clip.
302RW005
Legend
(2) Inner Shim
(3) Wear Indicator
(4) Inner Side
5C–34 POWER–ASSISTED BRAKE SYSTEM
302RW006
3. Carefyully use adjustable pliers to bottom the piston
into the caliper bore. Do not pull or twist the flexible
hose or damage will occur.
Install caliper assembly.
Set caliper assembly in place.
302RS008
4. Install lock bolt (5) and tighten the bolt to the specified
torque.
Torque: 74 N·m (54 lb ft)
302RW018
5. Install wheel and tire assembly, refer to Wheels and
Tires System in Section 3E.
6. Pump the brake pedal several times to make sure that
the pedal is firm. Check the brake fluid level in the
reservoir after pumping the brakes.
POWER–ASSISTED BRAKE SYSTEM
5C–35
Front Disc Brake Rotor
Inspection
Parallelism
In the manufacturing of the brake rotor, all the tolerances
regarding surface finish, parallelism and lateral runout are
held very closely. Maintaining these tolerances provides
the surface necessary to assure smooth brake operation.
Parallelism is the measurement of thickness of the rotor
at four or more points around the circumference of the
rotor. All measurement must be made at 29 mm (1.14 in)
from the edge of the rotor.
The rotor thickness must not vary more than 0.010 mm
(0.0004 in) from point to point.
Maximum runout: 0.010 mm (0.0004 in)
Lateral Runout
Lateral runout is the movement of the rotor from side to
side as it rotates on the spindle. This could also be
referred to as “rotor wobble”.
This movement causes the piston to be knocked back into
its bore. This results in additional pedal travel and a
vibration during braking.
Checking Lateral Runout
1. Adjust the wheel bearing correctly, refer to Differential
in Section 4A1.
2. Attach the dial indicator accordingly so that the stem
contacts the rotor surface to approximately 29mm
(1.14 in) from the rotor edge.
3. Rotate the rotor one complete turn and inspect for
signs of lateral runout. Lateral runout should not
exceed 0.13 mm (0.005 in).
Maximum runout: 0.13 mm (0.005 in)
411RS018
Replacing Brake Rotors
When installing new brake rotors, do not refinish the
surfaces. These parts are at the correct level of surface
finish.
Refinishing Brake Rotors
411RS019
Accurate control of the rotor tolerances is necessary for
proper performance of the disc brakes. Machining of the
rotor should be done only with precision equipment. All
brake rotors have a minimum thickness dimension cast
into them. This dimension is the minimum wear
dimension and not a refinish dimension. The minimum
wear dimension is 24.60 mm (0.969 in). The minimum
refinish dimension is 24.97 mm (0.983 in).
When refinishing rotors, always use sharp cutting tools or
bits. Dull or worn tools leave a poor surface finish which
will affect initial braking performance. Vibration
dampening attachments should always be used when
refinishing braking surfaces. These attachments
eliminate tool chatter and will result in better surface
finish.
After refinishing, replace any rotor that does not meet the
minimum thickness of 24.97 mm (0.983 in). Do not use a
brake rotor that exceeds the manufacturers
specifications.
Minimum wear dimension: 24.60 mm (0.969 in)
Refinish dimension: 24.97 mm (0.983 in)
5C–36 POWER–ASSISTED BRAKE SYSTEM
411RW003
Front Disc Brake Caliper Assembly
Front Disc Brake Caliper Assembly and Associated Parts
302RW008
Legend
(1) Guide Bolt
(2) Brake Flexible Hose
(3) Lock Bolt
(4)
(5)
(6)
(7)
Caliper Assembly
Clip
Support Bracket with Pad Assembly
Pad Assembly
POWER–ASSISTED BRAKE SYSTEM
Removal
1. Raise the vehicle and support with suitable safety
stands.
2. Concernig wheel and tire assembly, refer to Wheels
and Tires System in Section 3E.
3. Remove the bolt and gaskets, then disconnect the
flexible hose from the caliper and after disconnecting
the flexible hose (1), cap or tape the openings to
prevent entry of foreign material.
5C–37
9. Remove pad assembly with shim and mark the lining
locations if they are to be reinstalled.
10. Remove clip.
Installation
1. Install clip.
302RS005
302RW009
4. Since the brake fluid flows out from the connecting
coupler, place a drain pan under the vehicle.
5. Remove guide bolt (2).
6. Remove lock bolt (3).
2. Apply special grease (approximately 0.2 g) to both
contacting surfaces of the inner shims (4). Wipe off
extruded grease after installing. Install pad assembly
with shim.
302RW011
302RW010
7. Remove caliper assembly.
8. Remove support bracket with pad assembly and take
care not to damage the flexible brake hose when
removing the support bracket.
Legend
(4) Inner Shim
(5) Wear Indicator
(6) Inner Side
5C–38 POWER–ASSISTED BRAKE SYSTEM
3. Install support bracket and tighten the bolt (7) to the
specified torque.
Torque: 155 N·m (115 lb ft)
6. Install brake flexible hose, always use new gaskets
and be sure to put the hooked edge of the flexible
hose end into the anti–rotation cavity then tighten the
I–bolt (10) to the specified torque.
Torque: 35 N·m (26 lb ft)
302RW012
4. Install caliper assembly.
5. Install lock bolt (9) and guide bolt (8) and tighten the
bolt to the specified torque.
Torque: 74 N·m (54 lb ft)
302RW013
302RW014
7. Install wheel and tire assembly, refer to Wheels and
Tires System in Section 3E.
8. Bleed brakes. Refer to Hydraulic Brakes in this
section.
POWER–ASSISTED BRAKE SYSTEM
5C–39
Front Disc Brake Caliper
Front Disc Brake Caliper Disassembled View
302RW015
Legend
(1) Guide Bolt
(2) Lock Bolt
(3) Bleeder with Cap
(4) Caliper Body
(5)
(6)
(7)
(8)
(9)
Dust Boot: Guide Bolt and Lock Bolt
Piston Seal
Piston
Dust Boot: Piston
Dust Boot Ring
Disassembly
1. Remove guide bolt.
2. Remove lock bolt.
3. Remove dust boot: guide bolt and lock bolt.
4. Remove dust boot ring, using a small screwdriver.
302RS016
5C–40 POWER–ASSISTED BRAKE SYSTEM
5. Insert a block of wood into the caliper and force out
the piston by blowing compressed air into the caliper
at the flexible hose attachment. This procedure must
be done prior to removal of the dust boot.
Remove piston.
WARNING: DO NOT PLACE YOUR FINGERS IN
FRONT OF THE PISTON IN AN ATTEMPT TO CATCH
OR PROTECT IT WHEN APPLYING COMPRESSED
AIR. THIS COULD RESULT IN PERSONAL INJURY.
CAUTION: Use just enough air to ease the piston
out of the bore. If the piston is blown out, it may be
damaged.
Reassembly
1. Install caliper body.
2. Install bleeder with cap and tighten the cap to the
specified torque.
Torque: 8 N·m (69 lb in)
3. Apply special rubber grease to the piston seal and
cylinder wall, then insert the piston seal into the
cylinder. The special rubber grease is included in the
repair kit.
302RS018
302RS017
6. Remove dust boot: piston.
7. Remove piston seal.
8. Remove bleeder with cap.
9. Remove caliper body.
4. When inserting the piston into the cylinder, use finger
pressure only and do not use a mallet or other impact
tool, since damage to the cylinder wall or piston seal
can result.
Install piston.
Inspection and Repair
Make necessary parts replacement, if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
Check the following parts:
B Rotor
B Cylinder body
B Cylinder bore
B Piston
B Guide bolt, lock bolt
B Support bracket
NOTE: The piston seal, boot ring and dust boot are to be
replaced each time the caliper is overhauled. Discard
these used rubber parts and replace them with new ones.
302RS019
POWER–ASSISTED BRAKE SYSTEM
5. Apply special grease (approximately 1 g) to the piston
and attach the dust boot to the piston and caliper.
Insert the dust boot ring into the dust boot.
302RS020
6. Install guide bolt and lock bolt dust boot.
7. Install the dust boot on the support bracket after
applying special grease (approximately 1 g) onto the
dust boot inner surface. Apply special grease onto the
lock bolt and guide bolt setting hole of the support
bracket.
302RS021
8. Install lock bolt and guide bolt and tighten the bolt to
the specified torque.
Torque: 74 N·m (54 lb ft)
5C–41
5C–42 POWER–ASSISTED BRAKE SYSTEM
Main Data and Specifications
General Specifications
Type
Floating, pin slide
Pad dimension
55 [email protected] (8.52 [email protected])
Adjusting method
Piston diameter
Disc type
Self–adjusting
60.33 mm (2.38 in)
Ventilated
Disc thickness
26 mm (1.02 in)
Disc effective diameter
222 mm (8.74 in)
Torque Specifications
E05RW004
POWER–ASSISTED BRAKE SYSTEM
5C–43
Rear Disc Brake Pads (4×4 Model)
Brake Pads Inspection
Check the outer pads by looking at each caliper from
above. Check the thickness on the inner pad by looking
down through the inspection hole in the top of the caliper.
Whenever the pad is worn to about the thickness of the
pad base, the pad should be removed for further
measurements. The pad should be replaced anytime the
pad thickness (1) is worn to within 1.0 mm (0.039 in) of the
pad itself.
Wear indicators are installed on disc brake pads, disc
brake pads need replacement when the wear indicator is
heard.
Minimum limit (1): 1.0 mm (0.039 in)
302RW016
Brake Pads and Associated Parts
306RW001
Legend
(1) Caliper Assembly
(2) Clip
(3) Lock Bolt
(4) Pad Assembly
5C–44 POWER–ASSISTED BRAKE SYSTEM
Removal
Installation
NOTE: If a squealing noise occurs from the rear brake
while driving, check the pad wear indicator plate. If the
indicator plate contacts the rotor, the disc pad assembly
should be replaced.
1. Install clip (2).
B Draw out two–thirds of the brake fluid from the
reservoir.
B Raise the vehicle and support it with suitable safety
stands.
1. Remove wheel and tire assembly, refer to Wheels
and Tires System in Section 3E.
2. Remove lock bolt (1)
306RW003
2. Apply special grease (approximately 0.2 g) to both
contacting surfaces of the inner shims. Wipe off
extruded grease after installing. Install pad assembly
with shim.
306RW002
3. Rotate caliper assembly and support the caliper
assembly so that the brake hose is not stretched or
damaged.
4. Remove pad assembly with shim.
5. Remove clip.
306RW004
Legend
(3) Inner Shim
(4) Wear Indicator
POWER–ASSISTED BRAKE SYSTEM
306RW005
3. Carefyully use adjustable pliers to bottom the piston
into the caliper bore. Do not pull or twist the flex hose
or damage will occur.
302RS008
4. Install lock bolt (5) and tighten the bolt to the specified
torque.
Torque: 44 N·m (32 lb ft)
5. Install wheel and tire assembly, refer to Wheels and
Tires System in Section 3E.
6. Pump the brake pedal several times to make sure that
the pedal is firm. Check the brake fluid level in the
reservoir after pumping the brakes.
5C–45
306RW006
5C–46 POWER–ASSISTED BRAKE SYSTEM
Rear Disc Brake Rotor (4×4 Model)
Inspection
Parallelism
In the manufacturing of the brake rotor, all the tolerances
regarding surface finish, parallelism and lateral runout are
held very closely. Maintaining these tolerances provides
the surface necessary to assure smooth brake operation.
Parallelism is the measurement of thickness of the rotor
at four or more points around the circumference of the
rotor. All measurement must be made at 22 mm (0.87 in)
from the edge of the rotor.
The rotor thickness must not vary more than 0.010 mm
(0.0004 in) from point to point.
Maximum parallelism: 0.010 mm (0.0004 in)
Lateral Runout
Lateral runout is the movement of the rotor from side to
side as it rotates on the spindle. This could also be
referred to as “rotor wobble”.
This movement causes the piston to be knocked back into
its bore. This results in additional pedal travel and a
vibration during braking.
Checking Lateral Runout
1. Adjust the wheel bearing correctly, refer to Differential
in Section 4A1.
2. Attach the dial indicator accordingly so that the stem
contacts the rotor surface to approximately 29mm
(1.14 in) from the rotor edge.
3. Rotate the rotor one complete turn and inspect for
signs of lateral runout. Lateral runout should not
exceed 0.13 mm (0.005 in).
1. The lateral runout should not exceed 0.13 mm
(0.005 in)
Maximum runout: 0.13 mm (0.005 in)
420RS013
Replacing Brake Rotors
When installing new brake rotors, do not refinish the
surfaces. These parts are at the correct level of surface
finish.
Refinishing Brake Rotors
306RY00013
Accurate control of the rotor tolerances is necessary for
proper performance of the disc brakes. Machining of the
rotor should be done only with precision equipment. All
brake rotors have a minimum thickness dimension cast
into them. This dimension is the minimum wear
dimension and not a refinish dimension. The minimum
wear dimension is 16.6 mm (0.654 in). The minimum
refinish dimension is 16.97 mm (0.668 in).
When refinishing rotors, always use sharp cutting tools or
bits. Dull or worn tools leave a poor surface finish which
will affect initial braking performance. Vibration
dampening attachments should always be used when
refinishing braking surfaces. These attachments
eliminate tool chatter and will result in better surface
finish.
POWER–ASSISTED BRAKE SYSTEM
After refinishing, replace any rotor that does not meet the
minimum thickness of 16.97 mm (0.668 in). Do not use a
brake rotor that exceeds the manufacturers
specifications.
Minimum wear dimension: 16.6 mm (0.654 in)
Refinish dimension: 16.97 mm (0.668 in)
420RW002
Rear Drum (In Disc) Inside Diameter
Check
Check the rear drum inside diameter by measuring at
more than two portions as shown in the illustration.
If the inside diameter is greater than the limit, replace the
rear rotor.
Standard: 210.0 mm (8.27 in)
Limit: 211.4 mm (8.32 in)
420RS035
5C–47
5C–48 POWER–ASSISTED BRAKE SYSTEM
Rear Disc Brake Caliper Assembly (4×4 Model)
Rear Disc Brake Caliper Assembly and Associated Parts
306RW007
(4)
(5)
(6)
(7)
Legend
(1) Brake Flexible Hose
(2) Clip
(3) Lock Bolt
Removal
1. Raise the vehicle and support with suitable safety
stands.
2. Remove wheel and tire assembly, refer to Wheels
and Tires System in Section 3E.
3. Remove the bolt and gaskets, then disconnect the
flexible hose from the caliper and after disconnecting
the flexible hose (1), cap or tape the openings to
prevent entry of foreign material.
Support Bracket
Guide Bolt
Pad Assembly with Shim
Caliper Assembly
5. Remove lock bolt (3).
6. Remove guide bolt (2).
306RW009
306RW008
4. Since the brake fluid flows out from the connecting
coupler, place a drain pan under the vehicle.
7. Remove caliper assembly.
8. Remove support bracket with pad assembly and take
care not to damage the flexible brake hose when
removing the support bracket.
9. Remove pad assembly with shim and mark the lining
locations if they are to be reinstalled.
10. Remove clip.
POWER–ASSISTED BRAKE SYSTEM
5C–49
3. Install support bracket and tighten the bolt (7) to the
specified torque.
Installation
1. Install clip (4).
Torque: 103 N·m (76 lb ft)
306RW010
2. Apply special grease (approximately 0.2 g) to both
contacting surfaces of the inner shims (5). Wipe off
extruded grease after installing. Install pad assembly
with shim.
306RW012
4. Install caliper assembly.
5. Install lock bolt and guide bolt (8) and tighten the bolt
to the specified torque.
Torque: 44 N·m (32 lb ft)
306RW011
Legend
(5) Inner Shim
(6) Wear indicator
306RW013
6. Install brake flexible hose, always use new gaskets
and be sure to put the hooked edge of the flexible
hose end into the anti–rotation cavity then tighten the
eye–bolt (9) to the specified torque.
Torque: 35 N·m (26 lb ft)
5C–50 POWER–ASSISTED BRAKE SYSTEM
7. Install the wheel and tire assembly, refer to Wheels
and Tires System in Section 3E.
8. Bleed brakes. Refer to Hydraulic Brakes in this
section.
302RW017
Rear Disc Brake Caliper (4×4 Model)
Rear Disc Brake Caliper Disassembled View
306RW014
Legend
(1) Guide Bolt
(2) Lock Bolt
(3) Bleeder with Cap
(4) Caliper Body
(5)
(6)
(7)
(8)
(9)
Piston Seal
Piston
Dust Boot: Piston
Dust Boot Ring
Dust Boot: Guide Bolt and Lock Bolt
POWER–ASSISTED BRAKE SYSTEM
Disassembly
1. Remove guide bolt.
2. Remove lock bolt.
3. Remove dust boot; guide bolt and lock bolt.
4. Remove dust boot ring, using a small screwdriver.
5C–51
6. Remove dust boot: piston.
7. Remove piston seal.
8. Remove bleeder with cap.
9. Remove caliper body.
Inspection and Repair
Make necessary parts replacement, if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
Check the following parts:
B Rotor
B Cylinder body
B Cylinder bore
B Piston
B Guide bolt, lock bolt
B Support bracket
NOTE: The piston dust seal and dust boot are to be
replaced each time the caliper is overhauled. Discard
these used rubber parts and replace with new ones.
Reassembly
302RS016
5. Insert a block of wood into the caliper and force out
the piston by blowing compressed air into the caliper
at the flexible hose attachment. This procedure must
be done prior to removal of the dust boot.
Remove piston.
WARNING: DO NOT PLACE YOUR FINGERS IN
FRONT OF THE PISTON IN AN ATTEMPT TO CATCH
OR PROTECT IT WHEN APPLYING COMPRESSED
AIR. THIS COULD RESULT IN PERSONAL INJURY.
1. Install caliper body.
2. Install bleeder with cap and tighten the cap to the
specified torque.
Torque: 8 N·m (69 lb ft)
3. Install piston seal and apply special rubber grease to
the piston seal and cylinder wall, then insert the piston
seal into the cylinder. The special rubber grease is
included in the repair kit.
CAUTION: Use just enough air to ease the piston
out of the bore. If the piston is blown out, it may be
damaged.
302RS018
4. When inserting the piston into the cylinder, use finger
pressure only and do not use a mallet or other impact
tool, since damage to the cylinder wall or piston seal
can result.
Install piston.
302RS017
5C–52 POWER–ASSISTED BRAKE SYSTEM
302RS019
5. Apply special grease (approximately 1g) to the piston
and attach the dust boot to the piston and caliper.
Insert the dust boot ring into the dust boot.
302RS020
6. Install guide bolt and lock bolt dust boot.
7. Install the dust boot on the support bracket after
applying special grease (Approx. 1g) onto the dust
boot inner surface. Also apply special grease onto
the lock bolt and guide bolt setting hole of the support
bracket.
302RS021
8. Install lock bolt and guide bolt and tighten the bolt to
the specified torque.
Torque: 44 N·m (32 lb ft)
POWER–ASSISTED BRAKE SYSTEM
5C–53
Main Data and Specifications (4×4 Model)
General Specifications
Type
Floating, pin slide
Pad dimension
33 [email protected] (5.11 [email protected])
Adjusting method
Piston diameter
Disc type
Disc thickness
Disc effective diameter
Self–adjusting
41.3 mm (1.63 in)
Ventilated
18 mm (0.71 in)
269.2 mm (10.60 in)
Torque Specifications
E05RW005
5C–54 POWER–ASSISTED BRAKE SYSTEM
Brake Lining
Brake Lining and Associated Parts
305RW001
Legend
(1) Wheel and Tire Assembly
(2) Drum
(3) Hold-down Spring and Cup
(4) Hold-down Spring and Cups
(5) Lower Return Spring
(6) Upper (other) Return Spring
(7) Trailing Shoe Assembly with Parking Brake
Lever
(8) Leading Shoe Assembly with Upper (inner)
Return Spring
Removal
1. Raise the vehicle and support with suitable safety
stands.
2. Remove wheel and tire assembly (1).
B Refer to “Wheel and Tires” in Wheel and Tire
System section.
3. Remove Drum (2).
B If difficulty is encountered in removing the drum:
– Mark the position of the drum to the axle.
– Make sure the parking brake is released.
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
Upper (inner) Return Spring
Auto Adjuster Lever
Parking Brake Lever
Adjuster Assembly
Wave Washer
Retainer
Hold-down Pin
Hold-down Pin
– Use a rubber mallet to tap gently on the outer rim of
the drum and/or around the inner drum. Be careful
to avoid damaging the drum.
4. Remove upper (other) return spring (6) and auto
adjuster lever.
5. Remove lower return spring (5).
6. Remove hold-down spring and cups (4) and
hold-down pin (15).
7. Remove adjuster assembly (12)
8. Remove leading shoe assembly (8) with upper (inner)
return spring (9).
POWER–ASSISTED BRAKE SYSTEM
NOTE: Do not over stretch the return spring.
5C–55
Installation
1. Apply grease lightly to back place A.
305RS003
9. Remove upper (inner) return spring (9).
10. Remove hold-down spring and cup (3) and hold-down
pin (16).
11. Remove Trailing shoe assembly (7) with parking
brake lever (16).
12. Remove parking brake cable from parking brake lever
(11).
13. Remove retainer (14), wave washer (13), and parking
brake lever (11).
Brake Lining Inspection
Check the shoe assemblies for wear by removing brake
drum.
Replace the shoe assemblies, if lining thickness is less
than 1.0 mm (0.039 in).
The shoe assemblies have a wear indicator that makes a
noise when the linings wear to a degree where
replacement is required.
Minimum limit: 1.0 mm (0.039 in)
305RW002
Legend
(1) Place A (3 portions for each side)
2. Install parking brake lever (11), wave washer (13),
and retainer (14).
3. Install trailing shoe assembly (7) with parking brake
lever (16).
4. Install the parking brake cable to parking brake lever
(11).
5. Install hold-down pin (16) and hold-down spring and
cup (3).
6. Install upper (inner) return spring (9).
7. Install leading shoe assembly (8) with upper (inner)
return spring (9).
NOTE: Do not over stretch the return spring.
305RS003
305RS001
8. Install adjuster assembly (12).
9. Install hold-down pin (15) and hold-down spring and
cups (4).
5C–56 POWER–ASSISTED BRAKE SYSTEM
10. Install lower return spring (5).
B Use brake spring tool.
11. Install auto adjuster lever (10).
12. Install upper (outer) return spring (6).
B Use brake spring tool.
13. Install brake drum (2).
B Adjust the brakes, refer to Drum Brake Adjustment
in this section.
14. Install wheel and tire assembly (1).
B Refer to “Wheels and Tires ” in wheel and Tire
System section.
Drum Brake Adjustment (4×2 Model)
NOTE: All brakes are self-adjusting. Brakes are adjusted
by repeated stepping on the brake pedal. (After stepping
on the pedal and releasing it, the rear auto adjuster, in the
rear brake, produces a clicking sound.
The same operation should be repeated until the sound
disappears.)
Take the following steps after overhauling the rear brake
assembly.
1. Move the parking brake handle to its fully released
position.
2. Parking cable must be loosened sufficiently. (Loosen
the adjust nut and the lock nut.)
3. Repeat stepping on the brake pedal firmly, and
releasing it until the clicking sound can no longer be
heard.
If the difference between the brake drum inside
diameter and diameter of the brake shoes is adjusted
to be 0,5 mm, the number of times for depressing the
brake pedal can be reduced.
4. Remove the drum. Measure the brake drum inside
diameter and diameter of the brake shoes.
Shoe clearance: 0.25-0.4 mm (0.0098-0.0157 in)
If incorrect, check the brake auto-adjusting system.
Servicing The Brake Drum
Whenever the brake drums are removed, they should be
thoroughly cleaned and inspected for cracks, scores,
deep grooves and out-of-round.
Cracked, Scored or Grooved Drum
A cracked drum is unsafe and must be replaced.
Do not attempt to weld a cracked drum.
Smooth any slight scores. Heavy or extensive scoring will
cause excessive brake lining wear, and it will probably be
necessary to machine the drum braking surface.
If the brake linings are slightly worn and the drum is
grooved, the drum should be polished with fine emery
cloth but should not be machined. At this stage,
eliminating all the grooves in the drum and smoothing the
ridges on the lining would require the removal of too much
metal and lining. If left alone, the grooves and ridges
match and satisfactory service can be obtained. If brake
linings are to be replaced, a grooved drum should be
machined. Using a grooved drum with new linings will
create inefficient braking performance and cause the
linings to wear quicker.
Out-Of-Round Drum
An out-of-round drum makes accurate brake shoe
adjustment impossible and is likely to cause excessive
wear to other parts of the brake mechanism due to its
eccentric action. An out-of-round drum can also cause
severe and irregular tire tread wear as well as a pulsing
brake pedal. When the braking surface of a brake drum
exceeds the specification limit of 0.15 mm (0.006 in) in
out-of-round, the drum should be machined to true up the
braking surface.
Out-of-round can be accurately
measured with an inside micrometer fitted with proper
extension rods. When measuring a drum for out-of-round
and wear, take measurements at the open and closed
edges of machines surfaces and at right angles to each
other.
Maximum out-of-round: 0.15 mm (0.006 in)
5. Rotate the adjust nut until all slack disappears from
the cable. Set the adjust nut.
6. Applying about 30 kg (66 lb) of force, pull the parking
brake handle to its fully set position three or four
times.
7. If the parking brake is properly adjusted, the travel
between the fully disengaged position and the fully
engaged position will be between 9 and 11 notches.
If the traveling range is not within these limits, again
repeat steps 1 through 5.
After adjusting has been done, check to see if the rear
wheel rotates smoothly without drag when turned by
hand.
420RS034
POWER–ASSISTED BRAKE SYSTEM
Machining The Drum
If a drum is to be machined, only enough metal should be
removed to obtain a true, smooth braking surface. If a
drum does not clean-up when machined to a maximum
diameter, it must be replaced. Removal of more metal will
5C–57
affect dissipation of heat and may cause distortion of the
drum.
After refinishing, replace any drum that exceeds a
maximum inside diameter of 296.5 mm (11.673 in). Do
not use a brake drum that is not within the specification.
Maximum inside diameter: 296.5 mm (11.673 in)
Wheel Cylinder Assembly (4×2 Model)
Wheel Cylinder Assembly and Associated Parts
305RW003
Legend
(1) Brake Linings
(2) Wheel Cylinder
Removal
1. Remove brake linings (1).
B Refer to Brake Lining and Associated Parts in this
section.
2. Remove brake pipe (4).
B Plug the opening in the line to prevent fluid loss and
contamination.
3. Remove bolts (3) and wheel cylinder (2).
(3) Bolts
(4) Brake Pipe
Installation
1. Install wheel cylinder (2) and tighten bolts (3) to the
specified torque.
Torque: 10 N·m (8 lb ft)
2. Install brake pipe (4) and tighten the nut to the
specified torque.
Torque: 16 N·m (12 lb ft)
3. Install brake linings (1).
B Refer to Brake Lining Replacement in this section.
B Bleed brake system. Refer to Hydraulic Brake in
this section.
5C–58 POWER–ASSISTED BRAKE SYSTEM
NOTE: Replace the piston cups and boots each time the
wheel cylinder is overhauled. Discard these used rubber
parts and replace with new ones.
Disassembled View
Reassembly
1. Lubricate the cylinder bore with clean rubber grease.
305RS006
Legend
(1) Boot
(2) Piston Assembly
(3) Piston Cup
(4) Return Spring
(5) Bleeder
(6) Wheel Cylinder
305RS007
2. Install bleeder (5) to wheel cylinder (6).
Torque: 10 N·m (8 lb ft)
Disassembly
1. Remove boot (1) and piston assembly (2).
2. Remove piston cup (3) from piston assembly (2).
3. Remove return spring (4) and bleeder (5) from wheel
cylinder (6).
Inspection and Repair
1. Make necessary parts replacement if wear, damage,
corrosion or any other abnormal condition are found
through inspection.
Check the following parts;
B Wheel cylinder body
B Cylinder bore
B Piston
B Return spring
B Bleeder
305RS008
POWER–ASSISTED BRAKE SYSTEM
3. Install new piston cups (3) on each piston so that the
flared end of the cups are turned to the inboard side of
the pistons.
Attach the return spring (4) and the boot (1) to the
piston.
305RS009
4. Apply DELCO silicone lube No. 5459912 (or
equivalent) to the piston and the inner face of the
boots.
5. Install piston assembly (2) to wheel cylinder (6).
5C–59
5C–60 POWER–ASSISTED BRAKE SYSTEM
Main Data and Specifications
General Specifications
Rear drum brake
Type
Leading-trailing, non-servo
Drum inside diameter
295 mm (11.6 in)
Wheel cylinder diameter
22.22 mm (7/8 in)
Torque Specifications
E05RW010
POWER–ASSISTED BRAKE SYSTEM
5C–61
AXIOM (Vehicles Produced After Aug./1/2001)
POWER-ASSISTED BRAKE SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . .
General Description . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Diagnosis . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Brakes . . . . . . . . . . . . . . . . . . . . . . . .
Filling Master Cylinder Reservoir . . . . . . . .
Deterioration of Brake Fluid . . . . . . . . . . . . .
Leakage of Brake Fluid . . . . . . . . . . . . . . . . .
Bleeding Brake Hydraulic System . . . . . . . .
Flushing Brake Hydraulic System . . . . . . . .
Brake Pipes and Hoses . . . . . . . . . . . . . . . .
Brake Hose Inspection . . . . . . . . . . . . . . . . .
Front Caliper Brake Hose . . . . . . . . . . . . . . . .
Front Caliper Brake Hose and Associated
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Axle Brake Hose . . . . . . . . . . . . . . . . . . .
Rear Axle Brake Hose and Associated
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P & B (Proportioning and Bypass) Valve . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications . . . . . . . . . . . . .
Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Pedal Height . . . . . . . . . . . . . . . . .
Checking Pedal Travel . . . . . . . . . . . . . . . . .
Brake Pedal and Associated Parts . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stoplight Switch . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Location . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications . . . . . . . . . . . . .
Master Cylinder Assembly . . . . . . . . . . . . . . . .
Master Cylinder Assembly and Associated
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5C–62
5C–62
5C–66
5C–67
5C–70
5C–70
5C–70
5C–70
5C–70
5C–71
5C–71
5C–71
5C–72
5C–72
5C–72
5C–72
5C–73
5C–73
5C–73
5C–73
5C–74
5C–74
5C–74
5C–75
5C–75
5C–75
5C–76
5C–77
5C–77
5C–77
5C–78
5C–78
5C–78
5C–79
5C–79
5C–79
5C–79
5C–80
5C–81
5C–81
5C–81
5C–81
Master Cylinder Assembly . . . . . . . . . . . . . . . .
Master Cylinder Assembly Desassembled
View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Desassembly . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications . . . . . . . . . . .
Vacuum Booster Assembly . . . . . . . . . . . . . . .
Vacuum Booster Assembly and Associated
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Exterior Components . . . . . . . . . . . . . . . . . . . .
Exterior Components and Associated
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vacuum Booster Overhaul . . . . . . . . . . . . . . . .
Vacuum Booster . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications . . . . . . . . . . . . .
Front Disc Brake Pads . . . . . . . . . . . . . . . . . . .
Front Disc Brake Pads Inspection . . . . . . . .
Front Disc Brake Pads and Associated
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Disc Brake Rotor . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Brake Rotors . . . . . . . . . . . . . . . .
Refinishing Brake Rotors . . . . . . . . . . . . . . .
Front Disc Brake Caliper Assembly . . . . . . . .
Front Disc Brake Caliper Assembly and
Associated Parts . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Disc Brake Caliper . . . . . . . . . . . . . . . . .
Front Disc Brake Caliper Disassembled
View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications . . . . . . . . . . .
Rear Disc Brake Pads (4×4 Model) . . . . . . . .
5C–82
5C–82
5C–82
5C–82
5C–83
5C–83
5C–84
5C–85
5C–85
5C–85
5C–86
5C–87
5C–87
5C–87
5C–88
5C–88
5C–88
5C–88
5C–89
5C–90
5C–90
5C–90
5C–91
5C–91
5C–93
5C–93
5C–93
5C–93
5C–95
5C–95
5C–95
5C–96
5C–98
5C–98
5C–98
5C–99
5C–99
5C–100
5C–101
5C–62 POWER–ASSISTED BRAKE SYSTEM
Brake Pads Inspection . . . . . . . . . . . . . . . . .
Brake Pads and Associated Parts . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Disc Brake Rotor (4×4 Model) . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Brake Rotors . . . . . . . . . . . . . . . .
Refinishing Brake Rotors . . . . . . . . . . . . . . .
Rear Drum (In Disc) Inside Diameter
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Disc Brake Caliper Assembly
(4×4 Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Disc Brake Caliper Assembly and
Associated Parts . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Disc Brake Caliper (4×4 Model) . . . . . .
Rear Disc Brake Caliper Disassembled
View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
5C–101
5C–101
5C–102
5C–102
5C–104
5C–104
5C–104
5C–104
5C–105
5C–106
5C–106
5C–106
5C–107
5C–108
5C–108
5C–109
5C–109
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications
(4×4 Model) . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Lining and Associated Parts . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Lining Inspection . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drum Brake Adjustment (4×2 Model) . . . . .
Servicing The Brake Drum . . . . . . . . . . . . . .
Wheel Cylinder Assembly (4×2 Model) . . . . .
Wheel Cylinder Assembly and Associated
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications . . . . . . . . . . . . .
Service Precaution
General Description
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.
Master Cylinder Assembly
5C–109
5C–111
5C–112
5C–112
5C–112
5C–113
5C–113
5C–114
5C–114
5C–115
5C–115
5C–115
5C–115
5C–116
5C–116
5C–116
5C–116
5C–118
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.
330R200002
POWER–ASSISTED BRAKE SYSTEM
The master cylinder contains two pistons that supply the
hydraulic pressure for a dual–circuit braking system. The
primary piston provides the fluid pressure to the front
brakes, while the secondary piston provides the fluid
pressure to the rear brakes. If the pressure is lost from
either system, the remaining system will function to stop
the vehicle.
5C–63
CAUTION:
1. If any hydraulic component is removed or
disconnected, it may be necessary to bleed all or
part of the brake system. (Refer to Bleeding Brake
Hydraulic System in this section.)
2. The torque values specified
unlubricated fasteners.
are
for
dry,
3. Perform service operations on a clean bench free
from all mineral oil materials.
Brake Booster
331R200001
This booster is a tandem vacuum unit with a diaphragm
effective diameter 205mm + 230mm (8.07in + 9.06in). In
normal operating mode, with the service brakes in the
released position, the tandem vacuum booster operates
with vacuum on both sides of its diaphragms. When the
brakes are applied, air at atmospheric pressure is
admitted to both sides of the diaphragm to provide the
power assist. When the service brake is released, the
atmospheric air is shut off from both sides of the
diaphram. The air is then drawn from the booster through
the vacuum check valve to the vacuum source.
CAUTION:
1. If any hydraulic component is removed or
disconnected, it may be necessary to bleed all or
part of the brake system.
2. The torque values specified
unlubricated fasteners.
are
for
dry,
3. The vacuum booster is not repairable and must be
replaced as complete assembly.
5C–64 POWER–ASSISTED BRAKE SYSTEM
Disc Brake
Front Disc Brake
A05R200001
Rear Disc Brake (4×4 Model)
A05RW002
The disc brake assembly consists of a caliper, piston,
rotor, pad assembly and support bracket. The caliper
assembly has a fornt dual bore, rear single bore and is
mounted to the support bracket with two mounting bolts.
The support bracket allows the caliper to move laterally
against the rotor. The caliper is a one–piece casting with
the inboard side containing the piston bore. A square cut
rubber seal is located in a groove in the piston bore which
provides the hydraulic seal between the piston and the
cylinder wall.
NOTE:
1. Replace all components included in repair kits used to
service this caliper.
2. Lubricate rubber parts with clean brake fluid to ease
assembly.
3. If any hydraulic component is removed or
disconnected, it may be necessary to bleed all or part
of the brake system.
4. Replace pads in axle sets only.
5. The torque values specified are for dry, unlubricated
fasteners.
6. Perform the service operation on a clean bench free
from all mineral oil materials.
Operation
Hydraulic pressure, created by applying the brake pedal,
is converted by the caliper to a stopping force. This force
creates a clamping action of the piston pressing towards
the rotors (outward) and the caliper slides inward toward
the vehicle. This clamping action forces the linings
against the rotor, creating friction to stop the vehicle.
POWER–ASSISTED BRAKE SYSTEM
5C–65
Leading/Trailing Drum Brakes (4×2 Model)
A05RS003
This drum brake assembly is a leading/trailing shoe
design. Both brake shoes are held against the wheel
cylinder pistons by the upper return spring and to the fixed
anchor plate by the lower return spring. When the brakes
are applied, the wheel cylinder pistons expand pushing
both shoes out contacting the drum.
With forward wheel rotation, the forward brake shoe will
wrap into the drum and becomes self-energized.
With reverse wheel rotation, the rear brake shoe is
self-energized. Force from the brake shoes is transferred
to the anchor plate through the braking plate to the axle
flange. Adjustment is automatic and occurs on any
service brake application. Also, with leading/trailing
brakes, it is normal for the front shoe to wear at a faster
rate than the rear shoe.
5C–66 POWER–ASSISTED BRAKE SYSTEM
Diagnosis
Road Testing The Brakes
Brake Test
Brakes should be tested on a dry, clean, reasonably
smooth and level roadway. A true test of brake
performance cannot be made if the roadway is wet,
greasy or covered with loose dirt where all tires do not grip
the road equally. Testing will also be adversely affected if
the roadway is crowned so as to throw the weight of the
vehicle toward wheels on one side or if the roadway is so
rough that wheels tend to bounce. Test the brakes at
different vehicle speeds with both light and heavy pedal
pressure; however, avoid locking the wheels and sliding
the tires. Braking without locking the tires will stop the
vehicle in less distance than braking to a skid (which has
no brake efficiency). More tire to road friction is present
while braking without locking the tires than braking to a
skid.
The standard brake system is designed and balanced to
avoid locking the wheels except at very high deceleration
levels.
It is designed this way because the shortest stopping
distance and best control is achieved without brake
lock–up.
Because of high deceleration capability, a firmer pedal
may be felt at higher deceleration levels.
External Conditions That Affect Brake Performance
1. Tires: Tires having unequal contact and grip on the
road will cause unequal braking. Tires must be
equally inflated, identical in size, and the thread
pattern of right and left tires must be approximately
equal.
2. Vehicle Loading: A heavily loaded vehicle requires
more braking effort.
3. Wheel Alignment: Misalignment of the wheels,
particularly in regard to excessive camber and caster,
will cause the brakes to pull to one side.
Brake Fluid Leaks
With engine running at idle and the transmission in
“Neutral”, depress the brake pedal and hold a constant
foot pressure on the pedal. If pedal gradually falls away
with the constant pressure, the hydraulic system may be
leaking.
Check the master cylinder fluid level. While a slight drop in
the reservoir level will result from normal lining wear, an
abnormally low level in reservoir indicates a leak in the
system. The hydraulic system may be leaking internally
as well as externally. Refer to Master Cylinder Inspection.
Also, the system may appear to pass this test but still
have slight leakage. If fluid level is normal, check the
vacuum booster push rod length. If an incorrect length
push rod is found, adjust or replace the push rod. Check
the brake pedal travel and the parking brake adjustment.
When checking the fluid level, the master cylinder fluid
level may be lower than the “MAX” mark if the front and
rear linings are worn. This is normal.
Warning Light Operation
When the ignition switch is in the START position, the
“BRAKE” warning light should turn on and go off when the
ignition switch returns to the ON position.
The following conditions will activate the “BRAKE” light:
1. Parking brake applied. The light should be on
whenever the parking brake is applied and the ignition
switch is on.
2. Low fluid level. A low fluid level in the master cylinder
will turn the “BRAKE” light on.
3. During engine cranking the “BRAKE” light should
remain on. This notifies the driver that the warning
circuit is operating properly.
POWER–ASSISTED BRAKE SYSTEM
5C–67
General Diagnosis
Condition
Possible cause
Brake Pull
Brake Roughness
(Pulsates)
or
Chatter
Excessive Pedal Effort
Excessive Brake Pedal Travel
Correction
Tire inflation pressure is unequal.
Adjust
Front wheel alignment is incorrect.
Adjust
Unmatched tires on same axle.
Tires with approx. the same amount
of tread should be used on the same
axle.
Restricted brake pipes or hoses.
Check for soft hoses and damaged
lines. Replace with new hoses and
new double walled steel brake
piping.
Water or oil on the brake pads.
Clean or replace.
Brake pads hardened.
Replace
Brake pads worn excessively.
Replace
Brake rotor worn or scored.
Grind or replace.
Disc brake caliper malfunctioning.
Clean or replace.
Front hub bearing preload incorrect.
Adjust or replace.
Loose suspension parts.
Check all suspension mountings.
Loose calipers.
Check and tighten the bolts to
specifications.
Excessive lateral runout.
Check per instructions. If not within
specifications, replace or machine
the rotor.
Parallelism not within specifications.
Check per instructions. If not within
specifications, replace or machine
the rotor.
Pad reversed (steel against iron).
Replace the brake pad and machine
rotor to within specifications.
Malfunctioning vacuum booster.
Check the vacuum booster operation
and repair, if necessary.
Partial system failure.
Check the front and rear brake
system for failure and repair. Also,
check the brake warning light. If a
failed system is found, the light
should indicate failure.
Excessively worn pad.
Check and replace pads in sets.
Piston in caliper stuck or sluggish.
Remove caliper and rebuild.
Fading brakes due to incorrect pad.
Remove and replace with original
equipment pad or equivalent.
Vacuum leak to vacuum booster.
Check for ruptured or loose hose.
Check the direction of check valve
within vacuum hose.
Correct vacuum hose direction.
Grease on the brake pads.
Replace or clean.
Air in hydraulic circuit.
Bleed the hydraulic circuit.
Level of brake fluid in the reservoir
too low.
Replenish brake fluid reservoir to
specified level and bleed hydraulic
circuit as necessary.
Master cylinder push rod clearance
excessive.
Adjust
Leakage in hydraulic system.
Correct or replace defective parts.
5C–68 POWER–ASSISTED BRAKE SYSTEM
Condition
Brake Drag
Grabbing or Uneven Braking Action
(All conditions listed under “Pulls”)
Brake Noisy
Possible cause
Correction
Master cylinder pistons not returning
correctly.
Adjust the stop light switch and
vacuum booster push rod. If
necessary, rebuild.
Restricted brake pipes or hoses.
Check for soft hoses or damaged
pipes, and replace with new hoses
and new double–walled steel brake
piping.
Parking brake maladjusted.
Adjust
Parking brake
insufficient.
Adjust
lining
clearance
Brake pedal free play insufficient.
Adjust the brake pedal height or
power cylinder operating rod.
Piston in the master cylinder sticking.
Replace
Piston in the disc brake caliper
sticking.
Replace piston seals.
Brake pads sticking in caliper.
Clean
Return spring weakened.
Replace
Parking brake binding.
Overhaul the parking brakes and
correct.
Front hub bearing preload incorrect.
Adjust or replace.
Parking brake shoes not returning.
Correct or replace the brake back
plate and brake shoe as necessary.
Obstructions in hydraulic circuit.
Clean
Rotor warped excessively.
Grind or replace.
Rear brake drum distorted.
Grind or replace.
Parking cable sticking.
Grind or replace.
Malfunctioning vacuum booster.
Check operation and correct as
necessary.
Binding brake pedal mechanism.
Check and lubricate, if necessary.
Corroded caliper assembly.
Clean and lubricate.
Brake pads are worn.
Replace
Brake pads are hardened.
Replace
Brake pads are in poor contact with
rotor.
Correct
Brake disc(s) warped, worn or
damaged.
Grind or replace.
Disc brake
fatigued.
Replace
anti–squeak
shims
Front hub bearings are loose or
preload is incorrect.
Adjust or replace.
Brake disc is rusted.
Grind or replace.
POWER–ASSISTED BRAKE SYSTEM
Condition
Poor Brake Action
Possible cause
Correction
Master cylinder faulty.
Correct or replace.
Vacuum booster faulty.
Correct or replace.
Level of brake fluid in reservoir too
low.
Replenish and bleed.
Air in hydraulic circuit.
Bleed
Disc brake caliper faulty.
Clean or replace.
Water or oil on brake pads.
Clean or replace.
Brake pads in poor contact with the
rotor.
Correct
Brake pads worn.
Replace
Brake disc rusted.
Grind or replace.
Check valve in vacuum hose faulty.
Correct or replace.
5C–69
5C–70 POWER–ASSISTED BRAKE SYSTEM
Hydraulic Brakes
Filling Master Cylinder Reservoir
Bleeding Brake Hydraulic System
CAUTION: Use only specified brake fluid. Do not
use any fluid which contains a petroleum base. Do
not use a container which has been used for
petroleum based fluids or a container which is wet
with water. Petroleum based fluid will cause swelling
and distortion of rubber parts in the hydraulic brake
system. Water mixed with brake fluid lowers the fluid
boiling point. Keep all fluid containers capped to
prevent contamination.
Always fill the master cylinder reservoir when the engine is cold.
Never allow the brake fluid to come in contact with
the painted surfaces.
The master cylinder reservoir must be kept properly
filled to ensure adequate reserve and to prevent air
and moisture from entering the hydraulic system.
However, because of expansion due to heat absorbed from the brakes and the engine, the reservoir
must not be overfilled. The brake fluid reservoir is on
the master cylinder, which is located under the hood
on the left side of the cowl. Thoroughly clean reservoir cap before removal to avoid getting dirt into reservoir. Remove the diaphragm. Add fluid as required
to bring level to the “MAX” mark on the reservoir
tank. Use “DOT 3” Hydraulic Brake Fluid. If the fluid
cap diaphragm is stretched, return it to the original
position before installing.
A bleeding operation is necessary to remove air from the
hydraulic brake system whenever air is introduced into
the hydraulic system. It may be necessary to bleed the
hydraulic system at all four brakes if air has been
introduced through a low fluid level or by disconnecting
brake pipes at the master cylinder. If a brake pipe is
disconnected at one wheel, only that wheel
cylinder/caliper needs to be bled. If the pipes are
disconnected at any fitting located between the master
cylinder and brakes, then the brake system served by the
disconnected pipe must be bled.
1. For 4–Wheel Antilock Brake System (ABS) equipped
vehicle, be sure to remove the ABS main fuse 60A
located at the relay and fuse box before bleeding air. If
you attempt to bleed air without removing the main
fuse, air cannot be let out thoroughly, and this may
cause damage to the hydraulic unit. After bleeding air,
be sure to replace the ABS main fuse back to its
original position.
2. Set the parking brake completely, then start the
engine.
Deterioration of Brake Fluid
Using any other brake fluid than specified or brake fluid
with mineral oil or water mixed in will drop the boiling point
of brake fluid. It may, in turn, result in vapor lock or
deteriorated rubber parts of the hydraulic system. Be sure
to change the brake fluid at specified intervals.
If the rubber parts are deteriorated, remove all the system
parts and clean them with alcohol. Prior to reassembly,
dry the cleaned parts with air to remove the alcohol.
Replace all the hoses and rubber parts of the system.
Leakage of Brake Fluid
With engine idling, set shift lever in the neutral position
and continue to depress brake pedal at a constant pedal
application force.
Should the pedal stroke become deeper gradually,
leakage from the hydraulic pressure system is possible.
Perform visual inspection for any signs of leakage.
NOTE: The vacuum booster will be damaged if the
bleeding operation is performed with the engine off.
3. Remove the master cylinder reservoir cap.
4. Fill the master cylinder reservoir with brake fluid.
Keep the reservoir at least half full during the air
bleeding operation
5. Always use new brake fluid for replenishment.
6. When replenishing the brake fluid reservoir, carefully
pour in the brake fluid to prevent air bubbles from
entering the brake system.
When the master cylinder is replaced or overhauled,
first bleed the air from the master cylinder, then from
each wheel cylinder and caliper following the
procedures described below.
Bleeding the Master Cylinder
7. Disconnect the rear wheel brake pipe (1) from the
master cylinder.
Check the fluid level and replenish as necessary. If
replenished, leave the system for at least one minute.
8. Depress the brake pedal slowly once and hold it
depressed.
9. Completely seal the delivery port of the master
cylinder with your finger, where the pipe was
disconnected then release the brake pedal slowly.
10. Release your finger from the delivery port when the
brake pedal returns completely.
11. Repeat steps 8 through 10 until the brake fluid comes
out of the delivery port during step 8.
POWER–ASSISTED BRAKE SYSTEM
NOTE: Do not allow the fluid level in the reservoir to go
below the half–way mark.
12. Reconnect the brake pipe (1) to the master cylinder
and tighten the pipe.
13. Depress the brake pedal slowly once and hold it
depressed.
14. Loosen the rear wheel brake pipe (1) at the master
cylinder.
15. Retighten the brake pipe, then release the brake
pedal slowly.
16. Repeat steps 13 through 15 until no air comes out of
the port when the brake pipe is loosened
NOTE: Be very careful not to allow the brake fluid to come
in contact with painted surfaces.
5C–71
24. Release the brake pedal slowly.
25. Repeat steps 21 through 24 until the air is completely
removed.
It may be necessary to repeat the bleeding procedure
10 or more times for front wheels and 15 or more
times for rear wheels.
26. Go to the next wheel in the sequence after each wheel
is bled.
Be sure to monitor reservoir fluid level.
27. Depress the brake pedal to check if you feel
“sponginess” after the air has been removed from all
wheel cylinders and calipers.
If the pedal feels “spongy”, the entire bleeding
procedure must be repeated.
28. After the bleeding operation is completed on the each
individual wheel, check the level of the brake fluid in
the reservoir and replenish up to the “MAX” level as
necessary.
29. Attach the reservoir cap.
If the diaphragm inside the cap is deformed, reform
it and install.
30. Stop the engine.
Flushing Brake Hydraulic System
330R200004
17. Bleed the air from the front wheel brake pipe
connection (2) by repeating steps 7 through 16.
Bleeding the Caliper
18. Bleed the air from each wheel in the order listed
below:
B Right rear caliper or wheel cylinder
B Left rear caliper or wheel cylinder
B Right front caliper
B Left front caliper
Conduct air bleeding from the wheels in the above
order. If no brake fluid comes out, it suggests that air
is mixed in the master cylinder. In this case, bleed air
from the master cylinder in accordance with steps 7
through 17, and then bleed air from the caliper or
wheel cylinder.
19. Place the proper size box end wrench over the
bleeder screw.
20. Cover the bleeder screw with a transparent tube, and
submerge the free end of the transparent tube in a
transparent container containing brake fluid.
21. Pump the brake pedal slowly three (3) times
(once/sec), then hold it depressed.
22. Loosen the bleeder screw until fluid flows through the
tube.
23. Retighten the bleeder screw.
It is recommended that the entire hydraulic system be
thoroughly flushed with clean brake fluid whenever new
parts are installed in the hydraulic system. Approximately
one quart of fluid is required to flush the hydraulic system.
The system must be flushed if there is any doubt as to the
grade of fluid in the system or if fluid has been used which
contains the slightest trace of mineral oil. All rubber parts
that have been subjected to a contaminated fluid must be
replaced.
Brake Pipes and Hoses
The hydraulic brake system components are
interconnected by special steel piping and flexible hoses.
Flexible hoses are used between the frame and the front
calipers, the frame and rear axle case and the rear axle
and the rear calipers.
When the hydraulic pipes have been disconnected for
any reason, the brake system must be bled after
reconnecting the pipe. Refer to Bleeding the Brake
Hydraulic System in this section.
Brake Hose Inspection
The brake hose should be inspected at least twice a year.
The brake hose assembly should be checked for road
hazard, cracks and chafing of the outer cover, and for
leaks and blisters. Inspect for proper routing and
mounting of the hose. A brake hose that rubs on
suspension components will wear and eventually fail. A
light and mirror may be needed for an adequate
inspection. If any of the above conditions are observed on
the brake hose, adjust or replace the hose as necessary.
CAUTION: Never allow brake components such as
calipers to hang from the brake hoses, as damage to
the hoses may occur.
5C–72 POWER–ASSISTED BRAKE SYSTEM
Front Caliper Brake Hose
Front Caliper Brake
Associated Parts
Hose
and
Installation
To install, follow the removal steps in the reverse order,
noting the following points.
1. Tighten the brake pipes to the specified torque
Torque: 16 N·m (12 lb ft)
2. Tighten the bolt to the specified torque.
Torque: 35 N·m (26 lb ft)
NOTE: Always use new gaskets and be sure to put the
hooked edge of the flexible hose end into the anti–rotation
cavity.
After installing the brake hoses, bleed the brakes as
described in this section.
352RW001
Legend
(1) Bolt and Gasket
(2) Clip
(3) Hose
(4) Brake Pipe
Removal
1. Raise the vehicle and support it with suitable safety
stands.
2. Remove the wheel and tire assembly.
3. Clean dirt, grease, and other foreign material off the
hose fittings at both ends.
4. Disconnect brake pipe.
5. Remove clip.
6. Remove bolt and gasket.
7. Remove hose.
POWER–ASSISTED BRAKE SYSTEM
5C–73
Rear Axle Brake Hose
Rear Axle Brake Hose and Associated
Parts
Installation
To install, follow the removal steps in the reverse order,
noting the following points.
1. Tighten the brake pipes to the specified torque
Torque: 16 N·m (12 lb ft)
2. Tighten the bolt to the specified torque.
Torque: 15 N·m (11 lb ft)
After installing the brake hoses, bleed the brakes as
described in this section.
352RW002
Legend
(1) Brake Pipe
(2) Clip
(3) Bolt
(4) Brake Pipe
(5) Hose
Removal
1. Raise the vehicle and support it with suitable safety
stands.
2. Remove wheel and tire assembly.
3. Clean dirt, grease, and other foreign material off the
hose fittings at both ends.
4. Disconnect brake pipe.
5. Remove clip.
6. Remove brake pipe.
7. Remove bolt.
8. Remove hose.
5C–74 POWER–ASSISTED BRAKE SYSTEM
Brake Pipe
Removal
Installation
1. Raise the vehicle and support it with suitable safety
stands.
2. Remove wheel and tire assembly as necessary.
3. Clean dirt, grease, and other foreign material off the
pipe fittings at both ends.
4. Remove brake pipe (1).
To install, follow the removal steps in the reverse order,
noting the following points.
1. Tighten the brake pipes to the specified torque.
Master cylinder and P&B valve sides
Torque: 12 N·m (104 lb in)
Others
Torque: 16 N·m (12 lb ft)
After installing the brake pipes, bleed the brakes as
described in this section.
330R200003
5. Remove plastic clip (2).
330RW002
POWER–ASSISTED BRAKE SYSTEM
5C–75
P & B (Proportioning and Bypass) Valve
P & B (Proportioning and Bypass)
Valve Sectional View
Removal
1. The P&B valve is not repairable and must be replaced
as a complete assembly. Care must be taken to
prevent brake fluid from contacting any painted
surface.
2. Remove hydraulic pipes (1) and plug the pipes (1) to
prevent the loss of fluid or the entrance of dirt.
3. Remove bolt (3).
4. Remove P&B valve (2).
350RW014
Legend
(1) Master Cylinder (Secondary)
(2) Master Cylinder (Primary)
(3) Rear Brake
(4) Front Brake
The P&B valve contains two sections, each serving a
different function.
The proportioning section of the P&B valve proportions
outlet pressure to the rear brakes after a predetermined
rear input pressure has been reached. This is done to
prevent rear wheel lock up on the vehicles with light rear
wheel loads. The valve has a by–pass feature which
assures full system pressure to the rear brakes in the
event of front brake system malfunction. Also full front
pressure is retained in the event of rear brake
malfunction.
The P&B valve is not repairable and must be replaced as
complete assembly.
350R200003
Installation
1. Install P&B valve (2).
2. Install bolt (3) and tighten the bolt to the specified
torque.
Torque: 22 N·m (16 lb ft)
3. Install hydraulic pipes (1) and tighten the bolt to the
specified torque.
Torque: 12 N·m (104 lb in)
4. After installing the brake pipes, bleed the brakes as
described in Bleeding Brake Hydraulic System in this
section.
5C–76 POWER–ASSISTED BRAKE SYSTEM
Main Data and Specifications
Torque Specifications
E05R200007
POWER–ASSISTED BRAKE SYSTEM
5C–77
Brake Pedal
Checking Pedal Height
The push rod serves as the brake pedal stopper when the
pedal is fully released. Brake pedal height adjustment
should be performed as follows:
Adjust Brake Pedal
310RY00005
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.
310R200002
1. Measure the brake pedal height after making sure the
pedal is fully returned by the pedal return spring.
Pedal height must be measured after starting the
engine and stepping on it several times.
Checking Pedal Travel
Pedal Free Play: 6-10 mm (0.23-0.39 in)
Pedal Height: 173-185 mm (6.81-7.28 in)
NOTE: Pedal free play must be measured after turning
off the engine and stepping on the brake pedal firmly five
times or more.
2. If the measured value is not within the above range,
adjust the brake pedal as follows:
a. Disconnect the stoplight switch connector.
b. Loosen the stoplight switch lock nut.
c. Rotate the stoplight switch so that it moves away
from the brake pedal.
d. Loosen the lock nut (1) on the push rod.
e. Adjust the brake pedal to the specified height by
rotating the push rod in the appropriate direction.
f. Tighten the lock nut to the specified torque.
Torque: 20 N·m (15 lb ft)
g. Adjust the stoplight switch (2) to the specified
clearance (between the switch housing and the
brake pedal) by rotating the switch housing.
Clearance: 0.5–1.0 mm (0.02–0.04 in)
310R200002
1. Pedal height must be measured after starting the
engine and revving it several times to apply vacuum
to the vacuum booster fully.
NOTE: Pedal height must be 95 mm (3.7 in) or more
when about 50 kg (110.25 lb) of stepping force is applied.
2. If the measured value is lower than the above range,
air may still be present in the hydraulic system
Perform the bleeding procedure.
5C–78 POWER–ASSISTED BRAKE SYSTEM
Brake Pedal and Associated Parts
310RY00006
Legend
(1) Brake Pedal Bracket Assembly
(2) Fulcrum Pin and Nut
(3) Connector
(4) Snap Pin
(5) Return Spring
Removal
1. Disconnect the battery “–” terminal cable, and wait at
least 5 minutes.
2. Disconnect the yellow 3 way SRS connector located
under the steering column.
3. Remove the engine hood opening lever.
4. Remove lower cover (8).
5. Remove driver knee bolster (10).
6. Disconnect the stop light switch connector (3).
Disconnect the anti-theft control module connector.
Refer to Body and Accessories section.
7. Remove snap pin (4) and push rod pin (7).
8. Remove the steering column shaft fixing bolt and nut
(9) on the steering wheel side, and lower the steering
column shaft.
9. Remove the brake pedal bracket assembly (1).
10. Remove return spring (5).
11. Remove fulcrum pin and nut (2).
(6)
(7)
(8)
(9)
(10)
Peadl Assembly
Push Rod Pin
Lower Cover
Bolts and Nut
Driver Knee Bolster
12. Remove pedal assembly (6).
Installation
1. Apply grease to the entire circumference of the
fulcrum pin.
2. Install pedal assembly (6) and fulcrum pin and nut (2).
Tighten the nut (2) to the specified torque.
Torque: 35 N·m (26 lb ft)
3. Install the brake pedal bracket assembly (1).
Tighten the bolts and nuts soecified torque.
Torque: 15 N·m (11 lb ft)
4. Install return spring (5).
5. Adjust pedal free travel.
Refer to Brake Pedal Adjustment in this section.
6. Tighten the steering column fixing bolt (9) (dash
panel) to the specified torque.
Torque: 20 N·m (14 lb ft)
POWER–ASSISTED BRAKE SYSTEM
7. Tighten the steering column fixing nut (9) (Cross
Beam) to the specified torque.
Torque: 17 N·m (12 lb ft)
8. Apply grease to the entire circumference of the Push
rod pin (7).
9. Install push rod pin (7).
10. Install snap pin (4).
11. Connect the anti-theft control module connector.
Refer to Body and Accessories section.
5C–79
12. Connect the stop light switch connector (3).
13. Install driver knee bolster (10) and lower cover (8).
14. Install the engine hood opening lever.
15. Connect the yellow 3 way SRS connector located
under the steering column.
16. Connect the battery “–” terminal cable.
Stoplight Switch
Parts Location
Installation
1. Adjust the stop light switch to the specified clearance
(between switch housing and brake pedal) by rotating
the switch housing.
Clearance : 0-0.2 mm (0-0.08 in)
NOTE: Do not attempt to force the push rod into position
during the stop light switch installation and adjustment
procedure.
310RW008
Legend
(1) Connector
(2) Switch
(3) Lock Nut
Removal
1. Disconnect connector (1)
2. Remove lock nut (3).
3. Remove switch (2).
310RY00005
2. Connect connector (1).
3. Install lock nut (3).
5C–80 POWER–ASSISTED BRAKE SYSTEM
Main Data and Specifications
General Specifications
Pedal free play
6–10 mm (0.23 –0.39 in)
Pedal Height
173–185 mm (6.81–7.28 in)
Torque Specifications
310RY00007
POWER–ASSISTED BRAKE SYSTEM
5C–81
Master Cylinder Assembly
Master Cylinder Assembly and Associated Parts
330R200006
Legend
(1) Electrical Connector
(2) Master Cylinder
(3) 2 attaching Nuts
(4) P&B Valve and Bracket
(5) Brake Pipes
Removal
Inspection
CAUTION: When removing the master cylinder from
the vacuum booster, be sure to get rid of the internal
negative pressure of the vacuum booster (by,
disconnecting the vacuum hose) in advance.
If any negative pressure remains in the vacuum
booster, the piston may possibly come out when the
master cylinder is being removed, letting the brake
fluid run out.
While removing the master cylinder, do not hold the
piston as it can be easily pulled out.
Outside surface of the piston is the surface on which
seals are to slide. Care should be taken to keep the
surface free of cuts and dents.
Excessive brake pedal travel, malfunction or dragging
brake suggests that the master cylinder is defective. In
such cases perform the following visual check:
1. Disconnect electrical connector.
2. Remove brake pipes and after disconnecting the
brake pipe, cap or tape the openings of the brake pipe
to prevent the entry of foreign matter.
3. Remove 2 attaching nuts.
4. Remove P&B valve and bracket.
5. Remove master cylinder.
Visual Check
Make parts replacement as required if wear, distortion,
nicks, cuts, corrosion, or other abnormal conditions are
found through the following parts inspection:
B Master cylinder body
B Fluid reservoir
B O–ring
5C–82 POWER–ASSISTED BRAKE SYSTEM
Master Cylinder Assembly
Master Cylinder Assembly Desassembled View
330R200005
Legend
(1) Spring Pin
(2) Reserve Tank and Reserve Tank Cap
(3) O–ring
Desassembly
1. Remove the spring pin.
2. Remove the reserve tank and the reserve tank cap.
The brake fulid level switch is built–in to the reserve tank
and cannot be removed.
3. Remove the O–ring.
4. Remove the snap ring.
5. Remove the primary piston assembly.
6. Invert the cylinder body and push on the secondary
piston until the pin falls free.
(4) Primary Piston Assembly
(5) Secondary Piston Assembly
(6) Cylinder Body
7. Remove the secondary piston assembly.
8. Remove the cylinder body.
Inspection
Excessive brake pedal travel, malfunction or dragging
brake suggests that the master cylinder is defective. In
such cases perform the following visual check:
POWER–ASSISTED BRAKE SYSTEM
Visual Check
Make parts replacement as required if wear, distortion,
nicks, cuts, corrosion, or other abnormal conditions are
found through the following parts inspection:
B Master cylinder body
B Fluid reservoir
B O–ring
B Wash each part in brake fluid before beginning the
inspection procedure.
B Check the inside surfaces of the master cylinder for
abrasion, corrosion, and other damage. Replace the
cylinder if necessary.
B Check the return port for clogging. Clean the port with
a wire and compressed air if nesessay.
B Check the piston and piston cup for abrasion,
damage, and wear. Replace the piston assembly if
any of these conditions exist.
B Check the return spring. Replace the spring if it is
weak.
B Check the snap ring. Replace the snap ring if it is
stretched or weak.
Reassembly
1. Wash each master cylinder internal part in brake fluid
before beginning installation.
2. Install the cylinder body.
3. Press the secondary piston assembly into the
cylinder body and hold it. Thread the pin through the
long hole of the piston to secure the piston assembly.
4. Install the primary piston assembly.
5. Install the snap ring.
6. Install the O–ring
7. Install the reserve tank and the reserve tank cap.
8. Install the spring pin.
5C–83
Installation
1. Install master cylinder.
When replacing the master cylinder or vacuum
booster or both, always measure the vacuum booster
push rod protrusion and adjust it as necessary (Refer
to Vacuum Booster in section).
2. Install P&B valve and bracket.
3. Install 2 attaching nuts and tighten the attaching nuts
to the specified torque.
Torque: 13 N·m (113 lb in)
4. Install brake pipes and tighten the brake pipe to the
specified torque.
Master cylinder and P&B valve sides
Torque: 12 N·m (104 lb in)
Others
Torque: 16 N·m (12 lb in)
5. Connect electrical connector.
5C–84 POWER–ASSISTED BRAKE SYSTEM
Main Data and Specifications
General Specifications
Type
Dual–circuit
Piston bore diameter
25.4 mm (1.000 in)
Torque Specifications
E05R200005
POWER–ASSISTED BRAKE SYSTEM
5C–85
Vacuum Booster Assembly
Vacuum Booster Assembly and Associated Parts
331R200004
Legend
(1) Snap Pin
(2) Vacuum Booster Fixing Nut
(3) Vacuum Hose
Removal
1. Before removing the vacuum booster assembly,
disconnect and remove the brake pipes.
2. Remove master cylinder, refer to Master Cylinder
Removal in this section.
CAUTION: When removing the master cylinder from
the vacuum booster, be sure to get rid of the internal
negative pressure of the vacuum booster (by,
disconnecting the vacuum hose) in advance.
If any negative pressure remains in the vacuum
booster, the piston may possibly come out when the
master cylinder is being removed, letting the brake
fluid run out.
Do not hold the piston while removing the master cyliner, the piston can be easily pulled out.
Outside surface of the piston is the surface on which
seals are to slide. Care should be taken to keep the
surface free of cuts and dents.
3. Remove vacuum hose.
4. Disconnect the yoke clevis from the brake pedal.
(4) Master Cylinder
(5) Vacuum Booster
(6) Pin
5. Remove vacuum booster fixing nut.
6. Remove vacuum booster.
5C–86 POWER–ASSISTED BRAKE SYSTEM
Inspection and Repair
Vacuum Hose (The built in check valve)
1. Inspect the check valve (2), which is installed inside
the vacuum hose.
2. Air should pass freely from the vacuum booster (3) to
the engine (1).
3. Air should not pass from the engine (1) to the vacuum
booster (3). If it does, the check valve is inoperative
and the vacuum hose built in the check valve must be
replaced.
HEC ENGINE
360RW001
6VD1 ENGINE
360RY00004
POWER–ASSISTED BRAKE SYSTEM
5C–87
Exterior Components
Exterior Components and Associated Parts
331R200006
Legend
(1) 2 Gaskets and Spacer
(2) Vacuum Booster
(3) Plate and Seal Assembly
(4) Retainer
(5) Master Cylinder
Removal
1. Remove master cylinder. Refer to Master Cylinder in
this section.
2. Remove vacuum booster. Refer to Vacuum Booster
in this section.
3. Remove 2 gaskets and spacer.
4. Remove retainer, plate and seal assembly.
331RS003
5C–88 POWER–ASSISTED BRAKE SYSTEM
Inspection and Repair
Installation
Visual Check
Make necessary parts replacement if cuts, nicks,
excessive wear, or other abnormal conditions are found
through inspection.
NOTE: The parts listed below must be replaced with new
ones whenever the master cylinder is removed.
1. Plate and seal assembly
2. Retainer
1. Install plate and seal assembly.
2. Install retainer.
3. Install vacuum booster, refer to Vacuum Booster in
this section.
4. Install master cylinder, refer to Master Cylinder in this
section and after installation, perform brake pedal
check and adjustment. Refer to Brake Pedal in this
section.
Vacuum Booster Overhaul
Vacuum Booster
The vacuum booster cannot be disassembled for repair.
Replace a defective vacuum booster with a new one.
POWER–ASSISTED BRAKE SYSTEM
5C–89
Main Data and Specifications
General Specifications
Vacuum booster diaphragm diameter (Front)
205 mm (8.07 in)
Vacuum booster diaphragm diameter (Rear)
230 mm (9.06 in)
Push rod stroke
More than 32.0 mm (1.26 in)
Plunger diameter
10.25 mm (0.40 in)
Push rod diameter
27.4 mm (1.08 in)
Torque Specifications
E05R200004
5C–90 POWER–ASSISTED BRAKE SYSTEM
Front Disc Brake Pads
Front Disc Brake Pads Inspection
Check the outer pad by looking at each caliper from
above. Check the thickness on the inner pad by looking
down through the inspection hole in the top of the caliper.
Whenever the pad is worn to about the thickness of the
pad base, the pad should be removed for further
measurements. The pad should be replaced anytime the
pad thickness (1) is worn to within 1.00 mm (0.039 in) of
the pad itself.
Wear indicators are installed on disc brake pads, disc
brake pads need replacement when the wear indicator is
heard.
Minimum limit (1): 1.0 mm (0.039 in)
302RS002
Front Disc Brake Pads and Associated Parts
302R200026
Legend
(1) Pin Bolt
(2) Caliper Assembly
(3) Pad Assembly
(4) Clip
(5) Outer Side
POWER–ASSISTED BRAKE SYSTEM
Removal
5C–91
Installation
NOTE: If a squealing noise occurs from the front brake
while driving, check the pad wear indicator plate. If the
indicator plate contacts the rotor, the disc pad assembly
should be replaced.
1. Install clip.
B Draw out two–thirds of the brake fluid from the
reservoir.
B Raise the vehicle and support it with suitable safety
stands.
1. Remove wheel and tire assembly, refer to Wheels
and Tires System in Section 3E.
2. Remove pin bolt (1).
302R200023
2. Apply special grease (approximately 0.2 g) to both
contacting surfaces of the inner shims (2). Wipe off
extruded grease after installing. Install pad assembly
with shim.
302R200028
3. Rotate caliper assembly and support the caliper
assembly so that the brake hose is not stretched or
damaged.
4. Remove pad assembly with shim.
5. Remove Clip.
302R200024
Legend
(2) Inner Shim
(3) Wear Indicator
(4) Inner Side
5C–92 POWER–ASSISTED BRAKE SYSTEM
3. Carefyully use adjustable pliers to bottom the piston
into the caliper bore. Do not pull or twist the flexible
hose or damage will occur.
Install caliper assembly.
Set caliper assembly in place.
4. Install lock bolt (5) and tighten the bolt to the specified
torque.
Torque: 45 N·m (33 lb ft)
302R200008
5. Install wheel and tire assembly, refer to Wheels and
Tires System in Section 3E.
6. Pump the brake pedal several times to make sure that
the pedal is firm. Check the brake fluid level in the
reservoir after pumping the brakes.
POWER–ASSISTED BRAKE SYSTEM
5C–93
Front Disc Brake Rotor
Inspection
Parallelism
In the manufacturing of the brake rotor, all the tolerances
regarding surface finish, parallelism and lateral runout are
held very closely. Maintaining these tolerances provides
the surface necessary to assure smooth brake operation.
Parallelism is the measurement of thickness of the rotor
at four or more points around the circumference of the
rotor. All measurement must be made at 29 mm (1.14 in)
from the edge of the rotor.
The rotor thickness must not vary more than 0.010 mm
(0.0004 in) from point to point.
Maximum runout: 0.010 mm (0.0004 in)
Lateral Runout
Lateral runout is the movement of the rotor from side to
side as it rotates on the spindle. This could also be
referred to as “rotor wobble”.
This movement causes the piston to be knocked back into
its bore. This results in additional pedal travel and a
vibration during braking.
Checking Lateral Runout
1. Adjust the wheel bearing correctly, refer to Differential
in Section 4A.
2. Attach the dial indicator accordingly so that the stem
contacts the rotor surface to approximately 29mm
(1.14 in) from the rotor edge.
3. Rotate the rotor one complete turn and inspect for
signs of lateral runout. Lateral runout should not
exceed 0.13 mm (0.005 in).
Maximum runout: 0.13 mm (0.005 in)
411R200007
Replacing Brake Rotors
When installing new brake rotors, do not refinish the
surfaces. These parts are at the correct level of surface
finish.
Refinishing Brake Rotors
411R200008
Accurate control of the rotor tolerances is necessary for
proper performance of the disc brakes. Machining of the
rotor should be done only with precision equipment. All
brake rotors have a minimum thickness dimension cast
into them. This dimension is the minimum wear
dimension and not a refinish dimension. The minimum
wear dimension is 24.60 mm (0.969 in). The minimum
refinish dimension is 26.00 mm (1.024 in).
When refinishing rotors, always use sharp cutting tools or
bits. Dull or worn tools leave a poor surface finish which
will affect initial braking performance. Vibration
dampening attachments should always be used when
refinishing braking surfaces. These attachments
eliminate tool chatter and will result in better surface
finish.
After refinishing, replace any rotor that does not meet the
minimum thickness of 26.00 mm (1.024 in). Do not use a
brake rotor that exceeds the manufacturers
specifications.
5C–94 POWER–ASSISTED BRAKE SYSTEM
Minimum wear dimension: 24.60 mm (1.024 in)
Refinish dimension: 26.00 mm (1.024 in)
411R200009
POWER–ASSISTED BRAKE SYSTEM
5C–95
Front Disc Brake Caliper Assembly
Front Disc Brake Caliper Assembly and Associated Parts
302R200027
Legend
(1) Brake Flexible Hose
(2) Pin Bolt
(3) Caliper Assembly
(4)
(5)
(6)
(7)
Pad Assembly
Clip
Support Bracket with Pad Assembly
Outer Side
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.
302R200007
5C–96 POWER–ASSISTED BRAKE SYSTEM
4. Since the brake fluid flows out from the connecting
coupler, place a drain pan under the vehicle.
5. Remove pin bolt (2).
2. Apply special grease (approximately 0.2 g) to both
contacting surfaces of the inner shims (4). Wipe off
extruded grease after installing. Install pad assembly
with shim.
302R200020
6. Remove caliper assembly.
7. Remove support bracket with pad assembly and take
care not to damage the flexible brake hose when
removing the support bracket.
8. Remove pad assembly with shim and mark the lining
locations if they are to be reinstalled.
9. Remove clip.
302R200025
Legend
(4) Inner Shim
(5) Wear Indicator
(6) Inner Side
3. Install support bracket and tighten the bolt (7) to the
specified torque.
Torque: 155 N·m (115 lb ft)
Installation
1. Install clip.
302R200009
302R200023
POWER–ASSISTED BRAKE SYSTEM
4. Install caliper assembly.
5. Install pin bolt (8) and tighten the bolt to the specified
torque.
Torque: 45 N·m (33 lb ft)
302R200010
6. Install brake flexible hose, always use new gaskets
and be sure to put the hooked edge of the flexible
hose end into the anti–rotation cavity then tighten the
I–bolt (9) to the specified torque.
Torque: 35 N·m (26 lb ft)
302R200021
7. Install wheel and tire assembly, referring to Wheels
and Tires System in Section 3E.
8. Bleed brakes. Refer to Hydraulic Brakes in this
section.
5C–97
5C–98 POWER–ASSISTED BRAKE SYSTEM
Front Disc Brake Caliper
Front Disc Brake Caliper Disassembled View
302R200018
Legend
(1) Bleeder with Cap
(2) Caliper Body
(3) Piston
(4) Piston Seal
(5) Dust Boot: Piston
Disassembly
1. Insert a block of wood into the caliper and force out
the piston by blowing compressed air into the caliper
at the flexible hose attachment. This procedure must
be done prior to removal of the dust boot.
Remove piston.
WARNING: DO NOT PLACE YOUR FINGERS IN
FRONT OF THE PISTON IN AN ATTEMPT TO CATCH
OR PROTECT IT WHEN APPLYING COMPRESSED
AIR. THIS COULD RESULT IN PERSONAL INJURY.
CAUTION: Use just enough air to ease the piston
out of the bore. If the piston is blown out, it may be
damaged.
302R200012
POWER–ASSISTED BRAKE SYSTEM
5C–99
2. Remove dust boot: piston.
3. Remove piston seal.
4. Remove bleeder with cap.
5. Remove caliper body.
Inspection and Repair
Make necessary parts replacement, if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
Check the following parts:
B Rotor
B Cylinder body
B Cylinder bore
B Piston
B Guide pin, lock pin
B Support bracket
NOTE: The piston seal, boot ring and dust boot are to be
replaced each time the caliper is overhauled. Discard
these used rubber parts and replace them with new ones.
Reassembly
1. Install caliper body.
2. Install bleeder with cap and tighten the cap to the
specified torque.
Torque: 8 N·m (69 lb in)
302R200015
5. Apply special grease (approximately 1 g) to the piston
and attach the dust boot to the piston and caliper.
Insert the dust boot ring into the dust boot.
6. Install guide bolt and lock bolt dust boot.
7. Install the dust boot on the support bracket after
applying special grease (approximately 1 g) onto the
dust boot inner surface. Apply special grease onto the
lock pin and guide pin setting hole of the support
bracket.
3. Apply special rubber grease to the piston seal and
cylinder wall, then insert the piston seal into the
cylinder. The special rubber grease is included in the
repair kit.
302R200022
302R200013
4. When inserting the piston into the cylinder, use finger
pressure only and do not use a mallet or other impact
tool, since damage to the cylinder wall or piston seal
can result.
Install piston.
Legend
(1) Guide Pin
(2) Lock Pin
(3) Pin Boot
8. Install pin bolt and tighten the bolt to the specified
torque.
Torque: 45 N·m (33 lb ft)
5C–100POWER–ASSISTED BRAKE SYSTEM
Main Data and Specifications
General Specifications
Type
Pad dimension
Adjusting method
Piston diameter
Disc type
Floating, pin slide
48.7 [email protected] (7.55 [email protected])
Self–adjusting
45.4 mm (1.79 in) ×2
Ventilated
Disc thickness
26 mm (1.02 in)
Disc effective diameter
242 mm (9.53 in)
Torque Specifications
E05R200008
POWER–ASSISTED BRAKE SYSTEM 5C–101
Rear Disc Brake Pads (4×4 Model)
Brake Pads Inspection
Check the outer pads by looking at each caliper from
above. Check the thickness on the inner pad by looking
down through the inspection hole in the top of the caliper.
Whenever the pad is worn to about the thickness of the
pad base, the pad should be removed for further
measurements. The pad should be replaced anytime the
pad thickness (1) is worn to within 1.0 mm (0.039 in) of the
pad itself.
Wear indicators are installed on disc brake pads, disc
brake pads need replacement when the wear indicator is
heard.
Minimum limit (1): 1.0 mm (0.039 in)
302RW016
Brake Pads and Associated Parts
306RW001
Legend
(1) Caliper Assembly
(2) Clip
(3) Lock Bolt
(4) Pad Assembly
5C–102POWER–ASSISTED BRAKE SYSTEM
Removal
Installation
NOTE: If a squealing noise occurs from the rear brake
while driving, check the pad wear indicator plate. If the
indicator plate contacts the rotor, the disc pad assembly
should be replaced.
1. Install clip (2).
B Draw out two–thirds of the brake fluid from the
reservoir.
B Raise the vehicle and support it with suitable safety
stands.
1. Remove wheel and tire assembly, referring to Wheels
and Tires System in Section 3E.
2. Remove lock bolt (1)
306RW003
2. Apply special grease (approximately 0.2 g) to both
contacting surfaces of the inner shims. Wipe off
extruded grease after installing. Install pad assembly
with shim.
306RW002
3. Rotate caliper assembly and support the caliper
assembly so that the brake hose is not stretched or
damaged.
4. Remove pad assembly with shim.
5. Remove clip.
306RW004
Legend
(3) Inner Shim
(4) Wear Indicator
POWER–ASSISTED BRAKE SYSTEM 5C–103
306RW005
3. Carefyully use adjustable pliers to bottom the piston
into the caliper bore. Do not pull or twist the flex hose
or damage will occur.
302RS008
4. Install lock bolt (5) and tighten the bolt to the specified
torque.
Torque: 44 N·m (32 lb ft)
306R200003
5. Install wheel and tire assembly, referring to Wheels
and Tires System in Section 3E.
6. Pump the brake pedal several times to make sure that
the pedal is firm. Check the brake fluid level in the
reservoir after pumping the brakes.
5C–104POWER–ASSISTED BRAKE SYSTEM
Rear Disc Brake Rotor (4×4 Model)
Inspection
Parallelism
In the manufacturing of the brake rotor, all the tolerances
regarding surface finish, parallelism and lateral runout are
held very closely. Maintaining these tolerances provides
the surface necessary to assure smooth brake operation.
Parallelism is the measurement of thickness of the rotor
at four or more points around the circumference of the
rotor. All measurement must be made at 22 mm (0.87 in)
from the edge of the rotor.
The rotor thickness must not vary more than 0.010 mm
(0.0004 in) from point to point.
Maximum parallelism: 0.010 mm (0.0004 in)
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, referring to
Differential in Section 4A.
2. Attach the dial indicator accordingly so that the stem
contacts the rotor surface to approximately 29mm
(1.14 in) from the rotor edge.
3. Rotate the rotor one complete turn and inspect for
signs of lateral runout. Lateral runout should not
exceed 0.13 mm (0.005 in).
1. The lateral runout should not exceed 0.13 mm
(0.005 in)
Maximum runout: 0.13 mm (0.005 in)
420RS013
Replacing Brake Rotors
When installing new brake rotors, do not refinish the
surfaces. These parts are at the correct level of surface
finish.
Refinishing Brake Rotors
306RY00013
Accurate control of the rotor tolerances is necessary for
proper performance of the disc brakes. Machining of the
rotor should be done only with precision equipment. All
brake rotors have a minimum thickness dimension cast
into them. This dimension is the minimum wear
dimension and not a refinish dimension. The minimum
wear dimension is 16.6 mm (0.654 in). The minimum
refinish dimension is 16.97 mm (0.668 in).
When refinishing rotors, always use sharp cutting tools or
bits. Dull or worn tools leave a poor surface finish which
will affect initial braking performance. Vibration
dampening attachments should always be used when
refinishing braking surfaces. These attachments
eliminate tool chatter and will result in better surface
finish.
After refinishing, replace any rotor that does not meet the
minimum thickness of 16.97 mm (0.668 in). Do not use a
brake rotor that exceeds the manufacturers
specifications.
POWER–ASSISTED BRAKE SYSTEM 5C–105
Minimum wear dimension: 16.6 mm (0.654 in)
Refinish dimension: 16.97 mm (0.668 in)
420RW002
Rear Drum (In Disc) Inside Diameter
Check
Check the rear drum inside diameter by measuring at
more than two portions as shown in the illustration.
If the inside diameter is greater than the limit, replace the
rear rotor.
Standard: 210.0 mm (8.27 in)
Limit: 211.4 mm (8.32 in)
420RS035
5C–106POWER–ASSISTED BRAKE SYSTEM
Rear Disc Brake Caliper Assembly (4×4 Model)
Rear Disc Brake Caliper Assembly and Associated Parts
306RW007
(4)
(5)
(6)
(7)
Legend
(1) Brake Flexible Hose
(2) Clip
(3) Lock Bolt
Removal
1. Raise the vehicle and support with suitable safety
stands.
2. Remove wheel and tire assembly, referring to Wheels
and Tires System in Section 3E.
3. Remove the bolt and gaskets, then disconnect the
flexible hose from the caliper and after disconnecting
the flexible hose (1), cap or tape the openings to
prevent entry of foreign material.
Support Bracket
Guide Bolt
Pad Assembly with Shim
Caliper Assembly
4. Since the brake fluid flows out from the connecting
coupler, place a drain pan under the vehicle.
5. Remove lock bolt (3).
6. Remove guide bolt (2).
306RW009
306RW008
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.
POWER–ASSISTED BRAKE SYSTEM 5C–107
10. Remove clip.
3. Install support bracket and tighten the bolt (7) to the
specified torque.
Torque: 103 N·m (76 lb ft)
Installation
1. Install clip (4).
306RW012
306RW010
2. Apply special grease (approximately 0.2 g) to both
contacting surfaces of the inner shims (5). Wipe off
extruded grease after installing. Install pad assembly
with shim.
4. Install caliper assembly.
5. Install lock bolt and guide bolt (8) and tighten the bolt
to the specified torque.
Torque: 44 N·m (32 lb ft)
306R200004
306RW011
Legend
(5) Inner Shim
(6) Wear indicator
6. Install brake flexible hose, always use new gaskets
and be sure to put the hooked edge of the flexible
hose end into the anti–rotation cavity then tighten the
eye–bolt (9) to the specified torque.
Torque: 35 N·m (26 lb ft)
5C–108POWER–ASSISTED BRAKE SYSTEM
7. Install the wheel and tire assembly, referring to
Wheels and Tires System in Section 3E.
8. Bleed brakes. Refer to Hydraulic Brakes in this
section.
302RW017
Rear Disc Brake Caliper (4×4 Model)
Rear Disc Brake Caliper Disassembled View
306RW014
Legend
(1) Guide Bolt
(2) Lock Bolt
(3) Bleeder with Cap
(4) Caliper Body
(5)
(6)
(7)
(8)
(9)
Piston Seal
Piston
Dust Boot: Piston
Dust Boot Ring
Dust Boot: Guide Bolt and Lock Bolt
POWER–ASSISTED BRAKE SYSTEM 5C–109
Disassembly
1. Remove guide bolt.
2. Remove lock bolt.
3. Remove dust boot; guide bolt and lock bolt.
4. Remove dust boot ring, using a small screwdriver.
6. Remove dust boot: piston.
7. Remove piston seal.
8. Remove bleeder with cap.
9. Remove caliper body.
Inspection and Repair
Make necessary parts replacement, if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
Check the following parts:
B Rotor
B Cylinder body
B Cylinder bore
B Piston
B Guide bolt, lock bolt
B Support bracket
NOTE: The piston dust seal and dust boot are to be
replaced each time the caliper is overhauled. Discard
these used rubber parts and replace with new ones.
Reassembly
302RS016
5. Insert a block of wood into the caliper and force out
the piston by blowing compressed air into the caliper
at the flexible hose attachment. This procedure must
be done prior to removal of the dust boot.
Remove piston.
WARNING: DO NOT PLACE YOUR FINGERS IN
FRONT OF THE PISTON IN AN ATTEMPT TO CATCH
OR PROTECT IT WHEN APPLYING COMPRESSED
AIR. THIS COULD RESULT IN PERSONAL INJURY.
1. Install caliper body.
2. Install bleeder with cap and tighten the cap to the
specified torque.
Torque: 8 N·m (69 lb ft)
3. Install piston seal and apply special rubber grease to
the piston seal and cylinder wall, then insert the piston
seal into the cylinder. The special rubber grease is
included in the repair kit.
CAUTION: Use just enough air to ease the piston
out of the bore. If the piston is blown out, it may be
damaged.
302RS018
4. When inserting the piston into the cylinder, use finger
pressure only and do not use a mallet or other impact
tool, since damage to the cylinder wall or piston seal
can result.
Install piston.
302RS017
5C–110 POWER–ASSISTED BRAKE SYSTEM
302RS019
5. Apply special grease (approximately 1g) to the piston
and attach the dust boot to the piston and caliper.
Insert the dust boot ring into the dust boot.
302RS020
6. Install guide bolt and lock bolt dust boot.
7. Install the dust boot on the support bracket after
applying special grease (Approx. 1g) onto the dust
boot inner surface. Also apply special grease onto the
lock bolt and guide bolt setting hole of the support
bracket.
302RS021
8. Install lock bolt and guide bolt and tighten the bolt to
the specified torque.
Torque: 44 N·m (32 lb ft)
POWER–ASSISTED BRAKE SYSTEM 5C–111
Main Data and Specifications (4×4 Model)
General Specifications
Type
Floating, pin slide
Pad dimension
33 [email protected] (5.11 [email protected])
Adjusting method
Piston diameter
Disc type
Disc thickness
Disc effective diameter
Self–adjusting
41.3 mm (1.63 in)
Ventilated
18 mm (0.71 in)
269.2 mm (10.60 in)
Torque Specifications
E05RW005
5C–112 POWER–ASSISTED BRAKE SYSTEM
Brake Lining
Brake Lining and Associated Parts
305RW001
Legend
(1) Wheel and Tire Assembly
(2) Drum
(3) Hold-down Spring and Cup
(4) Hold-down Spring and Cups
(5) Lower Return Spring
(6) Upper (other) Return Spring
(7) Trailing Shoe Assembly with Parking Brake
Lever
(8) Leading Shoe Assembly with Upper (inner)
Return Spring
Removal
1. Raise the vehicle and support with suitable safety
stands.
2. Remove wheel and tire assembly (1).
B Refer to Wheel and Tires in Wheel and Tire System
section.
3. Remove Drum (2).
B If difficulty is encountered in removing the drum:
– Mark the position of the drum to the axle.
– Make sure the parking brake is released.
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
Upper (inner) Return Spring
Auto Adjuster Lever
Parking Brake Lever
Adjuster Assembly
Wave Washer
Retainer
Hold-down Pin
Hold-down Pin
– Use a rubber mallet to tap gently on the outer rim of
the drum and/or around the inner drum. Be careful
to avoid damaging the drum.
4. Remove upper (other) return spring (6) and auto
adjuster lever.
5. Remove lower return spring (5).
6. Remove hold-down spring and cups (4) and
hold-down pin (15).
7. Remove adjuster assembly (12)
8. Remove leading shoe assembly (8) with upper (inner)
return spring (9).
POWER–ASSISTED BRAKE SYSTEM 5C–113
NOTE: Do not over stretch the return spring.
Installation
1. Apply grease lightly to back place A.
305RS003
9. Remove upper (inner) return spring (9).
10. Remove hold-down spring and cup (3) and hold-down
pin (16).
11. Remove Trailing shoe assembly (7) with parking
brake lever (16).
12. Remove parking brake cable from parking brake lever
(11).
13. Remove retainer (14), wave washer (13), and parking
brake lever (11).
Brake Lining Inspection
Check the shoe assemblies for wear by removing brake
drum.
Replace the shoe assemblies, if lining thickness is less
than 1.0 mm (0.039 in).
The shoe assemblies have a wear indicator that makes a
noise when the linings wear to a degree where
replacement is required.
Minimum limit: 1.0 mm (0.039 in)
305RW002
Legend
(1) Place A (3 portions for each side)
2. Install parking brake lever (11), wave washer (13),
and retainer (14).
3. Install trailing shoe assembly (7) with parking brake
lever (16).
4. Install the parking brake cable to parking brake lever
(11).
5. Install hold-down pin (16) and hold-down spring and
cup (3).
6. Install upper (inner) return spring (9).
7. Install leading shoe assembly (8) with upper (inner)
return spring (9).
NOTE: Do not over stretch the return spring.
305RS003
305RS001
5C–114 POWER–ASSISTED BRAKE SYSTEM
8. Install adjuster assembly (12).
9. Install hold-down pin (15) and hold-down spring and
cups (4).
10. Install lower return spring (5).
B Use brake spring tool.
11. Install auto adjuster lever (10).
12. Install upper (outer) return spring (6).
B Use brake spring tool.
13. Install brake drum (2).
B Adjust the brakes, refer to the Drum Brake
Adjustment in this section.
14. Install wheel and tire assembly (1).
B Refer to Wheels and Tires in wheel and Tire System
section.
Drum Brake Adjustment (4×2 Model)
NOTE: All brakes are self-adjusting. Brakes are adjusted
by repeated stepping on the brake pedal. (After stepping
on the pedal and releasing it, the rear auto adjuster, in the
rear brake, produces a clicking sound.
The same operation should be repeated until the sound
disappears.)
Take the following steps after overhauling the rear brake
assembly.
1. Move the parking brake handle to its fully released
position.
2. Parking cable must be loosened sufficiently. (Loosen
the adjust nut and the lock nut.)
3. Repeat stepping on the brake pedal firmly, and
releasing it until the clicking sound can no longer be
heard.
If the difference between the brake drum inside
diameter and diameter of the brake shoes is adjusted
to be 0,5 mm, the number of times for depressing the
brake pedal can be reduced.
4. Remove the drum. Measure the brake drum inside
diameter and diameter of the brake shoes.
Servicing The Brake Drum
Whenever the brake drums are removed, they should be
thoroughly cleaned and inspected for cracks, scores,
deep grooves and out-of-round.
Cracked, Scored or Grooved Drum
A cracked drum is unsafe and must be replaced.
Do not attempt to weld a cracked drum.
Smooth any slight scores. Heavy or extensive scoring will
cause excessive brake lining wear, and it will probably be
necessary to machine the drum braking surface.
If the brake linings are slightly worn and the drum is
grooved, the drum should be polished with fine emery
cloth but should not be machined. At this stage,
eliminating all the grooves in the drum and smoothing the
ridges on the lining would require the removal of too much
metal and lining. If left alone, the grooves and ridges
match and satisfactory service can be obtained. If brake
linings are to be replaced, a grooved drum should be
machined. Using a grooved drum with new linings will
create inefficient braking performance and cause the
linings to wear quicker.
Out-Of-Round Drum
An out-of-round drum makes accurate brake shoe
adjustment impossible and is likely to cause excessive
wear to other parts of the brake mechanism due to its
eccentric action. An out-of-round drum can also cause
severe and irregular tire tread wear as well as a pulsing
brake pedal. When the braking surface of a brake drum
exceeds the specification limit of 0.15 mm (0.006 in) in
out-of-round, the drum should be machined to true up the
braking surface. Out-of-round can be accurately
measured with an inside micrometer fitted with proper
extension rods. When measuring a drum for out-of-round
and wear, take measurements at the open and closed
edges of machines surfaces and at right angles to each
other.
Maximum out-of-round: 0.15 mm (0.006 in)
Shoe clearance: 0.25-0.4 mm (0.0098-0.0157 in)
If incorrect, check the brake auto-adjusting system.
5. Rotate the adjust nut until all slack disappears from
the cable. Set the adjust nut.
6. Applying about 30 kg (66 lb) of force, pull the parking
brake handle to its fully set position three or four
times.
7. If the parking brake is properly adjusted, the travel
between the fully disengaged position and the fully
engaged position will be between 9 and 11 notches.
If the traveling range is not within these limits, again
repeat steps 1 through 5.
After adjusting has been done, check to see if the rear
wheel rotates smoothly without drag when turned by
hand.
420RS034
POWER–ASSISTED BRAKE SYSTEM 5C–115
Machining The Drum
If a drum is to be machined, only enough metal should be
removed to obtain a true, smooth braking surface. If a
drum does not clean-up when machined to a maximum
diameter, it must be replaced. Removal of more metal will
affect dissipation of heat and may cause distortion of the
drum.
After refinishing, replace any drum that exceeds a
maximum inside diameter of 296.5 mm (11.673 in). Do
not use a brake drum that is not within the specification.
Maximum inside diameter: 296.5 mm (11.673 in)
Wheel Cylinder Assembly (4×2 Model)
Wheel Cylinder Assembly and Associated Parts
305RW003
Legend
(1) Brake Linings
(2) Wheel Cylinder
Removal
1. Remove brake linings (1).
B Refer to Brake Lining and Associated Parts in this
section.
2. Remove brake pipe (4).
B Plug the opening in the line to prevent fluid loss and
contamination.
3. Remove bolts (3) and wheel cylinder (2).
(3) Bolts
(4) Brake Pipe
Installation
1. Install wheel cylinder (2) and tighten bolts (3) to the
specified torque.
Torque: 10 N·m (8 lb ft)
2. Install brake pipe (4) and tighten the nut to the
specified torque.
Torque: 16 N·m (12 lb ft)
3. Install brake linings (1).
B Refer to Brake Lining Replacement in this section.
B Bleed brake system. Refer to Hydraulic Brake in
this section.
5C–116 POWER–ASSISTED BRAKE SYSTEM
Disassembled View
Reassembly
1. Lubricate the cylinder bore with clean rubber grease.
305RS006
Legend
(1) Boot
(2) Piston Assembly
(3) Piston Cup
(4) Return Spring
(5) Bleeder
(6) Wheel Cylinder
305RS007
2. Install bleeder (5) to wheel cylinder (6).
Torque: 10 N·m (8 lb ft)
Disassembly
1. Remove boot (1) and piston assembly (2).
2. Remove piston cup (3) from piston assembly (2).
3. Remove return spring (4) and bleeder (5) from wheel
cylinder (6).
Inspection and Repair
1. Make necessary parts replacement if wear, damage,
corrosion or any other abnormal condition are found
through inspection.
Check the following parts;
B Wheel cylinder body
B Cylinder bore
B Piston
B Return spring
B Bleeder
NOTE: Replace the piston cups and boots each time the
wheel cylinder is overhauled. Discard these used rubber
parts and replace with new ones.
305RS008
POWER–ASSISTED BRAKE SYSTEM 5C–117
3. Install new piston cups (3) on each piston so that the
flared end of the cups are turned to the inboard side of
the pistons.
Attach the return spring (4) and the boot (1) to the
piston.
305RS009
4. Apply DELCO silicone lube No. 5459912 (or
equivalent) to the piston and the inner face of the
boots.
5. Install piston assembly (2) to wheel cylinder (6).
5C–118 POWER–ASSISTED BRAKE SYSTEM
Main Data and Specifications
General Specifications
Rear drum brake
Type
Leading-trailing, non-servo
Drum inside diameter
295 mm (11.6 in)
Wheel cylinder diameter
22.22 mm (7/8 in)
Torque Specifications
E05RW010
SECTION
PARKING BRAKE SYSTEM (4x4 Model) 5D1–1
AXIOM
BRAKES
PARKING BRAKE SYSTEM (4×4 Model)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . .
General Description . . . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake Lever and Front Cable . . . . . .
Parking Brake Lever Assembly and
Associated Parts . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5D1–1
5D1–1
5D1–2
5D1–3
5D1–3
5D1–3
5D1–3
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING, REFER TO
THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fasteners joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fasteners.
When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.
Parking Brake Rear Cable . . . . . . . . . . . . . . . .
Parking Brake Rear Cable and Associated
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Parking Brake Adjustment . . . . . . . . . . . . . . . .
Main Data and Specifications . . . . . . . . . . . . .
5D1–4
5D1–4
5D1–5
5D1–5
5D1–6
5D1–6
5D1–7
General Description
Pulling up the parking brake lever by hand will set the
parking brake. By means of a ratchet type lock, the lever
can be held in that position until it is released. The position
of the lever is transmitted through cable/lever systems to
the rear wheels. These parts are designed to obtain
sufficient braking force even when parking on slopes.
When the parking brake is set, or when the ignition SW is
in the“ON” position, the brake warning light illuminates.
The rear wheel parking brake is a duo–servo brake
(mechanical inside expansion type) built in the rear disc
brake. Parking brake adjustment is made through the
adjusting hole (bored through back plate). Parking brake
lever stroke should be adjusted to 6–8 notches. Refer to
Parking Brake Adjustment in this section.
5D1–2 PARKING BRAKE SYSTEM (4x4 Model)
Operation
When pulled in the direction “A”, the parking lever presses
the secondary shoe against the brake drum using the
lever/shoe joint “B” as a fulcrum and pushes the strut in
the direction “C”. The strut ,in turn, presses the primary
shoe against the brake drum. Counter force “D” to the
primary shoe is transmitted again to the secondary shoe
through the fulcrum “B”. The secondary shoe contacts the
drum thereby producing braking effect. Clearance which
may result from worn parking brake shoe lining can be
adjusted by turning the adjusting screw. Refer to Parking
Brake Adjustment in this Section.
A05RS002
Legend
(1) Direction “A”
(2) Lever/Shoe Joint “B” as a fulcrum
(3) Direction “C”
(4) Counter Force “D”
(5) Parking Lever
(6) Secondary Shoe
(7) Adjusting Screw Notch
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Parking Cable Guide
Primary Shoe
Strut
Shoe Expanding Direction
Parking Brake Cable Guide
Adjusting Hole Plug
Adjusting Screw Notch
PARKING BRAKE SYSTEM (4x4 Model) 5D1–3
Parking Brake Lever and Front Cable
Parking Brake Lever Assembly and Associated Parts
311R200001
Legend
(1) Rear Console
(2) Switch Connector
(3) Bolt
(4) Adjust Nut and Lock Nut
Removal
1. Remove rear console (1).
B Refer to Body and Accessories section in this
manual.
2. Disconnect switch connector (2).
3. Remove bolt (3).
4. Remove adjust nut and lock nut (4).
5. Pull out equalizer (6) from trunnion pin (5).
6. Disconnect trunnion pin (5) from Parking brake lever
(8).
7. Disconnect parking brake rear cable (7).
(5)
(6)
(7)
(8)
Trunnion Pin
Equalizer
Parking Brake Rear Cable
Parking Brake Lever
Installation
1. Apply grease (BESCO L–2 or equivalent) to the
connecting portion of the rear cable (7) and equalizer
(6).
2. Connect parking brake rear cable (7) to equalizer
3. Install trunnion pin (5) to parking brake lever (8).
4. Insert equalizer (6) into trunnion pin (5) and tighten
adjust nut and lock nut (4).
B To adjust the parking brake lever, see “Parking
Brake Adjustment” in this section.
Lock Nut Torque: 13 N·m (113 lb in)
5. Tighten the parking brake lever fixing bolt (3) to the
specified torque.
Torque: 15 N·m (11 lb ft)
6. Connect switch connector (2).
7. Install rear console (1).
B Refer to Body and Accessories section in this
manual.
5D1–4 PARKING BRAKE SYSTEM (4x4 Model)
Parking Brake Rear Cable
Parking Brake Rear Cable and Associated Parts
311RY00004
Legend
(1) Rear Wheels
(2) Caliper Assembly
(3) Rotor (Drum)
(4) Holding Spring
(5) Upper Return Spring
(6) Lower Return Spring
(7) Shoe Assembly
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Cable Fixing Bolt
Bolt
Bolt
Bolt (Only Long Wheel Base Model)
Nut
Nut
Retainer
Rear Cable
PARKING BRAKE SYSTEM (4x4 Model) 5D1–5
Removal
1. Remove rear wheels (1).
2. Remove 2 bolts to remove the caliper assembly (2)
from the support bracket. Refer to “Rear Disc Brakes”
in Power Assisted Brake System section. Temporarily
hang the caliper with wire etc.
3. Remove rotor (drum) (3).
4. Remove holding spring (4), upper return spring (5)
and lower return spring (6).
5. Previously remove the rear cable from the parking
brake lever, then remove the brake shoe assembly
(7).
6. Install shoe assembly (7).
After installation of the shoe and cable assembly,
apply special grease (included in the repair kit) to the
following portions indicated in the figure.
308RS005
7. Install lower return spring (6) and upper return spring
(5).
The parking brake lever side (secondary side) return
spring must be installed on the outer side of the
primary side return spring.
308RW004
Legend
(1) Parking Brake Lever
6. Remove cable fixing bolt (8) and bolt (9) (10) (11).
7. Remove nut (12).
8. Remove nut (13) and retainer (14).
9. Remove rear cable (15).
Installation
1. Apply grease (BESCO L–2 or equivalent) to the
connecting portion of the rear cable and equalizer.
Install rear cable (15).
2. Install retainer (14).
B Tighten nut (13) to the specified torque.
Torque: 41N·m (30lb ft)
3. Tighten nut (12) to the specified torque.
308RS003
Legend
(1) Outer Side
(2) Parking Lever
Torque: 15N·m (11lb ft)
4. Tighten bolt (11) (10) (9) to the specified torque.
Torque: 6.5N·m (57lb in)
B To adjust the parking brake, refer to Parking Brake
Adjustment in this section.
5. Tighten the cable fixing bolt (8) to the specified
Torque: 6.5N·m (57lb in)
8. Install holding spring (4).
9. Install rotor (drum) (3).
10. Install caliper assembly (2).
11. Install rear wheels (1).
5D1–6 PARKING BRAKE SYSTEM (4x4 Model)
Inspection and Repair
Parking Brake Lining Inspection
Check the shoe assemblies for wear by removing the
brake drum.
Replace the shoe assemblies if the lining thickness is less
than 1.0 mm (0.039 in).
Minimum limit: 1.0 m (0.039 in)
7. When poor braking effect possibly resulting from
insufficient break–in is felt, or just after replacement
of parking brake shoe, be sure to conduct break–in as
follows:
8. Forward 50 km/h (30 mph) × 400 m (About 30
seconds) with a lever pull force of 15 kg (33 lb).
9. Backward 10 km/h (6 mph) × 50 m (About 18
seconds) with a lever pull force of 15 kg (33 lb).
NOTE: Break–in procedures must be performed under
safe conditions and traffic rules.
B If braking effect still remains poor after the above
break–in, wait for some time until parking brake shoe
cools down and repeat the procedures 8. and 9. noted
above.
B On completion of break–in, inspect parking brake
lever stroke, and if the lever does not come within the
specified number of notches when pulled up,
readjust.
B Excessive break–in may cause premature wear of
the parking brake lining.
308RS004
Parking Brake Rotor (Drum) Inspection
Refer to “Rear Disc Brakes” in Power-Assisted Brake
System section for inspection procedure of the rotor
(drum).
Parking Brake Adjustment
1. Prior to lever stroke adjustment, adjust rear brake
shoe/rotor (drum) gap. Perform this procedure with
loosening the adjust nut of the hand brake lever.
2. Remove the adjusting hole plug (rubber) and turn the
shoe adjusting screw downward with a small
screwdriver so that shoes will expand until they get
into close touch with the rotor. (Turn down the
adjusting screw notch by notch until the rotor does not
turn.)
3. Turn the adjusting screw in the opposite direction
(upward) until the rotor can be turned lightly. Standard
number of notches to turn upward: 7 or 8 notches
Turn the rotor and make sure that there is no brake
dragging.
4. After the rear brake shoe/rotor (drum) gap has been
adjusted, perform parking brake cable adjustment.
5. Turn the adjusting nut so that the parking brake lever
travels 6–8 notches when pulled up with a force of 30
kg (66 lb).
6. Make sure there is no brake dragging. Then tighten
the cable lock nut
Torque : 13 N·m (113 lb in)
PARKING BRAKE SYSTEM (4x4 Model) 5D1–7
Main Data and Specifications
General Specifications
Model
Type
Drum inside diameter
Parking brake lever stroke
Duo–servo
210 mm(8.27 in)
6–8 notches
When pulled with a force of 30 kg (66 lb)
Torque Specifications
311R200002
SECTION
PARKING BRAKE SYSTEM (4X2 Model) 5D2–1
AXIOM
BRAKES
PARKING BRAKE SYSTEM (4×2 Model)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . .
General Description . . . . . . . . . . . . . . . . . . . . .
Parking Brake Lever . . . . . . . . . . . . . . . . . . . . .
Parking Brake Lever Assembly and
Associated Parts . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5D2–1
5D2–1
5D2–2
5D2–2
5D2–2
5D2–2
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.
Parking Brake Rear Cable . . . . . . . . . . . . . . . .
Parking Brake Rear Cable and Associated
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake Adjustment . . . . . . . . . . . . . . . .
Main Data and Specifications . . . . . . . . . . . . .
5D2–3
5D2–3
5D2–4
5D2–4
5D2–4
5D2–5
General Description
Pulling up the parking brake lever by hand will set the
parking brake. By means of a ratchet type lock, the lever
can be held in that position until it is released. The position
of the lever is transmitted through cable/lever systems to
the rear wheels. These parts are designed to obtain
sufficient braking force even when parking on slopes.
When the parking brake is set, or when the ignition SW is
in the“ON” position, the brake warning light illuminates.
The rear wheel parking brake is a leading/trailing brake
(mechanical inside expansion type). Parking brake
adjustment is made through the adjusting hole (bored
through back plate). Parking brake lever stroke should be
adjusted to 6 notches. Refer to Parking Brake Adjustment
in this section.
5D2–2
PARKING BRAKE SYSTEM (4X2 Model)
Parking Brake Lever
Parking Brake Lever Assembly and Associated Parts
311R200001
Legend
(1) Rear Console
(2) Switch Connector
(3) Bolt
(4) Adjust Nut and Lock Nut
Removal
1. Remove rear console (1).
B Refer to Body and Accessories section in this
manual.
2. Disconnect switch connector (2).
3. Remove bolt (3).
4. Remove adjust nut and lock nut (4).
5. Pull out equalizer (6) from trunnion pin (5).
6. Disconnect trunnion pin (5) from parking brake lever
(8).
7. Disconnect parking brake rear cable (7).
(5)
(6)
(7)
(8)
Trunnion Pin
Equalizer
Parking Brake Rear Cable
Parking Brake Lever
Installation
1. Apply grease (BESCO L–2 or equivalent) to the
connecting portion of the rear cable (7) and equalizer
(8).
2. Connect parking brake rear cable (7) to equalizer (6).
3. Install trunnion pin (5) to parking brake lever (8).
4. Insert equalizer (6) into trunnion pin (5) and tighten
adjust nut and lock nut (4).
B To adjust the parking brake lever, see “Parking
Brake Adjustment” in this section.
Lock Nut Torque: 13 N·m (113 lb in)
5. Tighten parking lever fixing bolt (3) to the specified
torque.
Torque: 15 N·m (11 lb ft)
6. Connect switch connector (2).
7. Install rear console (1).
B Refer to Body and Accessories section in this
manual.
PARKING BRAKE SYSTEM (4X2 Model) 5D2–3
Parking Brake Rear Cable
Parking Brake Rear Cable and Associated Parts
311RY00006
Legend
(1) Rear Wheels
(2) Drums
(3) Clip and Bolt
(4) Clip and Bolt
(5)
(6)
(7)
(8)
(9)
Clip and Bolt (Only Long Wheel Base Model)
Nut
Nut
Retainer
Rear Cable
5D2–4
PARKING BRAKE SYSTEM (4X2 Model)
Removal
Parking Brake Adjustment
1. Remove rear wheels (1) and drums (2).
2. Remove bolt (3) (4) (5).
3. Remove nut (6).
4. Remove nut (7) and retainer (8).
5. Remove rear brake shoe assemblies. Refer to “Brake
Lining Assembly and Associated Parts” in Power
Assisted Brake System section.
6. Use offset box wrench (13 mm hex.) to compress the
locking lugs on the cable, then remove the rear cable
(9) from the Backing plate.
NOTE: All brakes are self adjusting. Brakes are adjusted
by repeated stepping on the brake pedal. (After stepping
on the pedal and releasing it, the rear auto–adjuster, in the
rear brake, produces a clicking sound. The same
operation should be repeated until the sound
disappears.)
Take the following steps after overhauling the rear brake
assembly.
1. Move the parking brake lever to its fully released
position.
2. Parking cable must be loosened sufficiently. (Loosen
the adjust nut and the lock nut.).
3. Repeat stepping on the brake pedal firmly, and
releasing it until the clicking sound can no longer be
heard.
If the difference between the brake drum inside
diameter and diameter of the brake shoes is adjusted
to be 0.5 mm, the number of times for depressing the
brake pedal can be reduced.
4. Remove the drum. Measure the brake drum inside
diameter and diameter of the brake shoes.
Shoe clearance: 0.25 mm to 0.40 mm
(0.0098 in to 0.0157 in)
If incorrect, check the brake auto–adjusting system.
311RS012
Legend
(1) Offset Box Wrench
Installation
1. Install rear cable (9).
2. Install retainer (8).
3. Tighten nut (7) to the specified torque.
Torque : 41 N·m (30 lb ft)
B To adjust the parking brake, refer to Parking Brake
Adjustment in this section.
4. Tighten nut (6) to the specified torque.
Torque : 15 N·m (11 lb ft)
5. Tighten bolt (5) (4) (3) to the specified torque.
Torque : 6.5 N·m (57 lb in)
6. Install rear drums (2) and wheels (1).
5. Rotate the adjust nut of hand brake lever until all slack
disappears from the cable. Set the adjust nut.
6. Applying about 30 kg (66 lb) of force, pull the parking
brake lever to its fully set position three or four times.
7. If the parking brake is properly adjusted, the travel
between the fully disengaged position and the fully
engaged position will be 6 notches.
If the traveling range is not within these limits, repeat
steps 1 through 5 again .
After adjusting has been done, check to see if the rear
wheel rotates smoothly without drag when turned by
hand.
PARKING BRAKE SYSTEM (4X2 Model) 5D2–5
Main Data and Specifications
General Specifications
Model
Type
Leading–Trailing
Drum inside diameter
295 mm (11.6 in)
Parking brake lever stroke
6–8 notches
When pulled with a force of 30 kg (66 lb)
Torque Specifications
311R200003
SECTION
ENGINE MECHANICAL (6VE1 3.5L)
6A–1
AXIOM
ENGINE
CONTENTS
Engine Mechanical . . . . . . . . . . . . . . . . . . . . . .
Engine Cooling . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . .
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . .
Starting and Charging System . . . . . . . . . . . .
6A
6B
6C
6D1
6D2
6D3
Driveability and Emissions . . . . . . . . . . . . . . . .
Engine Exhaust . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lubrication . . . . . . . . . . . . . . . . . . . . . .
Engine Speed Control System . . . . . . . . . . . .
Induction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6E
6F
6G
6H
6J
ENGINE MECHANICAL (6VE1 3.5L)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . .
General Description . . . . . . . . . . . . . . . . . . . . .
Engine Diagnosis . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Cover LH . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Cover RH . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Common Chamber . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold LH . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold RH . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Stem Oil Controller , Valve Spring
and Valve Guide . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston, Piston Ring and Connecting Rod . . .
6A–2
6A–3
6A–4
6A–19
6A–19
6A–20
6A–21
6A–21
6A–21
6A–22
6A–22
6A–22
6A–24
6A–24
6A–24
6A–25
6A–25
6A–25
6A–26
6A–26
6A–26
6A–27
6A–27
6A–28
6A–32
6A–32
6A–33
6A–35
6A–35
6A–35
6A–37
6A–37
6A–37
6A–38
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft and Main Bearings . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Associated Parts . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Spring, Oil Controller, Valve, Valve
Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Spring, Oil Controller, Valve, Valve
Guide and Associated Parts . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft and Associated Parts . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft and Associated Parts . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair for Bearings . . . . . .
Inspection and Repair for Crankshaft . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
6A–38
6A–39
6A–40
6A–40
6A–41
6A–45
6A–45
6A–45
6A–46
6A–46
6A–47
6A–49
6A–49
6A–50
6A–50
6A–50
6A–51
6A–53
6A–53
6A–53
6A–54
6A–57
6A–60
6A–60
6A–60
6A–61
6A–63
6A–67
6A–67
6A–67
6A–68
6A–70
6A–71
6A–2
ENGINE MECHANICAL (6VE1 3.5L)
Piston and Connecting Rod . . . . . . . . . . . . . . .
Piston, Connecting Rod and Associate
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . .
6A–75
6A–75
6A–75
6A–76
6A–80
6A–82
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.
Cylinder Block and Associated Parts . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specification . . . . . . . . . . . . . .
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6A–82
6A–82
6A–83
6A–84
6A–87
6A–93
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 (6VE1 3.5L)
6A–3
General Description
Cylinder Block
Engine Cleanliness And Care
The cylinder block is made of aluminum die–cast casting
for 75°V–type six cylinders. It has a rear plate integrated
structure and employs a deep skirt. The cylinder liner is
cast and the liner inner diameter and crankshaft journal
diameter are classified into grades. The crankshaft is
supported by four bearings of which width is different
between No.2, No.3 and No.1, No.4; the width of No.3
bearing on the body side is different in order to support the
thrust bearing. The bearing cap is made of nodular cast
iron and each bearing cap uses four bolts and two side
bolts.
An automobile engine is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are measured in the thousandths of a
millimeter (ten thousandths of an inch). Accordingly,
when any internal engine parts are serviced, care and
cleanliness are important. Throughout this section, it
should be understood that proper cleaning and protection
of machined surfaces and friction areas is part of the
repair procedure. This is considered standard shop
practice even if not specifically stated.
B A liberal coating of engine oil should be applied to all
friction areas during assembly to protect and lubricate
the surfaces on initial operation.
B Whenever valve train components, pistons, piston
rings, connecting rods, rod bearings, and crankshaft
journal bearings are removed for service, they should
be retained in order.
B At the time of installation, they should be installed in
the same locations and with the same mating
surfaces as when removed.
B Battery cables should be disconnected before any
major work is performed on the engine. Failure to
disconnect cables may result in damage to wire
harness or other electrical parts.
B The six cylinders of this engine are identified by
numbers; Right side cylinders 1, 3 and 5, Left side
cylinders 2, 4 and 6, as counted from crankshaft
pulley side to flywheel side.
General Information on Engine Service
The following information on engine service should be
noted carefully, as it is important in preventing damage
and contributing to reliable engine performance.
B When raising or supporting the engine for any reason,
do not use a jack under the oil pan. Due to the small
clearance between the oil pan and the oil pump
strainer, jacking against the oil pan may cause
damage to the oil pick–up unit.
B The 12–volt electrical system is capable of damaging
circuits. When performing any work where electrical
terminals could possibly be grounded, the ground
cable of the battery should be disconnected at the
battery.
B Any time the intake air duct or air cleaner is removed,
the intake opening should be covered. This will
protect against accidental entrance of foreign
material into the cylinder which could cause extensive
damage when the engine is started.
Cylinder Head
The cylinder head, made of aluminum alloy casting
employs a pent–roof type combustion chamber with a
spark plug in the center. The intake and exhaust valves
are placed in V–type design. The ports are cross–flow
type.
Valve Train
Intake and exhaust camshaft on both banks are driven
with a camshaft drive gear by the timing belt. The valves
are operated by the camshaft and the valve clearance is
adjusted to select suitable thickness shim.
Intake Manifold
The intake manifold system is composed of the aluminum
cast common chamber and intake manifold attached with
six fuel injectors.
Exhaust Manifold
The exhaust manifold is made of nodular cast iron.
Pistons and Connecting Rods
Aluminum pistons are used after selecting the grade that
meets the cylinder bore diameter. Each piston has two
compression rings and one oil ring. The piston pin made
of chromium steel is offset 1mm toward the thrust side,
and the thrust pressure of piston to the cylinder wall varies
gradually as the piston travels. The connecting rods are
made of forged steel. The connecting rod bearings are
graded for correct size selection.
Crankshaft and Bearings
The crankshaft is made of Ductile cast–iron. Pins and
journals are graded for correct size selection for their
bearing.
6A–4
ENGINE MECHANICAL (6VE1 3.5L)
Engine Diagnosis
First of all the engine diagnose to check the fuel quantity,
the engine level and the engine coolant level.
Hard Starting
1. Starting Motor Does Not Turn Over
Troubleshooting Procedure
Turn on headlights and starter switch.
Condition
Headlights
go
considerably
out
Possible cause
or
dim
Correction
Battery run down or under charged
Recharge or replace battery
Terminals poorly connected
Clean battery posts and terminals
and connect properly
Starting motor coil circuit shorted
Overhaul or replace
Starting motor defective
Overhaul or replace
2. Ignition Trouble — Starting Motor Turns Over But Engine Does Not Start
tester. Before starting the engine, make sure that the
Spark Test
spark plug tester is properly grounded. To avoid electrical
Disconnect an ignition coil from any spark plug. Connect
shock, do not touch the part where insulation of the
the spark plug tester (For example J–26792), start the
ignition coil is broken while the engine is running.
engine, and check if a spark is generated in the spark plug
Condition
Spark jumps across gap
No sparking takes place
Possible cause
Correction
Spark plug defective
Clean, adjust spark gap or replace
Ignition timing incorrect
Refer to Ignition System
Fuel not reaching fuel injector(s) or
engine
Refer to item 3 (Trouble in fuel
system)
Valve timing incorrect
Adjust
Engine lacks compression
Refer to item 4 (Engine lacks
compression)
Ignition coil disconnected or broken
Connect properly or replace
Electronic
module
Replace
Ignition
System
with
Poor connections in engine harness
Correct
Powertrain Control Module cable
disconnected or defective
Correct or replace
3. Trouble In Fuel System
Condition
Starting motor turns over and spark
occurs but engine does not start
start.
Possible cause
Correction
Fuel tank empty
Fill
Water in fuel system
Clean
Fuel filter clogged
Replace filter
Fuel pipe clogged
Clean or replace
Fuel pump defective
Replace
Fuel pump circuit open
Correct or replace
Evaporative
Emission
System circuit clogged
Control
Multiport Fuel Injection System faulty
Correct or replace
Refer to “Electronic Fuel Injection”
section
ENGINE MECHANICAL (6VE1 3.5L)
6A–5
4. Engine Lacks Compression
Condition
Engine lacks compression
Possible cause
Correction
Spark plug loosely fitted or spark
plug gasket defective
Tighten to specified torque or replace
gasket
Valve timing incorrect
Adjust
Cylinder head gasket defective
Replace gasket
Valve incorrectly seated
Lap valve
Valve stem seized
Replace valve and valve guide
Valve spring weakened or broken
Replace
Cylinder or piston rings worn
Overhaul engine
Piston ring seized
Overhaul engine.
Engine Compression Test Procedure
1. Start and run the engine until the engine reaches
normal operating temperature.
2. Turn the engine off.
3. Remove all the spark plugs.
4. Remove ignition coil fuse (15A) and disable the
ignition system.
5. Remove the fuel pump relay from the relay and fuse
box.
6. Engage the starter and check that the cranking speed
is approximately 300 rpm.
7. Install cylinder compression gauge into spark plug
hole.
8. With the throttle valve opened fully, keep the starter
engaged until the compression gage needle reaches
the maximum level. Note the reading.
9. Repeat the test with each cylinder.
If the compression pressure obtained falls below the
limit, engine overhaul is necessary.
Limit; 1000 kPa (145 psi)
6A–6
ENGINE MECHANICAL (6VE1 3.5L)
Rough Engine Idling or Engine Stalling
Condition
Trouble in fuel injection system
Trouble in emission control system
Others
Possible cause
Correction
Throttle shutting off incomplete
Correct or replace
Throttle position sensor circuit open
or shorted
Correct or replace
Fuel injector circuits open or shorted
Correct or replace
Fuel injectors damaged
Replace
Fuel pump relay defective
Replace
Mass Airflow Sensor circuit open or
poor connections
Correct or replace
Mass Airflow Sensor defective
Replace
Manifold Absolute Pressure Sensor
circuit open or poor connections
Correct or replace
Manifold Absolute Pressure Sensor
defective
Replace
Engine Coolant Temperature Sensor
circuit open or poor connections
Correct or replace
Engine Coolant Temperature Sensor
defective
Replace
Intake Air Temperature sensor circuit
open or poor connections
Correct or replace
Intake Air
defective
Replace
Temperature
sensor
Ion Sensing Module cable broken or
poor connections
Correct or replace
Ion Sensing Module defective
Replace
Vehicle Speed Sensor circuit open or
shorted
Correct or replace
Vehicle Speed Sensor defective
Replace
Powertrain Control Module defective
Replace
Exhaust Gas Recirculation Valve
circuit open or poor connections
Correct or replace
Exhaust Gas Recirculation Valve
faulty
Replace
Canister purge valve circuit open or
poor connections
Correct or replace
Canister purge valve defective
Replace
Evaporative Emission Canister
Purge control valve defective
Replace
Trouble in ignition system
Refer to “Hard Start”
Engine lacks compression
Refer to “Hard Start”
Valve incorrectly seated
Lap valve
Air Cleaner Filter clogged
Replace filter element
Valve timing incorrect
Readjust
Idle air control valve broken
Replace
Fast idle solenoid defective
Replace
Positive Crankcase Ventilation valve
defective or clogged
Replace
ENGINE MECHANICAL (6VE1 3.5L)
6A–7
Rough Engine Running
Condition
Engine misfires periodically
Engine knocks periodically
Engine lacks power
Possible cause
Correction
Ignition coil layer shorted
Replace
Spark plugs fouling
Clean or install hotter type plug
Spark plug(s) insulator nose leaking
Replace
Fuel injector(s) defective
Replace
Powertrain control module faulty
Replace
Spark plugs running too hot
Install colder type spark plugs
Powertrain control module faulty
Replace
Ion Sensing module faulty
Refer or replace
Spark plugs fouled
Clean
Fuel injectors defective
Replace
Mass Airflow Sensor or Intake
Airflow Sensor circuit defective
Correct or replace
Manifold Absolute Pressure (MAP)
Sensor or Manifold Absolute
Pressure Sensor circuit defective
Correct or replace
Engine Coolant Temperature Sensor
or Engine Coolant Temperature
Sensor circuit defective
Correct or replace
Powertrain Control Module faulty
Replace
Intake Air Temperature Sensor or
Intake Air Temperature Sensor
circuit defective
Correct or replace
Throttle Position Sensor or Throttle
Position Sensor circuit defective
Correct or replace
ION Sensing Module or ION Sensing
Module circuits defective
Correct or replace
6A–8
ENGINE MECHANICAL (6VE1 3.5L)
Hesitation
Condition
Hesitation on acceleration
Hesitation at high speeds
(Fuel pressure too low)
Hesitation at high speeds
(Fuel injector not working normally)
Possible cause
Correction
Throttle Position Sensor adjustment
incorrect
Replace throttle valve assembly
Throttle Position Sensor circuit open
or shorted
Correct or replace
Mass Airflow Sensor circuit open or
poor connections
Correct or replace
Mass Airflow Sensor defective
Replace
Manifold Absolute Pressure (MAP)
Sensor circuit open or shorted
Correct or replace
MAP Sensor defective
Replace
Intake Air Temperature (IAT) Sensor
circuit open or poor connections
Correct or replace
Ion Sensing Module circuit open or
poor connections
Correct or replace
Ion Sensing Module defective
Replace
IAT Sensor defective
Replace
Fuel tank strainer clogged
Clean or replace
Fuel pipe clogged
Clean or replace
Fuel filter clogged
Replace
Defective fuel pump system
Check and replace
Fuel Pressure Control Valve leaking
Replace
Power supply or ground circuit for
Multiport Fuel Injection System
shorted or open
Check and correct or replace
Fuel Injector defective
Replace
Cable of Multiport Fuel Injection
System circuit open or poor
connections
Correct or replace
ENGINE MECHANICAL (6VE1 3.5L)
Condition
Hesitation at high speeds
Possible cause
Correction
Powertrain Control Module defective
Replace
Throttle Position Sensor
broken or poor connections
Correct or replace
cable
Throttle Position Sensor defective
Replace
Engine Coolant Temperature Sensor
circuit open or shorted
Correct or replace
Engine Coolant Temperature Sensor
defective
Replace
Mass Airflow Sensor circuit open or
poor connections
Correct or replace
Mass Airflow Sensor defective
Replace
MAP Sensor cable broken or poor
connections
Correct or replace
MAP Sensor defective
Replace
IAT Sensor circuit open or poor
connections
Correct or replace
IAT Sensor defective
Replace
Ion Sensing Module circuit open or
poor connections
Correct or replace
Ion Sensing Module defective
Replace
Throttle valve not fully opened
Check and correct or replace
Air Cleaner Filter clogged
Replace filter element
Power supply voltage too low
Check and correct or replace
6A–9
6A–10
ENGINE MECHANICAL (6VE1 3.5L)
Engine Lacks Power
Condition
Trouble in fuel system
Trouble in intake or exhaust system
Ignition failure
Possible cause
Correction
Fuel Pressure Control Valve not
working normally
Replace
Fuel injector clogged
Clean or replace
Fuel pipe clogged
Clean
Fuel filter clogged or fouled
Replace
Fuel pump drive circuit not working
normally
Correct or replace
Fuel tank not sufficiently breathing
due
to
clogged
Evaporative
Emission Control System circuit
Clean or replace
Water in fuel system
Clean
Inferior quality fuel in fuel system
Use fuel of specified octane rating
Powertrain Control Module supplied
poor voltage
Correct circuit
Throttle Position Sensor
broken or poor connections
Correct or replace
cable
Throttle Position Sensor defective
Replace
Mass Airflow Sensor not working
normally
Replace
Manifold Absolute Pressure Sensor
not working normally
Replace
Intake Air Temperature Sensor not
working normally
Replace
Engine Coolant Temperature Sensor
circuit open or shorted
Correct or replace
Engine Coolant Temperature Sensor
defective
Replace
Powertrain Control Module defective
Replace
Air Cleaner Filter clogged
Replace filter element
Air duct kinked or flattened
Correct or replace
TWC defective
Repair
————
Refer to Hard Start Troubleshooting
Guide
Heat range of spark plug inadequate
Install spark plugs of adequate heat
range
Ignition coil defective
Replace
ENGINE MECHANICAL (6VE1 3.5L)
Condition
Engine overheating
Possible cause
6A–11
Correction
Level of Engine Coolant too low
Replenish
Fan clutch defective
Replace
Incorrect fan installed
Replace
Thermostat defective
Replace
Engine Coolant pump defective
Correct or replace
Radiator clogged
Clean or replace
Radiator filler cap defective
Replace
Level of oil in engine crankcase too
low or wrong engine oil
Change or replenish
Resistance
increased
Clean exhaust system or replace
defective parts
in
exhaust
system
Throttle Position Sensor adjustment
incorrect
Replace with Throttle Valve ASM
Throttle Position Sensor circuit open
or shorted
Correct or replace
Cylinder head gasket damaged
Replace
Engine overcooling
Thermostat defective
Replace (Use a thermostat set to
open at 82°C (180°F))
Engine lacks compression
————
Refer to Hard Start
Others
Tire inflation pressure abnormal
Adjust to recommended pressures
Brake drag
Adjust
Clutch slipping
Adjust or replace
Level of oil in engine crankcase too
high
Correct level of engine oil
Exhaust Gas Recirculation Valve
defective
Replace
6A–12
ENGINE MECHANICAL (6VE1 3.5L)
Engine Noisy
Abnormal engine noise often consists of various noises
originating in rotating parts, sliding parts and other
moving parts of the engine. It is, therefore, advisable to
locate the source of noise systematically.
Troubleshooting Procedure for Crankshaft Journals or Crankshaft Bearing Noise
Condition
Possible cause
Correction
Noise from crank journals or from
crank bearings
(Faulty
and crank
y crank journals
j
bearings usually make dull noise that
becomes more evident when
accelerating)
Oil clearance increased due to worn
crank journals or crank bearings
Replace crank bearings and
crankshaft or regrind crankshaft and
install the undersize bearing
Crankshaft out of round
Replace crank bearings and
crankshaft or regrind crankshaft and
install the undersize bearing
Crank bearing seized
Crank bearing seized Replace crank
bearings and crankshaft or regrind
crankshaft and install the undersize
bearing
Troubleshooting Procedure for Connecting Rods or Connecting Rod Bearing Noise
Short out each spark plug in sequence using insulated
spark plug wire removers. Locate cylinder with defective
bearing by listening for abnormal noise that stops when
spark plug is shorted out.
Condition
Noise from connecting rods or from
connecting rod bearings
(Faulty
connecting
rods
or
y
g
connecting rod bearings usually
make an abnormal noise slightly
higher than the crank bearing noise,
which becomes more evident when
engine
is accelerated))
g
Possible cause
Correction
Bearing or crankshaft pin worn
Replace connecting rod bearings
and crankshaft or regrind crankshaft
pin and install the undersize bearing
Crankpin out of round
Replace connecting rod bearings
and crankshaft or regrind crankshaft
pin and install the undersize bearing
Connecting rod bent
Correct or replace
Connecting rod bearing seized
Replace connecting rod bearings
and crankshaft or regrind crankshaft
pin and install the undersize bearing
Troubleshooting Procedure for Piston and Cylinder Noise
Abnormal noise stops when the spark plug on the cylinder
with defective part is shorted out.
Condition
Possible cause
Piston and cylinder noise
(Faulty piston or cylinder usually
makes
k
a combined
bi d mechanical
h i l
thumping
g noise which increases
when engine is suddenly accelerated
but diminishes gradually as the
engine warms up)
Piston clearance increased due to
cylinder wear
Replace piston and cylinder body
Piston seized
Replace piston and cylinder body
Piston ring broken
Replace piston and cylinder body
Piston defective
Replace pistons and others
Correction
Troubleshooting Procedure for Piston Pin Noise
Short out each spark plug and listen for change in engine
noise.
Condition
Piston pin noise
(Piston makes noise each time it
goes up and down)
Possible cause
Piston pin or piston pin hole worn
Correction
Replace piston, piston pin and
connecting rod assy
ENGINE MECHANICAL (6VE1 3.5L)
6A–13
Troubleshooting Procedure for Slapping or Hitting etc Noise
The slapping sound stops when spark plug on bad
cylinder is shorted out.
Condition
Timing belt noise
Possible cause
Correction
Timing belt tension is incorrect
Replace pusher or adjust the tension
pulley or replace timing belt
Tensioner bearing defective
Replace
Timing belt defective
Replace
Timing pulley defective
Replace
Timing belt comes in contact with
timing cover
Replace timing belt and timing cover
Valve clearance incorrect
Replace adjusting shim
Valve and valve guide seized
Replace valve and valve guide
Valve spring broken or weakened
Replace
Valve seat off–positioned
Correct
Camshaft worn out
Replace
Crankshaft noise
Crankshaft end play excessive
(noise occurs when clutch is
engaged)
Replace thrust bearing
Engine knocking
Preignition due to use of spark plugs
of inadequate heat range
Install Spark Plugs of adequate heat
range
Carbon deposits
chambers
Clean
Valve noise
Others
in
combustion
Fuel too low in octane rating
Replace fuel
Wide Open Throttle enrichment
system failure
Refer to Section 6E
Selection
incorrect
Caution operator of incorrect gear
selection
of
transmission
gear
Engine overheating
Refer to “Engine Lacks Power”
Water pump defective
Replace
Drive belt slipping
Replace auto tensioner or drive belt
6A–14
ENGINE MECHANICAL (6VE1 3.5L)
Abnormal Combustion
Condition
Trouble in fuel system
Trouble in emission control system
Trouble in ignition system
Possible cause
Correction
Fuel pressure control valve defective
Replace
Fuel filter clogged
Replace
Fuel pump clogged
Clean or replace
Fuel tank or fuel pipe clogged
Clean or replace
Fuel injector clogged
Clean or replace
Fuel pump relay defective
Replace
Power supply cable for fuel pump
broken or poor connections
Reconnect, correct or replace
Mass Airflow (MAF) Sensor circuit
open or defective
Correct or replace
MAF Sensor defective
Replace
Manifold Absolute Pressure Sensor
circuit open or shorted
Correct or replace
Manifold Absolute Pressure Sensor
defective
Replace
Engine Coolant Temperature (ECT)
Sensor circuit open or shorted
Correct or replace
ECT Sensor defective
Replace
Throttle Position Sensor adjustment
incorrect
Readjust
Throttle Position Sensor defective
Replace
Throttle Position Sensor connector
poor connections
Reconnect
Vehicle Speed Sensor cable poor
connections or defective
Correct or replace
Vehicle Speed Sensor loosely fixed
Fix tightly
Vehicle Speed Sensor in wrong
contact or defective
Replace
Powertrain Control Module cable
poor connections or defective
Correct or replace
Heated Oxygen Sensor circuit open
Correct or replace
Heated Oxygen Sensor defective
Replace
Signal vacuum hose loosely fitted or
defective
Correct or replace
EGR Valve circuit open or shorted
Correct or replace
Exhaust Gas Recirculation Valve
defective
Replace
ECT Sensor circuit open or shorted
Correct or replace
Canister Purge Valve circuit open or
shorted
Correct or replace
Canister Purge Valve defective
Replace
ECT Sensor defective
Replace
Positive
Crankcase
Ventilation
(PCV) valve and hose clogged
Correct or replace
Evaporator system
Refer to Section 6E
————
Refer to “Engine Lacks Power”
ENGINE MECHANICAL (6VE1 3.5L)
Condition
Trouble in cylinder head parts
Possible cause
Carbon deposits
chamber
in
Correction
combustion
Remove carbon
Carbon deposit on valve, valve seat
and valve guide
Remove carbon
6A–15
6A–16
ENGINE MECHANICAL (6VE1 3.5L)
Engine Oil Consumption Excessive
Condition
Possible cause
Oil leaking
Correction
Oil pan drain plug loose
Retighten or replace gasket
Crankcase fixing bolts loosened
Retighten
Oil pan setting bolts loosened
Retighten
Oil pan gasket broken
Replace gasket
Front cover retaining bolts loose or
gasket broken
Retighten or replace gasket
Head cover fixing bolts loose or
gasket broken
Retighten or replace gasket
Oil filter adapter cracked
Replace
Oil filter attachings bolt loose or
rubber gasket broken
Retighten or replace oil filter
Crankshaft front or rear oil seal
defective
Replace oil seal
Oil pressure unit loose or broken
Retighten or replace
Blow–by gas hose broken
Replace hose
Positive Crankcase Ventilation Valve
clogged
Clean
Engine/Transmission coupling failed
Replace oil seal
Oil
leaking
into
combustion
chambers due to poor
oor seal in valve
system
Valve stem oil seal defective
Replace
Valve stem or valve guide worn
Replace valve and valve guide
Oil
leaking
into
combustion
chambers due to poor seal in cylinder
parts
t
Cylinders
and
excessively
Replace cylinder body assembly and
pistons
Positive
Crankcase
System malfunctioning
Others
Ventilation
Piston
ring
positioned
pistons
gaps
worn
incorrectly
Correct
Piston rings set with wrong side up
Correct
Piston ring sticking
Replace cylinder body assembly and
pistons
Piston ring and ring groove worn
Replace pistons and others
Return ports in oil rings clogged
Clean piston and replace rings
Positive Crankcase Ventilation Valve
clogged
Clean
Improper oil viscosity
Use oil of recommended S.A.E.
viscosity
Continuous high speed driving
and/or severe usage such as trailer
towing
Continuous high speed operation
and/or severe usage will normally
cause increased oil consumption
ENGINE MECHANICAL (6VE1 3.5L)
6A–17
Fuel Consumption Excessive
Condition
Trouble in fuel system
Possible cause
Correction
Mixture too rich or too lean due to
trouble in fuel injection system
Refer to “Abnormal Combustion”
Fuel cut function does not work
Refer to “Abnormal Combustion”
Trouble in ignition system
Misfiring or abnormal combustion
due to trouble in ignition system
Refer to “Hard Start” or “Abnormal
Combustion”
Others
Engine idle speed too high
Reset Idle Air Control Valve
Fuel system leakage
Correct or replace
Clutch slipping
Correct
Brake drag
Correct
Selection
incorrect
of
transmission
gear
Excessive
Exhaust
Gas
Recirculation flow due to trouble in
Exhaust Gas Recirculation system
Caution operator of incorrect gear
selection
Refer to “Abnormal Combustion”
Lubrication Problems
Condition
Oil pressure too low
Oil contamination
Oil not reaching valve system
Possible cause
Correction
Wrong oil in use
Replace with correct engine oil
Relief valve sticking
Replace
Oil pump not operating properly
Correct or replace
Oil pump strainer clogged
Clean or replace strainer
Oil pump worn
Replace
Oil pressure gauge defective
Correct or replace
Crankshaft bearing or connecting
rod bearing worn
Replace
Wrong oil in use
Replace with correct engine oil
Oil filter clogged
Replace oil filter
Cylinder head gasket damage
Replace gasket
Burned gases leaking
Replace piston and piston rings or
cylinder body assembly
Oil passage in cylinder head or
cylinder body clogged
Clean or correct
Engine Oil Pressure Check
1. Check for dirt, gasoline or water in the engine oil.
a. Check the viscosity of the oil.
b. Check the viscosity of the oil.
c. Change the oil if the viscosity is outside the
specified standard.
d. Refer to the “Maintenance and Lubrication” section
of this manual.
2. Check the engine oil level.
The level should fall somewhere between the “ADD”
and the “FULL” marks on the oil level dipstick.
If the oil level does not reach the “ADD” mark on the
oil level dipstick, engine oil must be added.
3. Remove the oil pressure unit.
4. Install an oil pressure gauge.
5. Start the engine and allow the engine to reach normal
operating temperature (About 80°C).
6. Measure the oil pressure.
Oil pressure should be:
392–550 kPa (56.9–80.4 psi) at 3000 rpm.
7. Stop the engine.
8. Remove the oil pressure gauge.
9. Install the oil pressure unit.
10. Start the engine and check for leaks.
6A–18
ENGINE MECHANICAL (6VE1 3.5L)
Malfunction Indicator Lamp
The instrument panel “CHECK ENGINE” Malfunction Indicator Lamp (MIL) illuminates by self diagnostic system
when the system checks the starting of engine, or senses
malfunctions.
Condition
“CHECK ENGINE” MIL does not
illuminate at the starting of engine
“CHECK ENGINE” MIL illuminates,
and stays on
Possible cause
Correction
Bulb defective
Replace
MIL circuit open
Correct or replace
Command signal circuit to operate
self diagnostic system shorted
Correct or replace
Powertrain Control Module (PCM)
cable
loosely
connected,
disconnected or defective
Correct or replace
PCM defective
Replace
Deterioration of heated
sensor internal element
oxygen
Replace
Heated oxygen sensor connector
terminal improper contact
Reconnect properly
Heated oxygen sensor lead wire
shorted
Correct
Heated oxygen sensor circuit open
Correct or replace
Deterioration of engine coolant
temperature sensor internal element
Replace
Engine coolant temperature sensor
connector terminal improper contact
Reconnect properly
Engine coolant temperature sensor
lead wire shorted
Correct
Engine coolant temperature sensor
circuit open
Correct or replace
Throttle position sensor open or
shorted circuits
Correct or replace
Deterioration of crankshaft position
sensor
Replace
Crankshaft position sensor circuit
open or shorted
Correct or replace
Vehicle speed sensor circuit open
Correct or replace
Manifold absolute pressure sensor
circuit open or shorted
Correct or replace
Intake air temperature sensor circuit
open or shorted
Correct or replace
Fuel injector circuit open or shorted
Correct or replace
PCM driver transistor defective
Replace PCM
Malfunctioning of PCM RAM
(Random Access Memory) or ROM
(Read Only Memory)
Replace PCM
ENGINE MECHANICAL (6VE1 3.5L)
6A–19
Cylinder Head Cover LH
Removal
1. Disconnect battery ground cable.
2. Remove engine cover from the dowels on the
common chamber.
060RY022
Legend
(1) Ignition Coil Connector
(2) Bolt
(3) Ignition Coil Assemblies
F06RY001
3. Disconnect positive crankcase ventilation hose.
4. Remove ground cable fixing bolt on cylinder head
cover.
5. Ignition coil connector and ignition coil.
B Disconnect the three connectors from the ignition
coils.
6. Disconnect fuel injector harness connector then
remove fuel injector harness bracket bolt.
7. Remove eight fixing bolts, then the cylinder head
cover.
B Remove harness bracket bolt on cylinder head
cover.
B Remove fixing bolts on ignition coils.
010RW001
NOTE: Where do you refer the tech in case of bolt
removal difficulties.
6A–20
ENGINE MECHANICAL (6VE1 3.5L)
Installation
1. Install cylinder head cover.
B Clean the sealing surface of cylinder head and
cylinder head cover to remove oil and sealing
materials completely.
B Apply sealant (TB-1207B or equivalent) of bead
diameter 2-3 mm at eight place of arched area of
camshaft bearing cap on front and rear sides.
B The cylinder head cover must be installed with in 5
minutes after sealant application to prevent
hardening of sealant.
B Tighten bolts to the specified torque.
Torque : 9 N·m (78 lb in)
060RY022
Legend
(1) Ignition Coil Connector
(2) Bolt
(3) Ignition Coil Assembly
CAUTION: Ignition coil assembly #6 is different
from ignition coil assembly from #1 to #5. Ignition
coil assembly #6 is short type. So, note it when
installing ignition coil assembly of #6.
010RW008
2. Install fuel injection harness bracket and tighten bolt
to the specified torque.
Torque : 9 N·m (78 lb in)
3. Connect ignition coil connector and ignition coil, then
tighten bolt to the specified torque.
Torque : 4 N·m (35 lb in)
060RY00002
Legend
(1) Long Type Ignition Coil Assemblies (# 1 ∼ # 5)
(2) Short Type Ignition Coil Assembly (# 6)
4. Connect ground cable and tighten bolts to the
specified torque.
Torque : 9 N·m (78 lb in)
5. Install positive crankcase ventilation hose.
6. Install engine cover mating with the dowels.
ENGINE MECHANICAL (6VE1 3.5L)
6A–21
Cylinder Head Cover RH
Removal
Installation
1. Disconnect battery ground cable.
2. Remove engine cover from the dowele on the
common chamber.
1. Install cylinder head cover.
B Clean the sealing surface of cylinder head and
cylinder head cover to remove oil and sealing
materials completely.
Apply sealant (TB-1207B or equivalent) bead
(diameter 2-3 mm) at eight places of arched areas
of camshaft bracket on front and rear sides.
B The cylinder head cover must be installed within 5
minutes after sealant application to prevent
premature hardening of sealant.
B Tighten bolts to the specified torque.
Torque : 9 N·m (78 lb in)
F06RY001
3. Disconnect ventilation hose from cylinder head cover.
4. Disconnect three ignition coil connectors from ignition
coils and remove harness bracket bolts on cylinder
head cover then remove ignition coil fixing bolts on
ignition coils and remove ignition coils.
5. Disconnect fuel injector harness connector then
remove fuel injector harness bracket bolt.
6. Remove eight fixing bolts then the cylinder head
cover.
014RW019
2. Tighten fuel injector harness bracket bolts to
specified torque then reconnect fuel injector harness
connector.
Torque : 7.8 N·m (69 lb in)
3. Connect ignition coil connector and tighten ignition
coil fixing bolts to specified torque.
Torque : 4 N·m (35 lb in)
4. Connect ventilation hose to cylinder head.
5. Install engine cover mating with the dowels.
010RW002
6A–22
ENGINE MECHANICAL (6VE1 3.5L)
Common Chamber
9. Remove two bolts from common chamber rear side
to remove fuel hose bracket.
10. Remove common chamber four bolts and four nuts
then remove the common chamber.
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner duct assembly.
013RY00001
Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Air Flow Sensor
3. Disconnect vacuum booster hose from common
chamber.
4. Disconnect connector from manifold absolute
pressure sensor, Ion sensing module, throttle
position sensor, solenoid valve, electric vacuum
sensing valve, and EGR valve.
5. Disconnect vacuum hose on canister VSV and
positive crankcase ventilation hose, fuel rail
assembly with pressure control valve bracket.
6. Remove ventilation hose from throttle valve and
intake duct and remove water hose.
7. Remove the four throttle body fixing bolts.
8. Remove exhaust gas recirculation valve assembly
fixing bolt and nut on common chamber and remove
EGR valve assembly.
025RY002
Legend
(1) Common Chamber
(2) Throttle Valve Assembly
(3) Bolt
Installation
1. Install common chamber and tighten bolts and nuts to
the specified torque.
Torque :
Bolt : 25 N·m (18 lb ft)
Nut : 25 N·m (18 lb ft)
2. Install fuel hose bracket and tighten bolts to specified
torque.
Torque : 10 N·m (87 lb in)
3. Install exhaust gas recirculation valve assembly and
tighten bolt and nut to the specified torque.
Torque : 25 N·m (18 lb ft)
4. Install throttle body and tighten bolts to the specified
torque.
Torque : 25 N·m (18 lb ft)
5. Install ventilating hose to throttle valve and intake
duct.
6. Connect vacuum hoses on canister VSV and positive
crankcase ventilation hose. Tighten bolts for fuel rail
assembly with pressure control valve bracket.
Torque : 25 N·m (18 lb ft)
ENGINE MECHANICAL (6VE1 3.5L)
7. Connect each connector.
8. Connect vacuum booster hose.
9. Connect the Ion sensing module connectors as
shown in the illustration.
060RY00111
Legend
(1) Green Connector
(2) Blue Connector
(3) Identification Mark (6VE1 Engine Only)
10. Install air cleaner duct assembly.
013RY00001
Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Mass Air Flow Sensor
6A–23
6A–24
ENGINE MECHANICAL (6VE1 3.5L)
Exhaust Manifold LH
Removal
Installation
1. Disconnect battery ground cable.
2. Disconnect O2 sensor connector.
3. Remove exhaust front pipe three stud nuts from
exhaust side and two bolts from rear end of exhaust
front pipe.
1. Install exhaust manifold and tighten exhaust manifold
fixing nuts to the specified torque with new nuts.
Torque: 57 N·m (42 lb ft)
2. Install exhaust front pipe and tighten three stud nuts
and two bolts to the specified torque.
Torque :
Stud nuts: 67 N·m (49 lb ft)
Bolts: 43 N·m (32 lb ft)
150R100011
Legend
(1) Exhaust Front Pipe LH
(2) O2 Sensor
4. Remove exhaust manifold eight fixing nuts and
remove exhaust manifold from the engine.
150R100011
Legend
(1) O2 Sensor
(2) Exhaust Front Pipe LH
3. Reconnect O2 sensor connector.
ENGINE MECHANICAL (6VE1 3.5L)
6A–25
Exhaust Manifold RH
Removal
Installation
1. Disconnect battery ground cable.
2. Remove torsion bar. Refer to removal procedure in
Front Suspension section.
3. Remove exhaust front pipe three stud nuts and two
bolts then disconnect exhaust front pipe.
1. Install exhaust manifold and tighten nuts to the
specified torque.
Torque : 57 N·m (42 lb ft)
2. Install exhaust front pipe and tighten three stud nuts
and two bolts to the specified torque.
Torque:
Stud nuts: 67 N·m (49 lb ft)
Bolts: 43 N·m (32 lb ft)
3. Install the torsion bar and readjust the vehicle height.
Refer to installation and vehicle height adjustment
procedure for front suspension.
150R100013
Legend
(1) Exhaust Front Pipe RH
(2) O2 Sensor
4. Remove exhaust manifold eight fixing nuts then the
exhaust manifold.
6A–26
ENGINE MECHANICAL (6VE1 3.5L)
Crankshaft Pulley
Removal
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Idle Pulley
(8) Driver Belt
1. Disconnect battery ground cable.
2. Remove air cleaner assembly.
5. Remove cooling fan assembly four fixing nuts, then
the cooling fan assembly.
6. Remove crankshaft pulley assembly using J-8614-01
crankshaft holder, hold crankshaft pulley then
remove center bolt and pulley.
Installation
1. Install crankshaft pulley using J-8614-01 crankshaft
holder, hold the crankshaft pulley and tighten center
bolt to the specified torque.
Torque : 167 N·m (123 lb ft)
013RY00001
Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Air Flow Sensor
3. Remove radiator upper fan shroud from radiator.
4. Move serpentine belt tensioner to loose side using
wrench then remove serpentine belt.
850RW001
2. Install cooling fan assembly and tighten bolts/nuts to
the specified torque.
Torque : 22 N·m (16 lb ft) for fan pulley and fan
bracket.
Torque : 7.5 N·m (66.4 lb in) for fan and clutch
assembly.
3. Move serpentine belt tensioner to loose side using
wrench, then install serpentine belt to normal
position.
4. Install radiator upper fan shroud.
5. Install air cleaner assembly.
ENGINE MECHANICAL (6VE1 3.5L)
6A–27
Timing Belt
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner assembly.
3. Remove radiator upper fan shroud from radiator.
4. Move drive belt tensioner to loose side using wrench
then remove drive belt.
11. Remove right side timing belt cover then left side
timing belt cover.
12. Remove lower timing belt cover
13. Remove pusher.
CAUTION: The pusher prevents air from entering
the oil chamber. Its rod must always be facing
upward.
850RW001
014R100020
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Idle Pulley
(8) Drive Belt
5. Remove cooling fan assembly four nuts, then the
cooling fan assembly.
6. Remove cooling fan drive pulley assembly.
7. Remove idle pulley assembly.
8. Remove serpentine belt tensioner assembly.
9. Remove power steering pump assembly.
10. Remove crankshaft pulley assembly using J-8614-01
crankshaft holder, hold crankshaft pulley remove
center bolt, then the pulley.
Legend
(1) Up Side
(2) Down Side
(3) Direction For Installation
(4) Locking Pin
(5) Apply a force of 980 N (220 lb) when
compressing the pusher rod.
14. Remove timing belt.
CAUTION:
1. Do not bend or twist the belt, otherwise its core
could be damaged. The belt should not be bent at
a radius less than 30 mm (1.1811 in).
2. Do not allow oil or other chemical substances to
come in contact with the belt. They will shorten
the life.
3. Do not attempt to pry or stretch the belt with a
screw driver or any other tool during installation.
4. Store timing belt in a cool and dark place. Never
expose the belt direct sunlight or heat.
6A–28
ENGINE MECHANICAL (6VE1 3.5L)
Installation
NOTE: For correct belt installation, the letter on the belt
must be able to be read as viewed from the front of the
vehicle.
1. Install timing belt.
1. Align groove of crankshaft timing pulley (2) with
mark on oil pump (1).
Align the mark on the crankshaft timing pulley (3)
with alignment mark (white dotted line) on the timing belt (4).
Secure the belt with a double clip or equivalent
clip.
NOTE: When timing marks are aligned, No.2 piston will
be on Top Dead Center.
014RW005
Legend
(1) Crankshaft Timing Pulley
(2) RH Bank Camshaft Drive Gear Pulley
(3) Water Pump Pulley
(4) Idle Pulley
(5) LH Bank Camshaft Drive Gear Pulley
(6) Tension Pulley
(7) Alignment Mark on Oil Pump.
(8) Alignment Mark on Timing Belt
014RW003
Legend
(1) Alignment Mark on Oil Pump
(2) Groove on Crankshaft Timing Pulley
(3) Alignment Mark on Crankshaft Timing Pulley
(4) Alignment Mark on Timing Belt
2. Align the alignment mark on the RH bank
camshaft drive pulley (2) to the alignment mark of
the cylinder head cover RH (3).
The camshaft pulley is not 1:1 with the camshafts.
It is necessary to rotate the camshaft pulley until
the camshaft lobes are in the position as shown
in the diagram on page 6A–34.
The camshaft pulley alignment mark should also
align with alignment mark on the cylinder head
cover.
It may require up to four revolutions of the
camshaft pulley to achieve alignment of all marks.
014RW006
Legend
(1) Timing Belt
(2) Engine Rotation Direction
(3) Cylinder Head Side
ENGINE MECHANICAL (6VE1 3.5L)
3. Align the alignment mark (white line) on the timing
belt (1) with alignment mark on the RH bank
camshaft drive pulley (2) (on the left side as
viewed from the front of the vehicle) and put the
timing belt on the camshaft drive pulley.
Secure the belt with a double clip or equivalent
clip.
6A–29
NOTE: It is recommended for easy installation that the
belt be secured with a double clip or equivalent clips after
it is installed to each pulley.
014RW00005
014RW00004
Legend
(1) Alignment Mark on Timing Belt (White line).
(2) Alignment Mark on Camshaft Drive Pulley.
(3) Alignment Mark on Cylinder Head Cover RH.
4. Align the alignment mark on the LH bank
camshaft drive pulley (2) to the alignment mark of
the cylinder head cover LH (3).
The camshaft pulley is not 1:1 with the camshafts.
It is necessary to rotate the camshaft pulley until
the camshaft lobes are in the position as shown
in the diagram on page 6A–34.
The camshaft pulley alignment mark should also
align with alignment mark on the cylinder head
cover.
It may require up to four revolutions of the camshaft pulley to achieve alignment of all marks.
5. Align the alignment mark (white line) on the timing
belt (1) with the alignment mark on the LH bank
camshaft drive pulley (2).
When aligning the timing marks, use a wrench to
turn the camshaft drive pulley, then set the timing
mark between timing belt and camshaft drive
pulley and put the timing belt on the camshaft
drive pulley.
Secure the belt with a double clip or equivalent
clip.
Legend
(1) Alignment Mark on Timing Belt (White line).
(2) Alignment Mark on Camshaft Drive Pulley.
(3) Alignment Mark on Cylinder Head Cover LH.
6. Install crankshaft pulley temporarily and tighten
center bolt by hand (do not use a wrench).
Turn the crankshaft pulley clockwise to give some
belt slack between the crankshaft timing pulley
and the RH bank camshaft drive pulley.
2. Install pusher and tighten bolt to the specified torque.
Torque : 25 N·m (2.5 kg·m/18 lb ft)
1. Install the pusher while pushing the tension pulley
to the belt.
2. Pull out pin from the pusher.
NOTE: When reusing the pusher, press the pusher with
approximately 100Kg to retract the rod, and insert a pin
(1.4 mm (0.055 in) piano wire).
6A–30
ENGINE MECHANICAL (6VE1 3.5L)
3. Install timing belt cover.
Remove crankshaft pulley that was installed in step
1 item 5.
Tighten bolts to the specified torque.
Torque: 19 N·m (14 lb ft)
014R100020
Legend
(1) Up Side
(2) Down Side
(3) Direction for Installation
(4) Locking Pin
(5) Apply a force of 980 N (220 lb) when
compressing the pusher rod.
020RW004
After release the push rod from the locking pin,
the rod projection is approximate 5 mm (0.1969
in).
Legend
(1) Timing Belt Cover RH
(2) Timing Belt Cover LH
(3) Timing Belt Cover Lower
014R100032
Legend
(1) Tensioner Pulley
(2) Crankshaft Pulley Rotation Direction
(3) Crankshaft Pulley
(4) Pusher Assembly
3. Remove double clips or equivalent clips from
timing belt pulleys.
Turn the crankshaft pulley by six turns and check
for timing mark alignment.
020RW003
Legend
(1) Timing Belt Cover
(2) Rubber Bushing
(3) Sealing Rubber
(4) Cylinder Body
4. Install crankshaft pulley using J-8614-01, hold the
crankshaft pulley and tighten center bolt to the
specified torque.
Torque : 167 N·m (123 lb ft)
ENGINE MECHANICAL (6VE1 3.5L)
5. Install fan pulley bracket and tighten fixing bolts to the
specified torque.
Torque : 22 N·m (16 lb ft)
6. Install power steering pump assembly and tighten to
the specified torque.
Torque :
M8 bolt : 22 N·m (16 lb ft)
M10 bolt : 46 N·m (34 lb ft)
7. Install cooling fan assembly and tighten bolts/nuts to
the specified torque.
Torque : 22 N·m (16 lb ft) for fan pulley and fan
bracket.
Torque : 7.5 N·m (66.4 lb in) for fan and clutch
assembly.
8. Move drive belt tensioner to loose side using wrench,
then install drive belt to normal position.
850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Idle Pulley
(8) Drive Belt
9. Install radiator upper fan shroud.
10. Install air cleaner assembly.
6A–31
6A–32
ENGINE MECHANICAL (6VE1 3.5L)
Camshaft
9. Remove three fixing bolts from camshaft drive gear
retainer, then camshaft drive gear assembly.
Removal
1. Disconnect battery ground cable.
2. Remove crankshaft pulley.
B Refer to removal procedure for Crankshaft Pulley in
this manual.
3. Remove timing belt.
B Refer to removal procedure for Timing Belt in this
manual.
4. Remove cylinder head cover LH.
B Refer to removal procedure for Cylinder Head
Cover LH in this manual.
5. Remove cylinder head cover RH.
B Refer to removal procedure for Cylinder Head
Cover RH in this manual.
6. Remove twenty fixing bolts from inlet and exhaust
camshaft bearing cap on one side bank, then
camshaft bearing cap.
014RW026
Legend
(1) Right Bank
(2) Left Bank
(3) Timing Mark on Retainer
014RW027
7. Remove camshaft assembly.
8. Remove fixing bolt for camshaft drive gear pulley.
ENGINE MECHANICAL (6VE1 3.5L)
6A–33
Installation
1. Install camshaft drive gear assembly and tighten
three bolts to the specified torque.
Torque : 10 N·m (87 lb in)
2. Tighten bolt for camshaft drive gear assembly pulley
to the specified torque.
Torque : 98 N·m (72 lb ft)
3. Tighten sub gear setting bolt.
1. Use J-42686 to turn sub gear to right direction
until it aligns with the M5 bolt hole between
camshaft driven gear and sub gear.
2. Tighten the M5 bolt to a suitable torque to prevent
the sub gear from moving.
014RW020
Legend
(1) Intake Camshaft Timing Gear for Right Bank
(2) Intake Camshaft Timing Gear for Left Bank
(3) Exhaust Camshaft Timing Gear
(4) Discrimination Mark
(LI: Left bank intake, RI: Right bank intake)
(LE: Left bank exhaust, RE: Right bank
exhaust)
014RW041
4. Install camshaft assembly and camshaft bearing
caps, tighten twenty bolts on one side bank to the
specified torque.
1. Apply engine oil to camshaft journal and bearing
surface of camshaft bearing caps.
2.
Align timing mark on intake camshaft (one dot for
right bank, two dot for left bank) and exhaust
camshaft (one dots for right bank, two dots for left
bank) to timing mark on camshaft drive gear (one
dot).
014RW023
Legend
(1) Right Bank Camshaft Drive Gear
(2) Left Bank Camshaft Drive Gear
(3) Timing Mark on Drive Gear
(4) Dowel Pin
6A–34
ENGINE MECHANICAL (6VE1 3.5L)
014RW024
(3) Alignment Mark on Camshaft Drive Gear
(4) Alignment Mark on Camshaft
(5) Alignment Mark on Retainer
Legend
(1) Right Bank
(2) Left Bank
3. Tighten twenty bolts on numerical order an one
side bank as shown in the illustration.
Torque : 10 N·m (87 lb in)
014RW031
5. Install cylinder head cover RH.
B Refer to installation procedure for CYLINDER
HEAD COVER RH in this manual.
6. Install cylinder head cover LH.
B Refer to installation procedure for CYLINDER
HEAD COVER LH in this manual.
7. Install timing belt.
B Refer to installation procedure for TIMING BELT in
this manual.
8. Install crankshaft pulley.
B Refer to installation procedure for CRANKSHAFT
PULLEY in this manual.
ENGINE MECHANICAL (6VE1 3.5L)
6A–35
Cylinder Head
Removal
Installation
1. Remove engine hood.
2. Disconnect battery ground cable.
3. Drain radiator coolant.
4. Drain engine oil.
5. Remove crankshaft pulley.
B Refer to removal procedure for Crankshaft Pulley in
this manual.
6. Remove timing belt.
B Refer to removal procedure for Timing Belt in this
manual.
7. Remove cylinder head cover LH.
B Refer to removal procedure for Cylinder Head
Cover LH in this manual.
8. Remove cylinder head cover RH.
B Refer to removal procedure for Cylinder Head
Cover RH in this manual.
9. Remove common chamber.
B Refer to removal procedure for Common Chamber
in this manual.
10. Remove cylinder head assembly.
1. Loosen head bolts in reverse of tightening
sequence.
1. Install cylinder head assembly to cylinder block.
A. Put cylinder head gasket on the cylinder block.
NOTE: There is discrimination mark “R” for right bank
and “L” for left bank on the cylinder head gasket as shown
in the illustration.
Do not reuse cylinder head gasket.
2. Remove cylinder head assembly.
011RW005
B. Align dowel pin hole to dowel pin on the cylinder
block.
C. Position cylinder head on the cylinder block.
D. Tighten two bolts temporarily by hand to prevent
the cylinder head assembly from moving.
E. Using J-24239-01 cylinder head bolt wrench,
tighten bolts in numerical order as shown in the
illustration to the specified torque.
014RW028
Legend
(1) Cylinder Head
(2) Cylinder Head Bolt
(3) Camshaft
6A–36
ENGINE MECHANICAL (6VE1 3.5L)
NOTE: Do not reuse cylinder head bolts.
Do not apply any lubricant to the cylinder head bolts.
Torque :
Temporary : 29 N·m (22 lb ft)
Final : 64 N·m (47 lb ft)
014RW029
2. Install common chamber.
B Refer to installation procedure for Common
Chamber in this manual.
3. Install cylinder head cover RH.
B Refer to installation procedure for Cylinder Head
Cover RH in this manual.
4. Install cylinder head cover LH.
B Refer to installation procedure for Cylinder Head
Cover LH in this manual.
5. Install timing belt.
B Refer to installation procedure for Timing Belt in this
manual.
6. Install crankshaft pulley.
B Refer to installation procedure for Crankshaft
Pulley in this manual.
ENGINE MECHANICAL (6VE1 3.5L)
6A–37
Valve Stem Oil Controller , Valve Spring and Valve Guide
Removal
Installation
1. Disconnect battery ground cable.
2. Drain engine oil.
B Drain engine coolant.
3. Remove cylinder head assembly.
B Refer to removal procedure for Cylinder Head in
this manual.
4. Remove camshaft.
B Refer to removal procedure for Camshaft in this
manual.
5. Remove tappets with shim.
1. Install valve guide using J-42899 valve guide installer.
2. Install oil controller using J-38537 oil controller
installer.
3. Install lower valve spring seat, valve spring and upper
valve spring seat then put split collars on the upper
spring seat, using J-8062 valve spring compressor
and J-42898 valve spring compressor adapter to
install the split collars.
NOTE: Do not damage shim surface.
6. Remove valve springs using J-8062 valve spring
compressor and J-42898 valve spring compressor
adapter then remove upper valve spring seat and
lower seat.
014RW042
014RW042
7. Remove oil controller using J-37281 oil controller
remover, remove each valve stem oil controller.
8. Remove valve guide using J-37985 valve guide
replacer.
4. Install tappet with shim.
5. Install camshaft assembly.
B Refer to installation procedure for Camshaft in this
manual.
6. Install cylinder head assembly.
B Refer to installation procedure for Cylinder Head in
this manual.
7. Fill engine oil until full level.
8. Fill engine coolant.
6A–38
ENGINE MECHANICAL (6VE1 3.5L)
Piston, Piston Ring and Connecting Rod
Removal
F06RW011
Legend
(1) Cylinder Head
(2) Crankcase with Oil Pan
(3) Oil Pipe
1. Remove cylinder head assembly.
B Refer to removal procedure for Cylinder Head in
this manual.
(4) Oil Strainer
(5) Oil Gallery
(6) Piston with Connecting Rod Assembly
2. Remove crankcase with oil pan.
B Refer to removal procedure for Oil Pan and
Crankcase in this manual.
ENGINE MECHANICAL (6VE1 3.5L)
6A–39
3. Remove oil strainer fixing bolts, remove oil strainer
assembly with O-ring.
015RW003
050RW002
Legend
(1) Oil Pump
(2) Oil Strainer
(3) Oil Gallery
(4) From Oil Filter
(5) To Oil Filter
4. Remove three fixing bolts, oil pipe with O-ring.
5. Remove eight fixing bolts, oil gallery.
6. Remove piston with connecting rod assembly.
(before removing the bearing cap, remove carbon on
the top of cylinder bore and push piston with
connecting rod out from the top of cylinder bore.)
Legend
(1) Piston Front Mark
(2) Piston Grade
(3) Connecting Rod Front Mark
2. Install oil gallery and tighten the bolts in two steps, in
the order shown in illustration.
Torque :
1st step : 29 N·m (22 lb ft)
2nd step : 55°–65°
Installation
1. Install piston with connecting rod assembly.
B Apply engine oil to cylinder bore, connecting rod
bearing and crank pin.
When installing the piston, its front mark must face
the engine front side.
B The bearing cap number must be the same as
connecting rod number.
B Apply engine oil to the thread and seating surface of
each nut.
B Tighten nuts to the specified torque.
Torque : 54 N·m (40 lb ft)
B After tightening the nuts, make sure that the
crankshaft rotates smoothly.
NOTE: Do not apply engine oil to the bearing back faces
and connecting rod bearing fitting surfaces.
051RS009
3. Install oil pipe with O-ring.
Torque : 10 N·m (87 lb in)
4. Install oil strainer assembly with O-ring.
Torque : 25 N·m (18 lb ft)
5. Install crankcase with oil pan.
B Refer to installation procedure for Oil Pan and
Crankcase in this manual.
6. Install cylinder head assembly.
B Refer to installation procedure for Cylinder Head in
this manual.
6A–40
ENGINE MECHANICAL (6VE1 3.5L)
Crankshaft and Main Bearings
Removal
F06RY002
Legend
(1) Engine Assembly
(2) Crankshaft Pulley
(3) Timing Belt Cover
(4) Timing Belt
(5) Crankcase with Oil Pan
(6) Oil Pipe
(7) Oil Strainer
1. Remove engine assembly.
B Refer to removal procedure for Engine Assembly in
this manual.
2. Remove timing belt.
B Refer to removal procedure for Timing Belt in this
manual.
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Oil Pump Assembly
Cylinder Body Side Bolt
Oil Gallery
Flywheel
Rear Oil Seal Retainer
Connecting Rod Cap
Crankshaft Main Bearing Cap
Crankshaft and Main Bearing
3. Remove oil pan and crankcase.
B Refer to removal procedure for Oil Pan and
Crankcase in this manual.
4. Remove oil pipe with O-ring.
5. Remove oil strainer assembly with O-ring.
ENGINE MECHANICAL (6VE1 3.5L)
6A–41
6. Remove oil pump assembly.
B Refer to removal procedure for Oil Pump in this
manual.
7. Remove cylinder body side bolts.
8. Remove oil gallery.
9. Remove flywheel.
10. Remove rear oil seal retainer.
B Refer to removal procedure for Rear Oil Seal in this
manual.
11. Remove connecting rod caps.
12. Remove crankshaft main bearing caps.
13. Remove crankshaft and main bearings.
Installation
1. Install crankshaft and main bearings.
B Install main bearing in the cylinder block and main
bearing cap respectively.
Apply new engine oil to upper and lower main
bearings.
NOTE:
B
B
B
B
B
B
Do not apply engine oil to the bearing back faces.
Make sure that main bearings are in correct position.
Install crankshaft with care.
Apply engine oil to the thrust washer.
Install thrust washer on No.3 journal.
Oil grooves in thrust washer must face the
crankshaft.
015RS013
2. Install crankshaft main bearing caps.
B Apply engine oil to the thread and seating surface of
each bearing cap fixing bolt.
NOTE:
B Do not apply engine oil to the bearing back faces.
B Install bearing caps, starting with cylinder block front
side.
B Tighten main bearing fixing bolts to the specified
torque.
Torque : 39 N·m (29 lb ft)
B After tightening the bolts, make sure that the
crankshaft rotates smoothly.
3. Install connecting rod caps.
B The cap number must be same as connecting rod
number.
B Apply engine oil to the thread and seating surface of
each nut.
B Tighten nuts to the specified torque.
Torque : 54 N·m (40 lb ft)
B After tightening the nuts, make sure that the
crankshaft rotates smoothly.
4. Install rear oil seal retainer.
B Remove oil on cylinder block and retainer fitting
surface.
B Apply sealant (TB1207B or equivalent) to retainer
fitting surface as shown in illustration.
015RS012
B The oil seal retainer must be installed within 5
minutes after sealant application to prevent
premature hardening of sealant.
6A–42
ENGINE MECHANICAL (6VE1 3.5L)
015RW002
Legend
(1) Around Bolt Holes
(2) Around Dowel Pin
B Apply engine oil to oil seal lip and align a dowel pin
hole in the cylinder block with that in the retainer.
B Tighten retainer fixing bolts to the specified torque.
Torque : 18 N·m (13 lb ft)
015RS018
6. Install oil gallery.
B Clean contact surface of oil gallery and main
bearing cap.
Apply engine oil to oil gallery fixing bolts and tighten
the bolts in two steps, in the order shown.
Torque :
1st step : 29 N·m (22 lb ft)
2nd step : 55°–65°
7. Install cylinder body side bolts and tighten bolts in
order to the specified torque.
Torque : 39 N·m (29 lb ft)
NOTE: Do not apply the oil to the bolts.
015RW001
5. Install flywheel.
B Clean tapped holes in the crankshaft.
B Remove oil on crankshaft and flywheel fitting
surface.
NOTE:
B Do not reuse the bolts.
B Do not apply oil or thread lock to the bolts.
B Tighten fixing bolts to the specified torque.
Torque : 54 N·m (40 lb ft)
012RS007
8. Install oil pump assembly.
B Remove oil on cylinder block and oil pump mounting
surface.
B Apply sealant (TB1207B or equivalent) to the oil
pump mounting surface.
B The oil pump assembly must be installed within 5
minutes after sealant application to prevent
premature hardening of sealant.
ENGINE MECHANICAL (6VE1 3.5L)
B Apply engine oil to oil seal lip.
B Install oil pump in the cylinder block and tighten
fixing bolts to the specified torque.
Torque : 25 N·m (18 lb ft)
6A–43
B Properly apply a 4.5 mm (0.7 in) wide bead of
sealant (TB1207C or equivalent) to the crankcase
mounting surface. The bead must be continuous.
B The crankcase must be installed within 5 minutes
after sealant application to prevent premature
hardening of sealant.
B Tighten fixing bolts to the specified torque.
Torque : 10 N·m (87 lb in)
051RW002
Legend
(1) Around Bolt Holes
(2) Around Dowel Pin
013RW010
051RW001
9. Install oil strainer with O-ring, tighten to the specified
torque.
Torque : 25 N·m (18 lb ft)
10. Install oil pipe with O-ring, tighten fixing bolts to the
specified torque.
Torque : 25 N·m (18 lb ft)
11. Install crankcase.
B Remove oil on crankcase mounting surface and dry
the surface.
013RW004
12. Install oil pan
B Remove oil on oil pan mounting surface and dry the
surface.
B Properly apply a 4.5 mm (0.7 in) wide bead of
sealant (TB1207C or equivalent) to the oil pan
mounting surface. The bead must be continuous.
B The oil pan must be installed within 5 minutes after
sealant application to prevent premature hardening
of sealant.
6A–44
ENGINE MECHANICAL (6VE1 3.5L)
B Tighten fixing bolts to the specified torque.
Torque : 25 N·m (18 lb ft)
013RW003
013RW002
13. Install timing belt.
B Refer to installation procedure for Timing Belt in this
manual.
14. Install engine assembly.
B Refer to installation procedure for Engine
Assembly in this manual.
ENGINE MECHANICAL (6VE1 3.5L)
6A–45
Rear Oil Seal
Removal
1. Remove transmission assembly.
B See Transmission section in this manual.
2. Remove flywheel.
3. Remove rear oil seal using a seal remover.
NOTE: Take care not to damage the crankshaft or oil seal
retainer when removing oil seal.
Installation
1. Apply engine oil to oil seal lip and install oil seal using
J-39201.
015RS018
3. Install transmission.
B See Transmission section in this manual.
CAUTION: When assembling the engine and
transmission, confirm that dowels have been
mounted in the specified positions at the engine
side.
NOTE: Take care that dowel positions are different
between the manual transmission and the automatic
transmission.
Otherwise, the transmission may be damaged.
015RS017
2. Install flywheel.
B Clean tapped holes in the crankshaft.
B Remove oil on the crankshaft and flywheel
mounting surface.
B Tighten fixing bolts to the specified torque.
NOTE: Do not reuse the bolts and do not apply oil or
thread lock to the bolts.
Torque : 54 N·m (40 lb ft)
012RS009
6A–46
ENGINE MECHANICAL (6VE1 3.5L)
Engine Assembly
Removal
035R200001
1. Disconnect battery ground and positive cable.
2. Remove battery.
3. Make alignment mark on the engine hood and hinges
before removal in order to return the hood to original
position exactly.
4. Remove engine hood.
5. Drain radiator coolant.
6. Disconnect Ion sensing module harness connectors,
and manifold absolute pressure sensor harness
connectors from sensor on common chamber.
7. Disconnect throttle position sensor harness
connectors from throttle body.
8. Disconnect air duct with air cleaner cover.
9. Remove air cleaner assembly.
10. Disconnect canister vacuum hose.
11. Disconnect vacuum booster hose.
12. Disconnect three engine harness connectors.
13. Disconnect harness connector to transmission (left
front side of engine compartment), disconnect shift
on the fly harness connector from front side of front
axle and remove transmission harness bracket from
engine left side.
14. Disconnect ground cable between engine and frame.
15. Disconnect bonding cable connector on the back of
right dash panel.
16. Disconnect bonding cable terminal on the left bank.
17. Disconnect starter harness connector from starter.
18. Disconnect generator harness connector from
generator.
19. Disconnect coolant reserve tank hose from radiator.
20. Remove radiator upper and lower hoses.
21. Remove upper fan shroud.
22. Remove cooling fan assembly four fixing nuts, then
the cooling fan assembly.
23. Move drive belt tensioner to loose side using wrench
then remove drive belt.
24. Remove power steering pump fixing bolts, then
power steering pump. Place the power steering pump
along with piping on the body side.
25. Remove air conditioning compressor fixing bolts from
bracket and place the compressor along with piping
on the body side.
26. Remove four O2 sensor harness connectors (two
each bank) from exhaust front pipe.
27. Remove three exhaust pipe fixing nuts from each
bank.
28. Remove two exhaust pipe fixing nuts from each
exhaust pipe, then