Isuzu 1999 RODEO Workshop Manual
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Isuzu 1999 RODEO Workshop Manual

Rodeo 1999
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Table of Contents

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WORKSHOP MANUAL
RODEO
(UE)
FOREWORD
This manual includes special notes, important points, service
data, precautions, etc. that are needed for the maintenance,
adjustments, service, removal and installation of vehicle
components.
All information, illustrations and specifications contained in
this manual are based on the latest product information
available at the time of publication.
All rights are reserved to make changes at any time without
notice.
Arrangement of the material is shown in the table of contents
on the right-hand side of this page. A black spot on the first
page of each section can be seen on the edge of the book
below each section title. These point to a more detailed table
of contents preceding each section.
This manual applies to 1999 models.
SECTION
TABLE OF CONTENTS
Click
GENERAL INFORMATION
0A
General Information
0B
Maintenance and Lubrication
HEATING, VENTILATION AND AIR CONDITIONING
1A
HVAC System
STEERING
2A
Power-Assisted System
SUSPENSION
3C
Front Suspension
3D
Rear Suspension
3E
Wheel and Tire System
DRIVELINE/AXLE
4A1
Differential
4A2
Differential
4B
Driveline Control System
4C
Drive Shaft System
4D
Transfer Case
BRAKE
5A
Brake Control System
5B
Anti-Lock Brake System
5C
Power-Assisted Brake System
5D1
Parking Brake System (4x4 model)
5D2
Parking Brake System (4x2 model)
HEC
6VD1
ENGINE
6A
6A
Engine Mechanical
6B
6B
Engine Cooling
6C
6C
Engine Fuel
6D1
6D1
Engine Electrical
6D2
6D2
Ignition System
6D3
6D3
Starting and Charging System
6E
6E
Driveability and Emissions
6F
6F
Engine Exhaust
6G
6G
Engine Lubrication
6H
6H
Engine Speed Control System
6J
6J
Induction
TRANSMISSION
7A
Automatic Transmission
7A1
Transmission Control System
7B
Manual Transmission
7C
Clutch
BODY AND ACCESSORIES
8A
Lighting System
8B
Wiper/Washer System
8C
Entertainment
8D
Wiring System
8E
Meter and Gauge
8F
Body Structure
8G
Seats
8H
Security and Locks
8I
Sun Roof/Convertible Top
8J
Exterior/Interior Trim
RESTRAINTS
9A
Seat Belt System
9J
Supplemental Restraint System (Air Bag System)
9J1
Restraint Control System
CONTROL SYSTEM
10A
Cruise Control System
HOME

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Summary of Contents for Isuzu 1999 RODEO

  • Page 1 TABLE OF CONTENTS Click GENERAL INFORMATION General Information Maintenance and Lubrication HEATING, VENTILATION AND AIR CONDITIONING WORKSHOP MANUAL HVAC System STEERING Power-Assisted System RODEO SUSPENSION Front Suspension (UE) Rear Suspension Wheel and Tire System DRIVELINE/AXLE Differential Differential Driveline Control System...

  • Page 2: Table Of Contents

    1. “AIR BAG” warning light on the instrument efficient and reliable performance of service repairs. cluster. 6. Use genuine Isuzu parts. 2. A Code “J” for fifth digit of Vehicle Identification 7. Used cotter pins, plastic clips, gaskets, O–rings, oil Number.

  • Page 3: Illustration Arrows

    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 f Ambient/Clean air flow Front of vehicle f Cool air flow f Gas other than ambient air Up Side f Hot air flow f Ambient air mixed...

  • Page 4: Identification

    GENERAL INFORMATION 0A–3 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 F00RX002...
  • Page 5 0A–4 GENERAL INFORMATION Engine Serial Number Transmission Serial Number f 6VD1 Engine Manual : Stamped on the left side of the transmission intermediate plate. The gasoline engine serial number is stamped on the left rear lower area of the cylinder block above the starter. 220RS025 Automatic : Stamped on the identification plate, located F06RW001...

  • Page 6: Theft Prevention Standard

    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. INDICATION Reference COMPONENT...
  • Page 7 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 (6VD1) 901RW080 Engine (X22SE) 035RW025...
  • Page 8 GENERAL INFORMATION 0A–7 Manual Transmission (TREMEC T5) 240RW020 Manual Transmission (MUA) 901RW081...
  • Page 9 0A–8 GENERAL INFORMATION Automatic Transmission (THM) 901RW082–1 Body 604RW023...
  • Page 10 GENERAL INFORMATION 0A–9 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.

  • Page 11: Lifting Instructions

    0A–10 GENERAL INFORMATION Lifting Instructions f When jacking or lifting a vehicle at the frame side CAUTION: rail or other prescribed lift points, be certain that f If a lifting device other than the original jack is lift pads do not contact the catalytic converter, used, it is most important that the device be brake pipes or cables, or fuel lines.
  • Page 12 GENERAL INFORMATION 0A–11 Supportable Point: Front Supportable Point: Rear f Position the chassis stands at the bottom of the frame f Position the chassis stands at the bottom of the frame sidemember, behind the front wheel. sidemember, just behind the trailing link bracket. 501RS003 501RW002 Lifting Point: Rear...

  • Page 13: Standard Bolts Torque Specifications

    0A–12 GENERAL INFORMATION Standard Bolts Torque Specifications The torque values given in the following table should be applied where a particular torque is not specified. Strength Class Strength Class Refined Non-Refined Bolt Identification Bolt Diameter Pitch (mm) M 6X1.0 4 – 8 N·m (3 – 6 lb ft) 5 –...

  • Page 14: Abbreviations Charts

    GENERAL INFORMATION 0A–13 Abbreviations Charts Exh — Exhaust ° F — Degrees Fahrenheit List of automotive abbreviations which may be used Fed — Federal (All States Except Calif.) in this manual FF — Front Drive Front Engine A — Ampere(s) FL —...

  • Page 15: Service Parts Identification Plate

    0A–14 GENERAL INFORMATION N — Newtons TVRS — Television & Radio Suppression NA — Natural Aspirated TVV — Thermal Vacuum Valve NC — Normally Closed TWC — Three Way Catalytic Converter N·M — Newton Meters 3 A/T — Three Speed Automatic Transmission/Transaxle NO —...

  • Page 16: Maintenance And Lubrication

    SECTION MAINTENANCE AND LUBRICATION 0B–1 RODEO GENERAL INFORMATION Maintenance and Lubrication CONTENTS Maintenance Schedule List ....0B–1 Lubricant Viscosity Chart ....
  • Page 17 MAINTENANCE AND LUBRICATION 0B–2 Mileage Only Items F00RX004...
  • Page 18 MAINTENANCE AND LUBRICATION 0B–3 Mileage/Months F00RX006...
  • Page 19 MAINTENANCE AND LUBRICATION 0B–4 F00RX013...

  • Page 20: Maintenance Schedule List

    MAINTENANCE AND LUBRICATION 0B–5 Explanation of Complete Vehicle Check and adjust the valve clearance every 60,000 miles (100,000 km). Maintenance Schedule Tire Rotation Brief explanations of the services listed in the preceding Maintenance Schedule are presented below. Rotate tires every 7,500 miles (12,000 km). Replace all questionable parts and note any necessary repairs as you perform these maintenance procedures.
  • Page 21 MAINTENANCE AND LUBRICATION 0B–6 Battery fluid level normal highway speeds means a wheel balancing is needed. Check tire pressure when the tires are “cold” Check fluid level in the battery. (include the spare). Maintain pressure as shown in the tire placard, which is Fluid Leak Check located on the driver’s door lock pillar.
  • Page 22 MAINTENANCE AND LUBRICATION 0B–7 crank. The starter should crank only when the clutch Accelerator Linkage Inspection pedal is fully depressed. Inspect for interference, binding, and damaged or missing parts. Check accelerator pedal for smooth Accelerator Linkage Lubrication operation and even pedal effort. Replace parts as Lubricate the accelerator pedal fulcrum pin with chassis needed.

  • Page 23: Recommended Fluids And Lubricants

    MAINTENANCE AND LUBRICATION 0B–8 Recommended Fluids and Lubricants USAGE FLUID/LUBRICANT Engine API SE, SF, SG, SH or ILSAC GF-1 Engine oil (See oil chart on the following page for proper viscosity) Mixture of water and good quality ethylene glycol base Engine coolant type antifreeze.

  • Page 24: Lubricant Viscosity Chart

    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...
  • Page 25 MAINTENANCE AND LUBRICATION 0B–10 Oil Viscosity Chart for Manual Transmission and Transfer Case (Except T5 Type) B00RW002 Oil Viscosity Chart for Front Axle B00RW003...

  • Page 26: Recommended Liquid Gasket

    Three Bond 1281 Three Bond Repairs T/M Water Base Three Bond 1141E Three Bond For Engine Repairs Three Bond 1104 Three Bond Belco Bond 4 Isuzu Solvent For Engine Repairs Belco Bond 401 Isuzu Belco Bond 402 Isuzu LOCTITE 515 Loctite Anaerobic...

  • Page 27: Recommended Thread Locking Agents

    MAINTENANCE AND LUBRICATION 0B–12 Recommended Thread Locking Agents LOCTITE Type LOCTITE Color LOCTITE 242 Blue LOCTITE 262 LOCTITE 271 Application Steps 1. Completely remove all lubricant and moisture from the bolts and the female-threaded surfaces of the parts to be joined. The surfaces must be perfectly dry.

  • Page 28: Maintenance Service Data

    MAINTENANCE AND LUBRICATION 0B–13 Maintenance Service Data Service Data and Specifications ENGINE Valve clearance (cold): only V6–3.2L ENG 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) CLUTCH Clutch pedal free play 5-15 mm (0.20-0.59 in)
  • Page 29 SECTION HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–1 RODEO HEATING, VENTILATION AND AIR CONDITIONING (HVAC) HVAC SYSTEMS CONTENTS Service Precaution ..... .

  • Page 30: Service Precaution

    When you replace a fastener, use ONLY the exact part number for that application. WARNING: THIS VEHICLE HAS A SUPPLEMENTAL ISUZU will call out those fasteners that require a RESTRAINT SYSTEM (SRS). REFER TO THE SRS replacement after removal. ISUZU will also call out...
  • Page 31 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–3 840RW002 Legend (5) Duct (W/O A/C) (1) Defroster Nozzle (6) Heater Unit (2) Ventilation Duct (7) Ventilation Lower Duct (3) Blower Assembly (8) Lap Vent Duct (4) Evaporator Assembly (With A/C) (9) Rear Heater Duct...

  • Page 32: Control Lever Assembly

    1A–4 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Control Lever Assembly The control lever assembly has some cables to control The fan control is used to control the amount of air sent the mode and temperature of the heater unit and the out by the resistor at four levels from “LOW”...
  • Page 33 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–5 C01RW001 Air Source Select Lever Temperature Control Knob The intake of outside air and the circulation of inside air When the temperature control knob is in the “COLD” are controlled by sliding this lever left or right. position, the air mix door closes to block the flow air to the heater core.

  • Page 34: Wiring Diagram

    1A–6 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Wiring Diagram D08RW060...

  • Page 35: Diagnosis

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–7 Diagnosis Heating Cycle diagnosis Condition Possible cause Correction No heating or insufficient heating. Blower motor does not run or runs Refer to “FAN CONTROL LEVER improperly. (FAN SWITCH) DIAGNOSIS”. Engine coolant temperature is low. Check engine coolant...
  • Page 36 1A–8 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Fan Control Lever (Fan Switch) Diagnosis Current flows to the blower motor through the heater relay (X-6) to activate the rotation of the blower motor by turning “ON” the fan control knob (fan switch). Blower motor speed is controlled in stages by the resistor, by operating the switch from “LOW”...
  • Page 37 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–9 Chart “A” Blower Motor Does Not Run Step Action Is relay (X-6) OK? Go to Step 2 Replace Is fuse EB-4 (20A) OK? Go to Step 3 Replace Is resistor OK? Go to Step 4 Replace Is fan control lever OK? Replace control...
  • Page 38 1A–10 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Chart “E” Blower Motor Does Not Run At High Position Step Action Is resistor OK? Go to Step 2 Replace Is fan control lever (Fan Switch) OK? Open circuit between Chassis side connector terminal No.

  • Page 39: Individual Inspection

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–11 Individual Inspection Fan Control Lever (Fan Switch) 1. Check for continuity between the terminals of the fan Blower Motor switch. 1. Disconnect the blower motor (B-5) connector from the blower motor. 2. Connect the battery positive terminal to the No. 1 terminal of the blower motor and the negative to the No.
  • Page 40 1A–12 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 2. Check for continuity between the heater relay (X-6) terminals. 825RS179...

  • Page 41: Heater Unit 1A-13

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–13 Heater Unit Heater Unit and Associated Parts 840RW003 Legend (6) Driver Lap Vent Duct (1) Instrument Panel Assembly (7) Evaporator Assembly (A/C only) (2) Cross Beam Assembly (8) Duct (3) Instrument Panel Bracket (9) Heater Unit Assembly (4) Ventilation Lower Duct (10) Heater Hose...

  • Page 42: Removal

    1A–14 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Installation 2. Adjust the control cables. f Refer to Control Lever Assembly in this section. To install, follow the removal steps in the reverse order, 3. When installing the heater unit, defroster nozzle and noting the following points: center vent duct, be sure that the proper seal is made, 1.

  • Page 43: Inspection

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–15 4. Remove heater unit. 9. Pull out the mode door while raising up the catch of f Refer to Heater Unit in this section. the door lever. 5. Remove duct. 6. Remove case (Mode control) and do not remove link unit at this step.

  • Page 44: Heater Mode Control Link Unit 1A-16

    1A–16 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Heater Mode Control Link Unit Disassembled View 860RW002 Legend (4) Clip (1) Case (Mode Control) (5) Door Lever (2) Heater Unit (6) Rod (3) Mode Sub-lever (7) Washer and Mode Main Lever Removal 1.

  • Page 45: Removal

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–17 9. Pull out the door lever while raising up the catch of the Installation door lever. To install, follow the remove steps in the reverse order, 10. Remove clip. noting the following points: 1.

  • Page 46: Removal

    1A–18 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Installation 1. Apply grease to the sub-lever and to the abrasive surface of the heater unit. To install, follow the removal steps in the reverse order, 2. After installing the link unit, check to see if the link unit noting the following points: operates correctly.

  • Page 47: Removal

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–19 6. Remove evaporator assembly (A/C only). Installation f Refer to Evaporator Assembly in this section. To install, follow the removal steps in the reverse order, 7. Disconnect blower motor connector. noting the following point: 8.
  • Page 48 1A–20 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 5. Separate the upper case and slit the lining parting face with a knife. 873RS002 6. Pull out the mode door while raising up the catch of door lever. 7. Remove sub-lever. 8. Remove door lever. Installation To install, follow the removal steps in the reverse order, noting the following points:...

  • Page 49: Removal

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–21 Blower Motor Blower Motor and Associated Parts 873RW001 Legend (4) Clip (1) Attaching Screw (5) Fan (2) Blower Motor Connector (6) Blower Motor (3) Blower Motor Assembly Removal Installation To install, follow the removal steps in the reverse order. 1.

  • Page 50: Removal

    1A–22 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Rear Heater Duct, Defroster Nozzle and Ventilation Duct Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts 840RW008 Legend (4) Instrument Panel Bracket (1) Defroster Nozzle (5) Instrument Panel Assembly (2) Cross Beam Assembly (6) Rear Heater Duct (3) Center Ventilation Duct and Side Defroster (7) Lap Ventilation Duct...

  • Page 51: Installation

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–23 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. Control Lever Assembly and / or Control Cable Control Lever Assembly, Control Cable and Associated Parts 865RW004 Legend...
  • Page 52 1A–24 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Removal 1. Disconnect the battery ground cable. 2. Remove instrument panel driver lower cover assembly. 3. Remove meter cluster assembly. f Refer to Instrument Panel Assembly in Body and Accessories section. 4. Remove glove box. 5.
  • Page 53 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–25 Installation To install, follow the removal steps in the reverse order, noting the following points: 1. Adjust the control cable. 865RW005 f Air source control cable. 1. Slide the control lever to the left (“CIRC” position).

  • Page 54: Removal

    1A–26 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Control Panel Illumination Bulb Control Panel Illumination Bulb and Removal Associated Parts 1. Disconnect the battery ground cable. 2. Remove control lever assembly. f Refer to Control Lever Assembly in this section. 3. Pull out the bulb socket from the panel by turning it counterclockwise.
  • Page 55 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–27 Air Conditioning System General Description Air Conditioning Refrigerant Cycle Construction C01RS003 Legend (9) Condenser (1) Electronic Thermostat (10) Compressor (2) Evaporator Core (11) Magnetic Clutch (3) Evaporator Assembly (12) Mode (HEAT) Control Door (4) Temperature Sensor (13) Temp.
  • Page 56 1A–28 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) evaporator vaporizes readily. The liquid refrigerant This vehicle is equipped with a five-vane rotary removes the required quantity of heat (latent heat of compressor (1). vaporization) from the air around the evaporator core The specified amount of the compressor oil is 150cc cooling fins and rapidly vaporizes.
  • Page 57 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–29 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.
  • Page 58 1A–30 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Triple Pressure Switch (V6, A/T) liquid refrigerant by forcing it through a tiny port before sending it to the evaporator (4). Triple pressure switch (2) is installed on the upper part of This type of expansion valve consists of a temperature the receiver/drier.
  • Page 59 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–31 The evaporator core with a laminate louver fin is a single-sided tank type where only one tank is provided under the core. 874RX002 Electronic Thermostat The thermostat consists of the thermo sensor (3) and thermostat unit (5) which functions electrically to reduce the noises being generated while the system is in operation.
  • Page 60 1A–32 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Refrigerant Line Restriction in the refrigerant line will be indicated by: 1. Suction line — A restricted suction line will cause low suction pressure at the compressor, low discharge pressure and little or no cooling. 2.
  • Page 61 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–33 Air Conditioning Parts 852RX002 Legend (5) Receiver/Drier (1) Liquid Line (High-Pressure Pipe) (6) Condenser Assembly (2) Clip (7) Compressor (3) Discharge Line (High-Pressure Hose) (8) Suction Line (Low-Pressure Hose) (4) Pressure Switch (9) Evaporator Assembly...
  • Page 62 1A–34 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Wiring Diagram D08RX001...
  • Page 63 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–35 Diagnosis Air Conditioning Cycle Diagnosis Condition Possible cause Correction No cooling or insufficient cooling. Magnetic clutch does not run. Refer to “Magnetic Clutch Diagnosis” in this section. Compressor is not rotating properly. Adjust the drive belt to the specified Drive belt is loosened or broken.
  • Page 64 1A–36 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Checking The Refrigerant System With HFC-134a Pressure-Temperature Relationship Manifold Gauge Pressure Temperature Since Refrigerant-134a (HFC-134a) is used in the air (kPa) (psi) (°C) (°F) conditioning system in this vehicle, be sure to use manifold gauges, charging hoses and other air –20 –4.4...
  • Page 65 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–37 Legend (1) Low Side (2) High Side Condition Possible cause Correction Discharge (High Gauge) Pressure Condenser clogged or dirty. Clean the condenser fins Abnormally High Abnormally High Cooling does operate Check the cooling fan operation. properly.
  • Page 66 1A–38 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Condition Possible cause Correction Suction (Low Gauge) Pressure Expansion valve clogged. Replace the expansion valve. Abnormally Low. Frost on the expansion valve inlet line Suction (Low Gauge) Pressure Receiver/Drier clogged. Replace the receiver/drier. Abnormally Low Receiver/drier inlet...
  • Page 67 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–39 Magnetic Clutch Diagnosis D08RX002...
  • Page 68 1A–40 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) When the air conditioning switch and the fan control knob Powertrain Control Module (PCM;V6-3.2L)/ Engine (fan switch) are turned on with the engine running, current Control Module (ECM;L4-2.2L) is used to stop the air flows through the thermostat and the compressor relay to conditioning temporarily by turning off the magnetic clutch activate the magnetic clutch.
  • Page 69 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–41 Magnetic Clutch Does Not Run (Cont’d) Step Action Check to see if battery voltage is present between chassis side relay terminal No. X4-2 and No. X4-4. Is there a battery voltage? Go to Step 14 Go to Step 15 Check to see if battery voltage is present at chassis side relay Open circuit...
  • Page 70 1A–42 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Condenser Fan Diagnosis While the air conditioning is ON, the cycling switch in the exceeds a set pressure value. The condenser fan stops triple pressure switch senses the refrigerant pressure, when the air conditioning is turned “OFF” or when the and activates the condenser fan to improve the cooling pressure goes down below the set pressure value.
  • Page 71 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–43 Chart “A” Condenser Fan Does Not Run Step Action Are 30A fuse OK? Go to Step 2 Replace Is relay (X-9) OK? Go to Step 3 Replace Is pressure switch OK? Switch defective or insufficient Go to Step 4 refrigerant.
  • Page 72 1A–44 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Individual Inspection Pressure Switch 1. Disconnect pressure switch connector and check for Fan Control Knob (Fan Switch) And Air continuity between pressure switch side connector Conditioning (A/C) Switch terminals (1) and (2). 1. Check for continuity between the fan switch and the A/C switch side connector terminals.
  • Page 73 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–45 f Keep moisture and contaminants out of the system. Condenser Fan When disconnecting or removing any lines or parts, 1. Disconnect the condenser fan connector. use plugs or caps to close the fittings immediately. 2.
  • Page 74 1A–46 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 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.
  • Page 75 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–47 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.
  • Page 76 1A–48 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 2. Perform a leak test on the refrigerant line fitting. WARNING: 3. If the leak is still present, discharge and recover the f SHOULD HFC-134A CONTACT YOUR EYE(S), refrigerant from the system. CONSULT A DOCTOR IMMEDIATELY. 4.
  • Page 77 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–49 Refrigerant Recycling 8. If no leaks are found, again operate the vacuum pump for 20 minutes or more. After confirming that the Recycle refrigerant recovered J-39500 gauge manifold pressure is at 750 mmHg (30 inHg), (ACR :HFC-134a Refrigerant Recovery / Recycling / close both hand valves.
  • Page 78 1A–50 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.
  • Page 79 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–51 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.
  • Page 80 1A–52 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Compressor Assembly Compressor Assembly and Associated Parts 871RX004 Legend (3) Compressor (1) Magnetic Clutch Harness Connector (4) Serpentine Belt (2) Refrigerant Line Connector Removal 1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant f Refer to Refrigerant Recovery in this section.
  • Page 81 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–53 4. Remove serpentine belt. New Compressor Installation f Move serpentine belt tensioner to loose side using The new compressor is filled with 150cc (5.0fl.oz.)of wrench then remove serpentine belt. compressor oil and nitrogen gas. When mounting the compressor on the vehicle, perform the following steps;...
  • Page 82 1A–54 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Condenser Assembly Condenser Assembly and Associated Parts 875RW008 Legend (4) Radiator Grille (1) Engine Hood Lock (5) Engine Hood Front End Stay (2) Pressure Switch Connector (6) Condenser Assembly (3) Refrigerant Line Removal Installation 1.
  • Page 83 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–55 f Be sure to apply new compressor oil to the O-rings 4. Install engine hood lock. when connecting the refrigerant line. 5. Install engine hood front end stay. 3. Connect pressure switch connector. 6.
  • Page 84 1A–56 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 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.
  • Page 85 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–57 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.

  • Page 86: Evaporator Assembly

    1A–58 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Evaporator Assembly Evaporator Assembly and Associated Parts 874RW007 Legend (3) Refrigerant Line (1) Resistor and Electronic Thermostat Connector (4) Glove Box (2) Drain Hose (5) Evaporator Assembly Removal 1. Disconnect the battery ground cable. 2.

  • Page 87: Installation

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–59 6. Disconnect refrigerant line. Installation f Use a back-up wrench when disconnecting and To install, follow the removal steps in the reverse order, reconnecting the refrigerant lines. noting the following points: f When removing the refrigerant line connected part, 1.

  • Page 88: Removal

    1A–60 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Removal 9. Remove evaporator core. 1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. f Refer to Refrigerant Recovery in this section. 3. Remove evaporator assembly. f Refer to Evaporator Assembly in this section. 4.

  • Page 89: Refrigerant Line

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–61 4. O-rings cannot be reused. Always replace with new 7. To install a new evaporator core, add 50cc (1.7 fl. oz.) ones. of new compressor oil to the new core. 5. Be sure to apply new compressor oil to the O-rings 8.

  • Page 90: Removal

    1A–62 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) D When removing the refrigerant line connecting part, Removal the connecting part should immediately be plugged 1. Disconnect the battery ground cable. or capped to prevent foreign matter from being mixed into the line. 2.
  • Page 91 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–63 PRESSURE SWITCH Type Dual pressure switch Low pressure control ON: 205.9 29.4 kPa (29.9 4.3 psi) OFF: 176.5 24.5 kPa (25.6 3.6 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) Triple pressure switch (V6, A/T) Low pressure control...
  • Page 92 1A–64 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 874RX006...

  • Page 93: Compressor

    ONLY the exact part number for that application. DKV-14G Type Compressor ISUZU will call out those fasteners that require a DKV–14G is equipped with five–vane rotary compressor. replacement after removal. ISUZU will also call out...

  • Page 94: Diagnosis

    1A–66 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Diagnosis Condition Possible cause Correction Noise from compression Defective rotor/piston Replace compressor/cylinder and shaft assembly Defective shaft Replace compressor/cylinder and shaft assembly Noise from magnetic clutch Defective bearing Replace magnetic clutch Defective clutch Replace magnetic clutch Clearance between drive plate and Adjust the clearance or replace...

  • Page 95: Magnetic Clutch Assembly (Dkv-14D Type) 1A-67

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–67 Magnetic Clutch Assembly (DKV-14D Type) Parts Location View 871RW009 Legend (4) Pulley Assembly (1) Drive Plate bolt (5) Field Coil (2) Drive Plate (6) Shim (s) (3) Snap Ring (7) Lead Wire Removal 2.

  • Page 96: Inspection And Repair

    1A–68 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 3. Remove shim (s). 6. Loosen screw and disconnect the coil lead wire connector. 4. Remove snap ring (1) by using snap ring pliers. 871RS010 871RW016 7. Loosen three screws and remove the field coil. 5.

  • Page 97: Installation

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–69 Installation 4. Install snap ring. 5. Install shim (s). 1. Install field coil. 6. Install the drive plate to the compressor drive shaft f Align the located portion (1) of the field coil and together with the original shim(s)(1).

  • Page 98: Compressor Oil

    1A–70 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) f Check to be sure that the clutch clearance is f If necessary, install adjusting shim(s). between 0.3-0.6 mm (0.01-0.02 in.) f Adjusting shims are available in the following thickness. Thickness f 0.1 mm (0.0039 in.) f 0.3 mm (0.0118 in.) f 0.5 mm (0.0197 in.) 871RW011...

  • Page 99: Checking And Adjusting For Compressor Replacement

    HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–71 f The oil has changed to red. 2. Drain the compressor oil and measure the extracted oil with a measuring cylinder. f Foreign substances, metal powder, etc., are present 3. Check the oil for contamination. in the oil.

  • Page 100: Main Data And Specifications

    1A–72 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Main Data and Specifications General Specifications COMPRESSOR Model DKV-14G Type Vane rotary type Number of vanes Rotor diameter 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)
  • Page 101 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–73 Torque Specifications 871RW010...

  • Page 102: Special Tools

    1A–74 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Special Tools TOOL NO. TOOL NO. ILLUSTRATION ILLUSTRATION TOOL NAME TOOL NAME J-33939 J-33940-A Drive plate holder Pulley installer J-33944-A J-8092 Drive plate puller Drive handle J-33944-4 Forcing screw J-38424 Pulley puller pilot J-8433 Pulley puller J-24092-2...
  • Page 103 SECTION 2A–1 POWER–ASSISTED STEERING SYSTEM RODEO STEERING POWER-ASSISTED STEERING SYSTEM CONTENTS Service Precaution ..... . 2A–2 Removal ......

  • Page 104: Caution: Always Use The Correct Fastener In The Proper Location. When You Replace A Fastener, Use

    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.
  • Page 105 2A–3 POWER–ASSISTED STEERING SYSTEM Condition Possible cause Correction Wheel Hop Blister or bump on tire. Replace tire. Improper shock absorber operation. Replace shock absorber. Shimmy, Shake or Vibration Tire or wheel out of balance. Balance wheels or replace tire/or wheel. Loose wheel bearings.
  • Page 106 2A–4 POWER–ASSISTED STEERING SYSTEM Condition Possible cause Correction Abnormal Noise Worn, sticky or loose upper or lower Replace. ball joint, steering linkage ball joints or drive axle joints. Faulty shock absorbers. Replace. Worn upper or lower control arm Replace. bushing. Loose stabilizer bar.
  • Page 107 2A–5 POWER–ASSISTED STEERING SYSTEM Power Steering System There is some noise in all power steering systems. One tween this noise and steering performance. Do not re- of the most common is a hissing sound when the steering place the valve unless the “hissing” noise is extremely ob- wheel is fully turned and the car is not moving.
  • Page 108 2A–6 POWER–ASSISTED STEERING SYSTEM Power Steering Pump Foaming milky power steering fluid, low fluid level, and is low. If the fluid level is correct and the pump still foams, possible low pressure can be caused by air in the fluid, or remove the pump from the vehicle and check housing for loss of fluid due to internal pump leakage.
  • Page 109 2A–7 POWER–ASSISTED STEERING SYSTEM Turn Signal Switch This diagnosis covers mechanical problems only. Refer to Turn Signal Switch in Electrical section for electrical diagnosis. Condition Possible cause Correction Turn Signal Will Not Stay In Turn Foreign material or loose parts Repair or replace signal switch.

  • Page 110: General Description

    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.
  • Page 111 2A–9 POWER–ASSISTED STEERING SYSTEM The hydraulic pump is vane-type design. The submerged Pressure Switch pump has housing and internal parts that are inside the When hydraulic pressure reaches 3430 kPa (500 psi), the reservoir and operate submerged in oil. There are two pressure switch of the power steering pump closes bore openings at the rear of the pump housing.

  • Page 112: Power Steering System Test

    2A–10 POWER–ASSISTED STEERING SYSTEM The steering column has three important features in The column can be disassembled and reassembled. addition to the steering function: However, to insure the energy absorbing action, use only the specified screws, bolts and nuts as designated, and 1.

  • Page 113: Maintenance

    2A–11 POWER–ASSISTED STEERING SYSTEM 4. Bleed the system. Refer to Bleeding the Power Fluid Level Steering System in this section. 1. Run the engine until the power steering fluid reaches 5. Start the engine and check the fluid level. Add power normal operating temperature, about 55°C (130°F), steering fluid if required.

  • Page 114: Steering Wheel Free Play Inspection

    2A–12 POWER–ASSISTED STEERING SYSTEM 4. Install all the lines and hoses. Fill the system with new Front End Alignment Inspection and power steering fluid and bleed the system as Adjustment described in Bleeding The Power Steering System. Operate the engine for about 15 minutes. General Description Remove the pump return line at the pump inlet and “Front End Alignment”...
  • Page 115 2A–13 POWER–ASSISTED STEERING SYSTEM Caster: Toe-in is the measured amount the front wheels are turn in. The actual amount of toe-in is normally a fraction of a This illustration shows view from the side of the vehicle. degree. Toe-in is measured from the center of the tire treads or from the inside of the tires.
  • Page 116 2A–14 POWER–ASSISTED STEERING SYSTEM Trim Height Adjustment Caster Adjustment Adjust the trim height (1) by means of the adjusting bolt on The caster angle can be adjusted by means of the caster the height control arms. shims (1) installed between the chassis frame (2) and fulcrum pins.
  • Page 117 2A–15 POWER–ASSISTED STEERING SYSTEM Camber Adjustment The camber angle can be adjusted by means of the camber shims (2) installed in position between the chassis frame (1) and fulcrum pins Camber angle: 0° 30’ King pin inclination: 12°30’ 30’ CAUTION: Left and right side must be equal within 30’.

  • Page 118: Main Data And Specifications

    2A–16 POWER–ASSISTED STEERING SYSTEM 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 2 mm (0 0.08 in)

  • Page 119: Special Tools

    2A–17 POWER–ASSISTED STEERING SYSTEM Torque Specification E02RX001 Special Tools TOOL NO. TOOL NO. ILLUSTRATION ILLUSTRATION TOOL NAME TOOL NAME J–29877–A J–39213 Tester; Adapter; Power steering Power steering tester...

  • Page 120: Power Steering Unit

    2A–18 POWER–ASSISTED STEERING SYSTEM Power Steering Unit Power Steering Unit and Associated Parts 431RW013 Legend (3) Power Steering Unit Assembly (1) Bracket (4) Crossmember (2) Transfer Gear Assembly Removal 1. Remove the stone guard. 2. Remove the transfer gear assembly. Make a setting mark across the coupling flange and steering unit to ensure reassembly of the parts in the original position.

  • Page 121: Installation (4 2 Model)

    2A–19 POWER–ASSISTED STEERING SYSTEM 5. Disconnect the feed line and return line from steering Installation (4 2 Model) unit. 1. Install power steering unit to crossmember. Remove the clips on the crossmember and frame. Tighten fixing bolt to specified torque. Wire the power steering line to frame.

  • Page 122: Power Steering Unit Disassembled View

    2A–20 POWER–ASSISTED STEERING SYSTEM Power Steering Unit Disassembled View 440RW003 Legend (6) Tie-rod Assembly (1) Tie-rod End (7) Tab Washer (2) Lock Nut (8) Oil Line (3) Clip (9) Valve Housing Assembly (4) Bellows (10) Mounting Rubber (5) Band (11) Dust Cover Disassembly Tie-rod Assembly If the resistance is insufficient or play is felt when checked...

  • Page 123: Main Data And Specifications

    2A–21 POWER–ASSISTED STEERING SYSTEM 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) Main Data and Specifications General Specifications Power Steering unit Type...

  • Page 124: Power Steering Pump

    2A–22 POWER–ASSISTED STEERING SYSTEM Power Steering Pump Power Steering Pump and Associated Parts 436RX001 Legend (3) Hose, Flexible (1) Pump Assembly (4) Bolt (2) Hose, Suction Removal Installation 1. Remove the drive belt. 1. Install the pump assembly to the pump braket, tighten the fixing bolt to the specified torque.

  • Page 125: Power Steering Pump Disassembled View 2A-23 Disassembly

    2A–23 POWER–ASSISTED STEERING SYSTEM Power Steering Pump Disassembled View 442RX001 Legend (12) Cam (1) Bolt (13) Pump Cartridge Assembly (2) Suction Pipe (14) O-ring (3) O-ring (15) Snap Ring (4) Shaft Assembly (16) Rear Housing (5) Oil Seal (17) Bolt (6) Front Housing (18) Spring (7) O-ring...

  • Page 126: Inspection And Repair

    2A–24 POWER–ASSISTED STEERING SYSTEM Inspection and Repair The inner face of the arm should have a uniform contact Make all necessary adjustments, repairs, and part pattern without a sign of step wear. When part replacements if wear, damage, or other problems are replacement becomes necessary, the pump cartridge discovered during inspection.
  • Page 127 2A–25 POWER–ASSISTED STEERING SYSTEM 3. Install the vanes to roter with curved face in contact with the inner wall of cam. 442RS005 4. Install roter 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.

  • Page 128: Main Data And Specifications

    2A–26 POWER–ASSISTED STEERING SYSTEM Main Data and Specifications General Specifications Oil pump Type Vane Operating ATF DEXRON –II–E fluid Torque Specifications E02RX004...

  • Page 129: Transfer Gear Assembly

    2A–27 POWER–ASSISTED STEERING SYSTEM Transfer Gear Assembly Transfer Gear Assembly and Associated Parts 441RW001 Legend (3) Fixing Bolt Nut (1) Transfer Gear Assembly (4) Shim (2) Bolt, Universal Joint (Steering Shaft Side) (5) Bolt, Universal Joint (Steering Unit Side) Removal Installation 1.

  • Page 130: Supplemental Restraint System Steering Wheel & Column

    2A–28 POWER–ASSISTED STEERING SYSTEM Supplemental Restraint System Steering Wheel & Column Service Precaution WHEN CARRYING A LIVE AIR BAG ASSEMBLY, MAKE SURE THE BAG AND TRIM COVER ARE This steering wheel and column repair section covers the POINTED AWAY FROM YOU. NEVER CARRY AN AIR Supplemental Restraint System (SRS) steering column.
  • Page 131 2A–29 POWER–ASSISTED STEERING SYSTEM Removal Installation To remove the connector, hold the cover insulator(1) and To install the connector, hold the soket insulator(1) and pull it. The cover insulator slides and lock will be released. insert it. The cover insulator slides and connector will be Do not hold the socket insulator(2).

  • Page 132: Inflator Module

    2A–30 POWER–ASSISTED STEERING SYSTEM Inflator Module Inflator Module and Associated Parts 827RW071 Legend (3) Fixing Bolt (1) Horn Lead (4) Inflator Module (2) SRS Connector Removal 1. Turn the steering wheel so that the vehicle’s wheels are pointing straight ahead. 2.

  • Page 133: Inspection And Repair

    2A–31 POWER–ASSISTED STEERING SYSTEM f Check for defects such as damage and breakage in 6. Disconnect the yellow 2-way SRS connector and horn lead located behind the inflator module. the lead wire for the igniter. If an abnormality is found as the result of the inspection, replace the inflator module with a new one.

  • Page 134: Steering Wheel

    2A–32 POWER–ASSISTED STEERING SYSTEM Steering Wheel Steering Wheel and Associated Parts 827RW069 Legend (3) Steering Wheel (1) Horn Lead (4) Steering Wheel Fixing Nut (2) SRS Connector (5) Inflator Module CAUTION: Once the steering column is removed Removal from the vehicle, the column is extremely 1.
  • Page 135 2A–33 POWER–ASSISTED STEERING SYSTEM 5. Loosen the inflator module fixing bolt from behind the 9. Apply a setting mark (1) across the steering wheel steering wheel assembly using a TORX driver or and shaft so parts can be reassembled in their original equivalent until the inflator module can be released position, then remove steering wheel.

  • Page 136: Installation

    2A–34 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 in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel.

  • Page 137: Combination Switch

    2A–35 POWER–ASSISTED STEERING SYSTEM Combination Switch Combination Switch and Associated Parts 431RX006 Legend (4) Combination Switch and SRS Coil Assembly (1) Steering Column Cover (5) Instrument Panel Lower Cover (2) Steering Wheel (6) Driver Knee Bolster (reinforcement) (3) Inflator Module Removal CAUTION: The wheels of the vehicle must be straight ahead and the steering column in the...
  • Page 138 2A–36 POWER–ASSISTED STEERING SYSTEM 7. Loosen the inflator module fixing bolt from behind the WARNING: THE INFLATOR MODULE SHOULD steering wheel assembly using a TORX driver or ALWAYS BE CARRIED WITH THE URETHANE equivalent until the inflator module can be released COVER AWAY FROM YOUR BODY AND SHOULD from steering assembly.

  • Page 139: Installation

    2A–37 POWER–ASSISTED STEERING SYSTEM CAUTION: Never apply force to the steering wheel Installation in direction of the shaft by using a hammer or other 1. Install combination switch and SRS coil assembly. impact tools in an attempt to remove the steering After installation of combination switch assembly, wheel.
  • Page 140 2A–38 POWER–ASSISTED STEERING SYSTEM 2. When installing the steering column cover, be sure to 7. Install driver knee bolster (reinforcement). route each wire harness as illustrated so that the 8. Install instrument panel lower cover then Install the harnesses do not catch on any moving parts. engine hood opening lever.

  • Page 141: Lock Cylinder

    2A–39 POWER–ASSISTED STEERING SYSTEM Lock Cylinder Lock Cylinder and Associated Parts 431RX005 Legend (6) Cushion Rubber (1) Inflator Module (7) Lock Cylinder Assembly (2) Steering Wheel (8) Instrument Panel Lower Cover (3) Steering Column Cover (9) Driver Knee Bolster (reinforcement) (4) Combination Switch and SRS Coil Assembly (10) Shift Lock Cable (for A/T) (5) Snap Ring...
  • Page 142 2A–40 POWER–ASSISTED STEERING SYSTEM 7. Loosen the inflator module fixing bolt from behind the 9. Apply a setting mark (1) across the steering wheel steering wheel assembly using a TORX driver or and shaft so parts can be reassembled in their original equivalent until the inflator module can be released position.

  • Page 143: Installation

    2A–41 POWER–ASSISTED STEERING SYSTEM WARNING: THE INFLATOR MODULE SHOULD 13. Remove the combination switch assembly with SRS ALWAYS BE CARRIED WITH THE URETHANE coil. COVER AWAY FROM YOUR BODY AND SHOULD NOTE: The SRS coil is a part of the combination switch ALWAYS BE LAID ON A FLAT SURFACE WITH THE assembly, which can not be replaced separately.

  • Page 144: System Inspection

    2A–42 POWER–ASSISTED STEERING SYSTEM 6. Turn the SRS coil counter clockwise to full, return 8. Install steering wheel by aligning the setting marks about 3 turns and align the neutral mark. made during removal. CAUTION: When turning the SRS coil counter CAUTION: Never apply force to the steering wheel clockwise to full, stop turning if resistance is felt.

  • Page 145: Steering Column

    2A–43 POWER–ASSISTED STEERING SYSTEM Steering Column Steering Column and Associated Parts 431RX004 Legend (7) Lock Cylinder Assembly (1) Inflator Module (8) Shift Lock Cable (For A/T) (2) Steering Wheel (9) Steering Column Assembly (3) Steering Column Cover (10) Second Steering Shaft (4) Combination Switch and SRS Coil Assembly (11) Instrument Panel Lower Cover (5) Snap Ring...
  • Page 146 2A–44 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.
  • Page 147 2A–45 POWER–ASSISTED STEERING SYSTEM 18. Apply a setting mark (1) across the universal joint and second steering shaft to reassemble the parts in their original position, then remove steering column assembly and second shaft. NOTE: A setting mark can be easily made if the shaft is withdrawn a little by loosening the steering shaft universal joint.

  • Page 148: Insepction

    2A–46 POWER–ASSISTED STEERING SYSTEM Insepction Column Tube Check for collapes by measuring the distance as shown in If the abnormal conditions are found through inspection, the figure. replace the steering column assembly. Standard distance: 162.2-165.8 mm (6.386-6.528 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.

  • Page 149: Installation

    2A–47 POWER–ASSISTED STEERING SYSTEM Shaft Length Tilt Mechanism Check the shaft length from the upper end of the slide joint Tilt mechanism should moves smoothly. to the end of the shaft. If column length is not in While locked the tilt mechanism, be sure the steering specifications, steering column should be replaced.

  • Page 150: System Inspection

    2A–48 POWER–ASSISTED STEERING SYSTEM CAUTION: When turning the SRS coil counter 13. Install steering wheel and align the setting marks clockwise to full, stop turning if resistance is felt. made when removing. Forced further turning may damage to the cable in CAUTION: Never apply force to the steering wheel the SRS coil.

  • Page 151: Supplemental Restraint System Steering Wheel & Column And Associated Parts

    2A–49 POWER–ASSISTED STEERING SYSTEM Supplemental Restraint System Steering Wheel & Column and Associated Parts Main Data and Specifications Torque Specifications E02RX003 Special Tools TOOL NO. ILLUSTRATION TOOL NAME J–29752 Steering wheel remover...
  • Page 152 When you replace a fastener, use ONLY the exact part number for that application. WARNING: THIS VEHICLE HAS A SUPPLEMENTAL ISUZU will call out those fasteners that require a RESTRAINT SYSTEM (SRS). REFER TO THE SRS replacement after removal. ISUZU will also call out...

  • Page 153: Front Suspension

    FRONT SUSPENSION 3C–2 General Description each shock absorber is attached to the lower control arm. The upper portion of each shock absorber extends The front suspension is designed to allow each wheel to through a frame bracket and is secured with two rubber compensate for changes in the road surface level without bushings, two retainers and a nut.
  • Page 154 FRONT SUSPENSION 3C–3 Condition Possible cause Correction Shimmy, Shake or Vibration 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.
  • Page 155 FRONT SUSPENSION 3C–4 Condition Possible cause Correction Abnormal Noise Worn, sticky or loose upper or lower Replace. ball joint, steering linkage ball joints or drive axle joints. Faulty shock absorbers. Replace. Worn upper or lower control arm Replace. bushing. Loose stabilizer bar. Retighten bolts or replace bushings.

  • Page 156: Removal

    FRONT SUSPENSION 3C–5 Shock Absorber Shock Absorber and Associated Parts 450RW009 Legend (3) Bolt and Nut (1) Nut (4) Shock Absorber (2) Rubber Bushing and Washer (5) Rubber Bushing and Washer Removal Installation 1. Raise the vehicle and support it with suitable safety 1.

  • Page 157: Stabilizer Bar 3C-6

    FRONT SUSPENSION 3C–6 Stabilizer Bar Stabilizer Bar and Associated Parts 410RW007 Legend (3) Link (1) Rubber Bushing (4) Nut (2) Bracket (5) Stabilizer Bar f Stabilizer bar Removal f Rubber bushing 1. Raise the vehicle and support the frame with suitable f Link ball joint safety stands.

  • Page 158: Torsion Bar

    FRONT SUSPENSION 3C–7 Torsion Bar Torsion Bar and Associated Parts 410RS003 Legend (2) Height Control Arm (1) Adjust Bolt, End Piece and Seat (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.

  • Page 159: Inspection And Repair

    FRONT SUSPENSION 3C–8 3. Apply the setting marks(2) to the height control arm Installation and torsion bar, then remove height control arm. 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).
  • Page 160 FRONT SUSPENSION 3C–9 2. Apply grease to the portion that fits into the bracket 4. Apply grease to the serrated portions. then install height control arm and align the setting 5. Install adjust bolt and seat, then turn the adjust bolt to marks(2).

  • Page 161: Knuckle

    3C–10 FRONT SUSPENSION Knuckle Knuckle and Associated Parts 410RW006 Legend (6) Needle Bearing (1) Torsion Bar (7) Thrust Washer (2) Lower Ball Joint (8) Oil Seal (3) Back Plate (9) Upper Ball Joint (4) Knuckle Assembly (10) Wheel Speed Sensor (5) Knuckle Removal 4.

  • Page 162: Inspection And Repair

    FRONT SUSPENSION 3C–11 9. Remove back plate. 15. Remove needle bearing by using remover J–23907 (Except 2WD model). 10. Remove lower ball joint by using remover J–29107. CAUTION: Be careful not to damage the ball joint boot. 901RW044 Inspection and Repair 901RW163 11.
  • Page 163 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.

  • Page 164: Upper Control Arm

    FRONT SUSPENSION 3C–13 Upper Control Arm Upper Control Arm and Associated Parts 450RW005 Legend (7) Bushing (1) Bolt and Plate (8) Plate (2) Camber Shims (9) Nut (3) Caster Shims (10) Speed Sensor Cable (4) Nut Assembly (11) Nut and Cotter Pin (5) Upper Control Arm Assembly (12) Upper Ball Joint (6) Fulcrum Pin...

  • Page 165: Inspection And Repair

    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. Inspection and Repair 8. Remove bolt and plate. Make necessary parts replacement if wear, damage, 9. Remove nut assembly. corrosion or any other abnormal conditions are found through inspection.
  • Page 166 FRONT SUSPENSION 3C–15 901RW159 450RS013 3. Install plate. Legend 4. Install nut and tighten fulcrum pin nut finger–tight. (1) Projection NOTE: Torque fulcrum pin nut after adjusting buffer (2) Outward clearance. 6. Install the caster shims(2) between the chassis frame Buffer clearance: 22 mm (0.87 in) and fulcrum pin.

  • Page 167: Lower Control Arm

    3C–16 FRONT SUSPENSION Lower Control Arm Lower Control Arm and Associated Parts 450RW010 Legend (8) Bolt, Torsion Bar Arm (1) Nut, Front (9) Torsion Bar Arm Bracket (2) Bush, Front (10) Torsion Bar (3) Bolt, Front (11) Lower Control Arm (4) Nut, Rear (12) Lower Ball Joint (5) Bush, Rear...

  • Page 168: Inspection And Repair

    FRONT SUSPENSION 3C–17 6. Remove front nut. 19. Remove rear bushing by using remover J–36834. 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.

  • Page 169: Installation

    3C–18 FRONT SUSPENSION Installation 11. Install torsion bar arm bracket and tighten it to the specified torque. 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.

  • Page 170: Upper Ball Joint

    FRONT SUSPENSION 3C–19 Upper Ball Joint Upper Ball Joint and Associated Parts 450RW004 Legend (2) Upper Ball Joint (1) Bolt and Nut (3) Nut and Cotter Pin Removal 1. Raise the vehicle and support the frame with suitable safety stands. 2.

  • Page 171: Inspection And Repair

    3C–20 FRONT SUSPENSION f After moving the ball joint 4 or 5 times, attach nut then 3. Remove upper ball joint nut and cotter pin, then use remover J–36831 to remove the upper ball joint from measure the preload. the knuckle. Starting torque: 0.5 –3.2 N·m (0.4–2.4 lb ft) CAUTION: Be careful not to damage the ball joint boot.

  • Page 172: Lower Ball Joint

    FRONT SUSPENSION 3C–21 Lower Ball Joint Lower Ball Joint and Associated Parts 450RW011 Legend (3) Nut (1) Bolt (4) Nut and Cotter Pin (2) Lower Ball Joint Removal 1. Raise the vehicle and support the frame with suitable safety stands. 2.

  • Page 173: Inspection And Repair

    3C–22 FRONT SUSPENSION 7. Remove nut. Installation 8. Remove bolt. 1. Install lower ball joint. 9. Remove lower ball joint. 2. Install bolt. 3. Install nut and tighten it to the specified torque. Inspection and Repair Torque: 116 N·m (85 lb ft) Make necessary parts replacement if wear, damage, 4.

  • Page 174: Main Data And Specifications

    FRONT SUSPENSION 3C–23 Main Data and Specifications General Specifications Front suspension Type Independent wishbone arms, torsion bar spring with stabilizer bar. Torsion bar spring Length 1142 mm (45.0 in) Diameter 28.0 mm (1.10 in) Front shock absorber Type Hydraulic, double acting, telescopic Piston diameter 30.0 mm (1.18 in) Stroke...

  • Page 175: Special Tools

    3C–24 FRONT SUSPENSION Special Tools TOOL NO. TOOL NO. ILLUSTRATION ILLUSTRATION TOOL NAME TOOL NAME J–36833 J–23907 Remover and Installer Remover;Needle kit; bearing Lower arm front bushing J–36834 J–36838 Remover and Installer Installer; Needle bearing kit; Lower arm rear bushing J–8092 J–36831 Grip...

  • Page 176: Caution: Always Use The Correct Fastener In The Proper Location. When You Replace A Fastener, Use

    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.
  • Page 177 REAR SUSPENSION 3D–2 Diagnosis Condition Possible cause Correction Vehicle Pulls 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.
  • Page 178 REAR SUSPENSION 3D–3 Condition Possible cause Correction Hard Steering Bind in steering linkage ball studs, Replace ball joint. upper or lower 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.
  • Page 179 REAR SUSPENSION 3D–4 Condition Possible cause Correction Erratic Steering When Braking 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.

  • Page 180: Coil Spring

    REAR SUSPENSION 3D–5 Coil Spring Coil Spring and Associated Parts 460RW003 Legend (4) Coil Spring (1) Stabilizer Bar (5) Insulator (2) Upper Link Fixing Bolt and Nut (6) Shock Absorbar (3) Rubber Plate (7) Breather Hose Removal 6. Disconnect the stabilizer bar at the stabilizer link. 7.

  • Page 181: Inspection And Repair

    REAR SUSPENSION 3D–6 Inspection and Repair 3. Install the insulator on the coil spring. Jack up the axle case gently with the top of the coil spring set to the Make necessary correction or parts replacement if wear, spring seat on the frame side. damage, corrosion or any other abnormal condition are found through inspection.

  • Page 182: Shock Absorber

    REAR SUSPENSION 3D–7 Shock Absorber Shock Absorber and Associated Parts 461RW001 Legend (2) Shock Absorber (1) Nut, Bush and Washer (3) Nut and Washer Removal Installation 1. Remove shock absorber fixing nut, bush and washer 1. Install shock absorber. When mounting shock (upper side).

  • Page 183: Trailing Link

    REAR SUSPENSION 3D–8 Trailing Link Trailing Link and Associated Parts 460RW005 Legend (2) Protector (Left side only) (1) Bolt and Nut (Axle side) (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.

  • Page 184: Installation

    REAR SUSPENSION 3D–9 f 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.

  • Page 185: Upper Link

    3D–10 REAR SUSPENSION Upper Link Upper Link and Associated Parts 460RW006 Legend (3) Upper Link (1) Bolt and Nut (Axle side) (4) Protector (Left side only) (2) Rubber Plate (5) Bolt (Frame side) Removal 1. Remove fuel tank. Refer to Engine Fuel in Engine section.

  • Page 186: Installation

    REAR SUSPENSION 3D–11 f Install the rubber bushing by using to installer J–xxxxx. NOTE: When mounting rubber bushings, be sure not to use grease on bushings or any other nearby part. 901RW157 Installation 1. Install upper link. Make sure that the upper link is in its correct position.

  • Page 187: Lateral Rod

    3D–12 REAR SUSPENSION Lateral Rod Lateral Rod and Associated Parts 460RW007 Legend (2) Lateral Rod (1) Bolt and Nut (Frame side) (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...

  • Page 188: Installation

    REAR SUSPENSION 3D–13 f 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 1. Install lateral rod and make sure that the lateral rod is in its correct position.

  • Page 189: Stabilizer Bar

    3D–14 REAR SUSPENSION Stabilizer Bar Stabilizer Bar and Associated Parts 460RW009 Legend (3) Bolt and Nut (1) Bracket (4) Stabilizer Bar (2) Link (5) Rubber Bushing Removal 6. Remove rubber bushing. 1. Raise the vehicle and support the frame with suitable Inspection and Repair safety stands.

  • Page 190: Installation

    REAR SUSPENSION 3D–15 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.

  • Page 191: Main Data And Specifications

    3D–16 REAR SUSPENSION Main Data and Specifications General Specifications Rear suspension Type 5–Link, coil spring type with stabilizer bar. Coil spring Free length 389.5mm (15.33in) Spring diameter 12.2mm (0.48in) Coil diameter (inner) 105mm (4.13in) Effective No. of turns 5.74 Total No. of turns 7.24 Shock absorber Type...
  • Page 192 REAR SUSPENSION 3D–17 Torque Specifications E03RW003...

  • Page 193: Special Tools

    3D–18 REAR SUSPENSION Special Tools TOOL NO. ILLUSTRATION TOOL NAME J–39214 Remover and Installer; Trailing link bushing J–xxxxx Remover and Installer; Upper link bushing J–39792 Remover and Installer; Lateral rod bushing (axle side) J–39215 Remover and Installer; Lateral rod bushing...

  • Page 194: Wheel And Tire System

    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.
  • Page 195 WHEEL AND TIRE SYSTEM 3E–2 General Description 480RS008 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.
  • Page 196 WHEEL AND TIRE SYSTEM 3E–3 Diagnosis Condition Possible cause Correction Vehicle Pulls 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.
  • Page 197 WHEEL AND TIRE SYSTEM 3E–4 Condition Possible cause Correction Hard Steering Bind in steering linkage ball studs, Replace ball joint. upper or lower ball joint. Improper wheel alignment. Check wheel alignment. Tire not adequately inflated. Inflate tires to proper pressure. Bind in steering column or shaft.
  • Page 198 WHEEL AND TIRE SYSTEM 3E–5 Condition Possible cause Correction Erratic Steering When Braking 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.
  • Page 199 WHEEL AND TIRE SYSTEM 3E–6 Tire Rotation indicators may appear as wide bands. When the indica- tors appear in two or more grooves at three locations, tire Tire rotation is recommended to equalize wear for longer replacement is recommended. tire life. Inflation of Tires 480RS002 Legend...
  • Page 200 WHEEL AND TIRE SYSTEM 3E–7 5. Tire cord breakage. Radial Tire Lead/Pull 6. High tire temperatures. “Lead/Pull” is vehicle deviation from a straight path, on a level road with no pressure on the steering wheel. 7. Reduced handling. Lead is usually caused by: 8.
  • Page 201 WHEEL AND TIRE SYSTEM 3E–8 Radial Tire Lead/Pull Correction Chart Step Action 1. Inflate tires to recommended pressure. 2. Road test vehicle on level uncrowned road. Was a problem corrected? End. Go to Step 2 Switch front tires side to side and road test again. If roughness results,replace Was a problem corrected?
  • Page 202 WHEEL AND TIRE SYSTEM 3E–9 Localized tread wear. Wear in shoulders at points opposed to each other. 480RW004 480RW006 1. Once spotty wear develops in tread due to hard 1. Tire or wheel out of round or distorted. braking or abrupt starting, localized wear tends to be 2.
  • Page 203 WHEEL AND TIRE SYSTEM 3E–10 One sided feather edging. 480RW008 1. Wear caused by repeated hard cornering. 2. Camber or toe-in incorrect.
  • Page 204 WHEEL AND TIRE SYSTEM 3E–11 Wheel Wheel and Associated Parts 480RW010 Legend (1) Wheel Lug Nut (2) Wheel and Tire Removal 1. Loosen wheel lug nut by approximately 180 g (half a rotation), then raise the vehicle and remove the nuts. 2.

  • Page 205: Tire Replacement

    WHEEL AND TIRE SYSTEM 3E–12 Tire Tire Replacement Steel Aluminum When replacement is necessary, the original metric the 1– Vertical play: 1– Vertical play: size should be used. Most metric tire sizes do not have Less than Less than exact corresponding alphanumeric tire sizes. It is 1.5 mm (0.059 in) 0.7 mm (0.028 in)
  • Page 206 WHEEL AND TIRE SYSTEM 3E–13 Balancing Wheel and Tire On-vehicle Balancing On-Vehicle balancing methods vary with equipment and tool manufacturers. sure 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.
  • Page 207 WHEEL AND TIRE SYSTEM 3E–14 Main Data and Specifications General Specifications Wheels Size 15 x 6.5JJ 15 x 6.5JJ 16 x 7JJ Offset 38.0 mm (1.50 in) 38.0 mm (1.50 in) 38.0 mm (1.50 in) P.C.D., wheel studs 139.7 mm (5.50 in) 139.7 mm (5.50 in) 139.7 mm (5.50 in) Standard tire...
  • Page 208 When you replace a fastener, use ONLY the exact part number for that application. WARNING: THIS VEHICLE HAS A SUPPLEMENTAL ISUZU will call out those fasteners that require a RESTRAINT SYSTEM(SRS). REFER TO THE SRS replacement after removal. ISUZU will also call out...

  • Page 209: Differential (Front)

    4A1–2 DIFFERENTIAL (FRONT) Front Drive Axle Diagnosis Condition Possible cause Correction Oil Leak At Front Axle Worn or defective oil seal. Replace the oil seal. Front axle housing cracked. Repair or replace. Oil Leak At Pinion Shaft Too much gear oil. Correct the oil level.

  • Page 210: Pinion Shaft Oil Seal

    DIFFERENTIAL (FRONT) 4A1–3 Pinion Shaft Oil Seal Pinion Shaft Oil Seal and Associated Parts 415RW012 Legend (4) Oil Seal Slinger (1) Flange Nut (5) Outer Bearing (2) Flange (6) Collapsible Spacer (3) Oil Seal Removal 1. Raise the vehicle and support it at the frame. The hoist must remain under the front axle housing.

  • Page 211: Inspection And Repair

    4A1–4 DIFFERENTIAL (FRONT) 3. Remove the front propeller shaft. Refer to Front Inspection and Repair Propeller Shaft in this section. Make necessary correction or parts replacement if wear, 4. Remove flange nut by using pinion flange holder damage, corrosion or any other abnormal condition are J–8614–01.

  • Page 212: Front Drive Axle Assembly

    DIFFERENTIAL (FRONT) 4A1–5 Front Drive Axle Assembly Front Drive Axle Assembly and Associated Parts 412RW056 Legend (5) Mounting Bolt (1) Propeller Shaft (6) Tie–rod End; Power Steering Unit (2) Mounting Nut (7) Knuckle and Back Plate (3) Front Axle Case Assembly and Front Drive (8) Hub and Disc Assembly Shaft Assembly (9) Suspension Crossmember...

  • Page 213: Removal

    4A1–6 DIFFERENTIAL (FRONT) 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.

  • Page 214: Differential (Front)

    DIFFERENTIAL (FRONT) 4A1–7 17. Support the differential case by the jack. 5. Align the bolt hole of the lower control arm, install the bolts and nuts. 18. Remove the front axle mounting bolts and nuts, lower the jack slowly. Remove the left side drive shaft end NOTE: Adjust the buffer clearance before tighten the from the knuckle, then lower the axle assembly from bolts and nuts of the lower control arm.

  • Page 215: Differential Assembly

    4A1–8 DIFFERENTIAL (FRONT) Differential Assembly Disassembled View 415RW007 Legend (11) Collapsible Spacer (1) Differential Assembly (12) Inner Bearing Outer Race (2) Flange Nut (13) Inner Bearing (3) Flange (14) Adjust Shim (4) Oil Seal (15) Pinion Gear (5) Oil Seal Slinger (16) Diff Cage Assembly (6) Outer Bearing (17) Side Bearing Outer Race...
  • Page 216 DIFFERENTIAL (FRONT) 4A1–9 Disassembly 6. Remove differential cage assembly. 7. Remove side bearing outer race, after removal, keep 1. Remove differential carrier fixing bolt. the right and left hand side bearing assemblies 2. Remove differential assembly. separate maintain inner outer race combinations.
  • Page 217 4A1–10 DIFFERENTIAL (FRONT) 11. Remove flange using an universal puller. 15. Remove adjust shim. 12. Remove the drive pinion assembly using a soft metal 16. Remove oil seal. rod and a hammer. 17. Remove oil seal slinger. 18. Remove outer bearing. 19.
  • Page 218 DIFFERENTIAL (FRONT) 4A1–11 Reassembly 1. Using installer J–7817 and grip J–8092, install outer bearing outer race. 425RW030 Legend (1) Pilot : J–21777–42 (2) Pilot : J–42479–2 415RW013 (3) Gauge Plate : J–42479–1 2. Using installer J–7818 and grip J–8092, install Inner (4) Nut and Stud : J–21777–43 bearing outer race.
  • Page 219 4A1–12 DIFFERENTIAL (FRONT) 4. Set the dial indicator to “0”. Place it on the 6. After the ZERO setting is obtained, rotate the mounting post of the gauging arbor with the gauging arbor until the dial indicator rod does not contact button touching the indicator pad.
  • Page 220 DIFFERENTIAL (FRONT) 4A1–13 8. Select the shim using chart; Pinion marking Dial –1 –2 –3 –4 –5 –6 –7 indicator reading (Inches) 0.023 0.030 0.024 0.030 0.030 0.025 0.030 0.030 0.032 0.026 0.030 0.030 0.032 0.032 0.027 0.030 0.030 0.032 0.032 0.034 0.028...
  • Page 221 4A1–14 DIFFERENTIAL (FRONT) 4. Place the shim on the drive pinion. Install the inner 10. Install flange. bearing onto the pinion using an installer J–6133–01 11. Install flange nut. and a press. 1. Apply lubricant to the pinion threads. NOTE: Do not apply pressure to the roller cage and apply 2.
  • Page 222 DIFFERENTIAL (FRONT) 4A1–15 12. Install adjust shim. 3. Using two sets of feeler gauges, insert a feeler stock of sufficient thickness between each 1. Attach the side bearing to the differential bearing outer race and the carrier to remove all assembly without shims.
  • Page 223 4A1–16 DIFFERENTIAL (FRONT) 5. Use bearing remover J–42379 and pilot 14. Install side bearing outer race. J–8107–2 to remove side bearing. 15. Install differential cage assembly. f Select insert; 303173 and collet halves;44801 16. Install bearing cap then align the setting marks(1) in remover kit J–42379.
  • Page 224 DIFFERENTIAL (FRONT) 4A1–17 425RS038 Legend (1) Heel (2) Toe (3) Concave Side(Coast) (4) Convex Side(Drive) 425RS039...
  • Page 225 4A1–18 DIFFERENTIAL (FRONT) 18. Install differential assembly. 1. Clean the faces of the front axle case and differential carrier. Apply Three Bond TB1215 or equivalent to the sealing side of the axle case and the carrier. 2. Attach the differential case and the carrier assembly to the front axle case and tighten the nuts and bolts.

  • Page 226: Differential Cage Assembly 4A1-19

    DIFFERENTIAL (FRONT) 4A1–19 Differential Cage Assembly Disassembled View 415RW010 Legend (5) Cross Pin (1) Thrust Washer (6) Ring Gear (2) Pinion Gear (7) Bolt (3) Thrust Washer (8) Differential Cage (4) Side Gear (9) Lock Pin Disassembly 1. Remove bolt. 2.

  • Page 227: Inspection And Repair

    4A1–20 DIFFERENTIAL (FRONT) 4. Remove the cross pin, using a soft metal rod and a hammer. 415RS016 Reassembly 425RS043 5. Remove pinion gear and thrust washer. 1. Install thrust washer. 6. Remove side gear. 2. Install side gear. 7. Remove thrust washer. 3.
  • Page 228 DIFFERENTIAL (FRONT) 4A1–21 4. Install cross pin. f 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.

  • Page 229: Main Data And Specifications

    4A1–22 DIFFERENTIAL (FRONT) Main Data and Specifications General Specifications Axle tube Type It consists of the duct, a cast iron housing and the axle tube. Gear type Hypoid Gear ratio (to 1) 3.727 (6VD1 with A/T) 4.100 (6VD1 with A/T, 6VD1 with M/T) 4.300 (6VD1 with M/T) 4.555 (X22SE with M/T) 4.777 (X22SE with M/T)
  • Page 230 DIFFERENTIAL (FRONT) 4A1–23 Torque Specifications E04RX001...
  • Page 231 4A1–24 DIFFERENTIAL (FRONT) E04RW009...

  • Page 232: Special Tools

    DIFFERENTIAL (FRONT) 4A1–25 Special Tools TOOL NO. TOOL NO. ILLUSTRATION ILLUSTRATION TOOL NAME TOOL NAME J–7817 J–8614–01 Installer; Outer bearing Holder; Pinion flange outer race J–7818 J–24250 Installer; Inner bearing Installer; Oil seal outer race J–37264 Differential holding J–8092 fixture Driver handle (Use with J–3289–20 base)
  • Page 233 4A1–26 DIFFERENTIAL (FRONT) TOOL NO. TOOL NO. ILLUSTRATION ILLUSTRATION TOOL NAME TOOL NAME J–8001 J–42479–2 Dial indicator Pilot J–23597–8 Disc J–23597–1 Arbor J–6133–01 Installer; Pinion bearing J–24244 Installer; Side bearing J–39602 Remover; Outer bearing...
  • Page 234 When you replace a fastener, use ONLY the exact part number for that application. WARNING: THIS VEHICLE HAS A SUPPLEMENTAL ISUZU will call out those fasteners that require a RESTRAINT SYSTEM(SRS). REFER TO THE SRS replacement after removal. ISUZU will also call out...

  • Page 235: General Description

    DIFFERNTIAL (REAR) 4A2–2 General Description Limited Slip Differential (LSD) The axle assembly may be equipped with an limited slip The rear axle assembly is of the semi–floating type in differential (LSD). It is similar to the standard differential which the vehicle weight is carried on the axle housing . except that part of the torque from the ring gear is The center line of the pinion gear is below the center line transmitted through clutch packs between the side gears...

  • Page 236: Diagnosis

    DIFFERENTIAL (REAR) 4A2–3 Diagnosis 7. Make sure that there is no metal–to–metal contact between the floor and the frame. Many noises that seem to come from the rear axle After the noise has been determined to be in the axle, the actually originate from other sources such as tires, road type of axle noise should be determined, in order to make surface, wheel bearings, engine, transmission, muffler, or...
  • Page 237 DIFFERNTIAL (REAR) 4A2–4 Rear Axle Noise Condition Possible cause Correction Noise in Drive Excessive pinion ring gear Adjust. backlash. Worn pinion and ring gear. Replace Worn pinion .bearings. Replace. Loose pinion bearings. Adjust. Excessive pinion end play. Adjust. Worn side bearings. Replace.

  • Page 238: Axle Housing

    DIFFERENTIAL (REAR) 4A2–5 Axle Housing Axle Housing and Associated Parts 420RW030 Legend (6) Lateral Rod (1) Lower Link (7) Brake Hose (2) Stabilizer (8) Coil Spring (3) Upper Link (9) Parking Cable (4) Rear Propeller shaft (10) Axle Assembly (5) Shock Absorber Removal 1.
  • Page 239 DIFFERNTIAL (REAR) 4A2–6 9. Loosen the brake tube flare nut, remove the clip and 12. Remove the lateral rod fixing bolt and nut from the take out the brake tube. frame. 13. Remove the upper link mounting bolt and nut (3) from the axle housing.

  • Page 240: Installation

    DIFFERENTIAL (REAR) 4A2–7 Installation 9. Install the lateral rod fixing nut and bolt to the frame side. 1. Install brake pipe. 10. Install the stabilizer linkage mounting nut and bolt to 2. Connect Antilock brake system (ABS) speed sensor the frame side. and harness, refer to 4–Wheel Anti–Lock Brake 11.

  • Page 241: Removal

    DIFFERNTIAL (REAR) 4A2–8 Removal 8. Remove oil seal, retainer, and emergency brake assembly. 1. Raise the vehicle. 9. Remove inner race from shaft with OTC–1126 2. Remove rear wheels and brake calipers or drums. bearing splitter and press. Do not let calipers hang from the vehicle by the brake line or hose.
  • Page 242 DIFFERENTIAL (REAR) 4A2–9 3. Install oil seal. Note direction. 5. Install retainer ring, using installer and press. 4. Install bearing assembly, using installer and press. 420RS033 6. Install snap ring. 420RS030 7. Install axle shaft assembly into housing. NOTE: Install bearing with cup towards inboard side. 8.

  • Page 243: Pinion Oil Seal

    4A2–10 DIFFERNTIAL (REAR) Pinion Oil Seal Pinion Oil Seal and Associated Parts 420RW013 Legend (3) Oil Seal (1) Flange Nut and Washer (4) Outer Oil Seal Slinger (2) Flange (5) Outer Pinion Bearing (Cup and Cone) Removal 1. Remove the rear propeller shaft. Refer to Rear Propeller Shaft in this section.

  • Page 244: Inspection And Repair

    DIFFERENTIAL (REAR) 4A2–11 4. Remove flange nut and washer by using pinion flange 6. Remove oil seal. holder J–8614–01 after raising up its staked parts 7. Remove pinion oil seal slinger. completely. 8. Remove outer bearing by using remover J–39602. 425RW037 5.
  • Page 245 4A2–12 DIFFERNTIAL (REAR) NOTE: Do not drive in, but just temporarily set in the outer 4. Install flange. bearing by hand, which should be indirectly pressed in 5. The pinion washer and a new nut while holding the finally by tightening the flange nut. pinion flange with J–8614–01.

  • Page 246: Differential Assembly

    DIFFERENTIAL (REAR) 4A2–13 Differential Assembly Disassembled View 420RW018 Legend (17) Lock Pin (1) ABS Speed Sensor (18) Axle Vent (2) Housing (19) Gasket (3) Outer Pinion Bearing (Cup and Cone) (20) Cover and Clip Assembly (4) Outer Oil Slinger (21) Fill Plug (with Magnet) (5) Oil Seal (22) Mounting Bracket (6) Companion Flange Assembly...

  • Page 247: Inspecting The Axle Before Disassembly

    4A2–14 DIFFERNTIAL (REAR) Inspecting the Axle Before 4. Remove Differential case. f Pry the case from the axle housing at the differential Disassembly “window”. 1. Remove the axle cover from the rear axle and drain the axle lubricant into a suitable container. 2.
  • Page 248 DIFFERENTIAL (REAR) 4A2–15 8. Remove ring gear from the differential. 12. Remove collapsible spacer(1). f Drive the ring gear off with a brass drift if necessary. f Check drive pinion bearing preload. 415RW011 13. Remove outer seal, outer oil slinger and outer pinion bearing.

  • Page 249: Inspection And Repair

    4A2–16 DIFFERNTIAL (REAR) f Ring and pinion gears are matched sets and are both NOTE: Discard the exciter ring after removal. replaced anytime a replacement of either is necessary. Bearings f Bearings visually and by feel. f The bearings should feel smooth when oiled and rotated while applying as much hand pressure as possible.
  • Page 250 DIFFERENTIAL (REAR) 4A2–17 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.
  • Page 251 4A2–18 DIFFERNTIAL (REAR) 14. Set the dial indicator to “0”. Place it on the mounting 16. After the ZERO setting is obtained, rotate the gauging post of the gauging arbor with the contact button arbor until the dial indicator rod does not touch the touching the indicator pad.
  • Page 252 DIFFERENTIAL (REAR) 4A2–19 18. Select the shim using the chart; Dial Indicator Marking (inches) Reading Reading –1 –2 –3 (inches) 0.027 0.030 0.028 0.030 0.031 0.029 0.030 0.031 0.032 0.030 0.030 0.031 0.032 0.033 0.031 0.030 0.031 0.032 0.033 0.034 0.032 0.030 0.031...

  • Page 253: Side Bearing Preload Adjustment

    4A2–20 DIFFERNTIAL (REAR) 19. Remove bearing caps and depth gauging tools. Tighten the ring gear bolts in sequence 20. Install the correct pinion shim and inner oil slinger Torque: 108 N·m (80 lb ft) onto pinion. NOTE: Discard used bolts and install new ones. NOTE: Do not install pinion gear into housing at this time.

  • Page 254: Pinion Installation

    DIFFERENTIAL (REAR) 4A2–21 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.

  • Page 255: Determination Of Backlash & Preload Shims 4A2-22

    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.

  • Page 256: Backlash Adjustment

    DIFFERENTIAL (REAR) 4A2–23 Backlash Adjustment 11. Install the cover with sealant. Torque: 40 N·m (30 lb ft) 1. Install the differential case assembly and bearing 12. Fill the axle lubricant. caps. 2. Rotate the case several times to seat the bearings. Gear Tooth Pattern Check 3.

  • Page 257: Adjustments Affecting Tooth Contact

    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;...

  • Page 258: Differential Case Assembly

    DIFFERENTIAL (REAR) 4A2–25 Differential Case Assembly Disassembled View 425RW014 Legend (5) Differential Shaft (1) Thrust Washer (for Pinion Gear) (6) Lock Pin (2) Pinion Mate Gear (7) Bolt (3) Thrust Washer(for Side Gear) (8) Differential Case (4) Side Gear...

  • Page 259: Disassembly

    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.

  • Page 260: Limited Slip Differential Assembly

    DIFFERENTIAL (REAR) 4A2–27 Limited Slip Differential Assembly Disassembled View 425RW004 Legend (6) Differential Plate Retainer (1) Thrust Washer–Differential Pinion Mate Gear (7) Lock Pin (2) Pinion Mate Gear (8) Differential Case (3) Dished Spacer (9) Ring Gear Bolts (4) Disc (10) Differential Shaft (5) Plate (11) Differential Side Gear...
  • Page 261 4A2–28 DIFFERNTIAL (REAR) 4. Assemble clutch pack unloading tool . 7. Assemble LSD service adapter J–39834 onto long drive handle J–8592.Insert it into differential shaft a. Install cap J–34174–1 to the bottom differential hole of case. Pull on handle and rotate case until side gear.

  • Page 262: Inspection And Repair

    DIFFERENTIAL (REAR) 4A2–29 12. Remove differential plate retainer from both clutch Reassembly packs to allow separation of the plates and discs. 1. Lubricate thrust face of side gears, plates and discs NOTE: with the proper limited slip rear axle lubricant. f Keep the discs and plates in the same order as they 2.
  • Page 263 4A2–30 DIFFERNTIAL (REAR) 9. While holding gears in place, insert LSD service 12. Position differential shaft in case and drive in with adapter J–39834 with long drive handle J–8592 in hammer. Be sure lock pin hole of differential shaft (5) differential shaft hole of case.

  • Page 264: Main Data And Specifications

    DIFFERENTIAL (REAR) 4A2–31 Main Data And Specifications General Specifications Rear axle Type Salisbury, Semi–floating Rear axle Size 226 mm (8.9 in) Gear type Hypoid Gear ratio (to 1) 3.727 (6VD1 with A/T) 4.100 (6VD1 with A/T, 6VD1 with M/T) 4.300 (6VD1 with M/T) 4.555 (X22SE with M/T) 4.777 (X22SE with M/T) Differential type...
  • Page 265 4A2–32 DIFFERNTIAL (REAR) Torque Specifications E04RX002...

  • Page 266: Special Tools

    DIFFERENTIAL (REAR) 4A2–33 Special Tools TOOL NO. TOOL NO. ILLUSTRATION ILLUSTRATION TOOL NAME TOOL NAME J–42836 J–8614–01 Installer; Inner bearing Pinion flange holder outer race J–37263 J–42824 Installer; Pinion oil seal Pilot;Outer J–42379 J–21777–43 Remover; Bearing Nut & Stud J–39830 J–42827 Adapter;...
  • Page 267 4A2–34 DIFFERNTIAL (REAR) TOOL NO. TOOL NO. ILLUSTRATION ILLUSTRATION TOOL NAME TOOL NAME J–39858 Clutch pack unloading tool kit Includes J–39837–1 J–34174–1/J–34174–2 Disc (2 required) Screw cap and Cap J–22342–15 Forcing screw J–39834 Limited–slip differential J–23597–1 (LSD) service adapter Arbor J–39824 J–42828 Holder...

  • Page 268: Driveline Control System

    When you replace a fastener, use ONLY the exact part number for that application. WARNING: THIS VEHICLE HAS A SUPPLEMENTAL ISUZU will call out those fasteners that require a RESTRAINT SYSTEM (SRS). REFER TO THE SRS replacement after removal. ISUZU will also call out...
  • Page 269 4B–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) electrically by driver’s pressing the 4WD switch (push button type) on instrument panel.
  • Page 270 DRIVELINE CONTROL SYSTEM 4B–3 Normal Operation The motor actuator mounted on transfer rear case is of the transfer position switch changes. The vacuum driven by signal from 4WD switch on instrument panel. solenoid valve (VSV) is driven by the signal from transfer After complete the connecting transfer front output gear position switch and the vacuum actuator connects front to, or disconnecting it from, front propeller shaft, condition...
  • Page 271 4B–4 DRIVELINE CONTROL SYSTEM Retrial The motor actuator starts transfer gear shifting after gear. This procedure is repeated 3 times in maximum. signal from 4WD switch on instrument panel has been While this procedure, 4WD indicator lamp blinks by 2 Hz. received.
  • Page 272 DRIVELINE CONTROL SYSTEM 4B–5 Warning at “4L” position :In view of the shifting switch when vehicle is in “4L” condition. In the case this mechanism of transfer, the gear shifting from 4WD to condition continues for 2 seconds, the shifting to 2WD is 2WD at “4L”...
  • Page 273 4B–6 DRIVELINE CONTROL SYSTEM Functions of Indicator Lamp Indication of vehicle condition : Indicator lamp is controlled by ECU of shift on the fly and shows vehicle conditions as below. Indicator Vehicle condition 4WD switch Transfer position Front axle switch switch Off (Close) 2WD (Open)
  • Page 274 DRIVELINE CONTROL SYSTEM 4B–7 Diagnosis When Switching from 4WD to 2WD 1. In case that the 4WD indicator continues blinking Before Judging That Troubles Occur by 2Hz . (Unfaulty mode) The 4WD indicator continues blinking by 2Hz until both shifting the transfer gear and disconnecting the When Switching from 2WD to 4WD front wheels are completed when switching 4WD to 1.
  • Page 275 4B–8 DRIVELINE CONTROL SYSTEM Parts Location D08RX118 Legend (10) C–32 (1) Battery (11) I–19 (2) Fuse & Relay Box (12) B–19 (3) C–4 (13) C–16 (4) M–11 (14) H–15, H–32 (5) B–8 (15) H–18 (6) C–31 (16) C–15 (7) I–1 (17) M–12 (8) Starter Switch (18) H–9, H–10, H–11...
  • Page 276 DRIVELINE CONTROL SYSTEM 4B–9 Wiring Diagram D08RW214–1...
  • Page 277 4B–10 DRIVELINE CONTROL SYSTEM D08RX119...
  • Page 278 DRIVELINE CONTROL SYSTEM 4B–11 Connector List Connector face Connector face H-11 B-19 H-15 H-18 C-15 H-32 C-16 C-31 C-32 I-19 M-11 M-10 M-12...
  • Page 279 4B–12 DRIVELINE CONTROL SYSTEM Diagnosis of The Faults Based on the Status of 4WD Indicator Lamp, 4WD Switch and T/F Change Lever Diagnosis charts are shown on below. If troubles can not be solved after every chart was traced, troubles may occur in the ECU.
  • Page 280 DRIVELINE CONTROL SYSTEM 4B–13 3. Case that the indicator keeps blinking by 2Hz after aforementioned Solution 2 is carried out. Step Action Check the air pressure and wear of all tires. Try Solution 2 after adjust the Were problems found? air pressure and replace worn tires.
  • Page 281 4B–14 DRIVELINE CONTROL SYSTEM Fault on Switching from 4WD to 2WD 1. Case that indicator dose not blink nor turn out. Step Action Short circuit of the indicator Dose the indicator turn out by ignition off? Go to Step 2 harness.
  • Page 282 DRIVELINE CONTROL SYSTEM 4B–15 2. Case that indicator keeps 2Hz blinking after aforementioned Solution 3 is carried out. Step Action Check the air pressure and wear of all tires. Try Solution 3 after adjust the Were problems found? air pressure and replace worn tires.
  • Page 283 4B–16 DRIVELINE CONTROL SYSTEM 3. Case that indicator’s blinking changes to 4Hz after aforementioned Solution 4 is carried out. Step Action Faults on the harness wiring of Can the transfer lever be operated from High to 4L or vice versa? motor actuator.
  • Page 284 DRIVELINE CONTROL SYSTEM 4B–17 Shift On The Fly Vacuum Piping and Electrical Equipment Vacuum Piping Diagram C04RW005 Actuator Assembly Vacuum Tank 412RW024 412RW025...
  • Page 285 4B–18 DRIVELINE CONTROL SYSTEM Inspection and Repair Vacuum Piping C04RW004 1. Pull out the Hose A in figure and install a vacuum Check Valve gauge. 2. Plug up Hose B in figure to prevent the leak of vacuum. 3. Start the engine and measure vacuum 2 or 3 minutes afterward.
  • Page 286 DRIVELINE CONTROL SYSTEM 4B–19 VSV Assembly 1. With battery not connected (Usual). A–C:There is continuity Inspect the vehicle side harness as follows: B:Closed 2. With battery connected A – B:There is continuity C:Closed 3. If 1) and 2) fail, replace with a new VSV. Functional Detective Switch 412RW026 Legend...
  • Page 287 4B–20 DRIVELINE CONTROL SYSTEM 412RW037 412RX002 Legend Legend (3) Shift Rod (1) 2WD (4) Connector (2) 4WD (3) Shift Rod 2. Connect the terminals as shown in figure. (4) Connector Shift rod of the motor actuator moves and stops 4. If 2) and 3) fail, replace with a new motor actuator. at 4WD position.
  • Page 288 DRIVELINE CONTROL SYSTEM 4B–21 4WD Control Unit 4WD Control Unit Associated Parts 412RW042 Legend (1) Center Console Assembly (2) 4WD Control Unit...
  • Page 289 4B–22 DRIVELINE CONTROL SYSTEM Removal 1. Remove center console assembly. Refer to Interior Trim in Body and Accessories section. 2. Remove two screws and harness connector (1) from 4WD control unit. 412RW041 Legend (1) Harness Connector Installation 1. Connect harness connector, then install 4WD control unit.
  • Page 290 When you replace a fastener, use ONLY the exact part number for that application. WARNING: THIS VEHICLE HAS A SUPPLEMENTAL ISUZU will call out those fasteners that require a RESTRAINT SYSTEM(SRS). REFER TO THE SRS replacement after removal. ISUZU will also call out...

  • Page 291: General Description

    4C–2 DRIVE SHAFT SYSTEM General Description The drive axles are completely flexible assemblies, consisting of inner and outer constant velocity (CV) drive This publication contains essential removal, installation, shaft joints connected by an axle shaft. adjustment and maintenance procedures. For description of front propeller shaft and universal joint, The front axle utilizes a central disconnect type front refer to Front Propeller Shaft in this section.

  • Page 292: Front Hub And Disc (2Wd Model)

    DRIVE SHAFT SYSTEM 4C–3 Front Hub and Disc (2WD Model) Disassembled View 411RX001 Legend (6) Hub and Disc Assembly (1) Bolt (7) ABS Sensor Ring (2) Cover and Gasket (8) Inner Bearing (3) Lock Washer (9) Oil Seal (4) Hub Nut (10) Bolt (5) Outer Bearing (11) Wheel Pin...

  • Page 293: Inspection And Repair

    4C–4 DRIVE SHAFT SYSTEM f Clamp hub and disc assembly in vise, using 7. Remove outer bearing. protective pads. Remove six(6) disc-to-hub 8. Remove oil seal. retaining bolts. 9. Remove inner bearing. 10. Use a brass bar to remove the outer bearing outer race(1), oil seal, inner bearing and inner bearing outer race(2) from the hub.

  • Page 294: Reassembly

    DRIVE SHAFT SYSTEM 4C–5 Reassembly 3. Install bolt. Tighten the bolts to the specified torque. 1. Install wheel pin. Torque: 103 N·m (76 lb ft) f Place hub on a wood workbench or a block of wood approx. 6” by 6” to protect the wheel stud ends and threads.
  • Page 295 4C–6 DRIVE SHAFT SYSTEM 5. Install inner bearing. 8. Install hub nut by using wrench J–36827. Install the outer race by driving it into the hub by using Turn the place where there is a chamfer in the tapped installer J–36829 and grip J–8092. hole to the outer side, and attach the nut.
  • Page 296 DRIVE SHAFT SYSTEM 4C–7 9. Install lock washer. f Turn the side with larger diameter of the tapered bore to the vehicle outer side, then attach the washer. If the bolt holes in the lock plate are not aligned with the corresponding holes in the nut, reverse the lock plate.

  • Page 297: Front Hub And Disc (4Wd Model)

    4C–8 DRIVE SHAFT SYSTEM Front Hub and Disc (4WD Model) Disassembled View 411RW001 Legend (7) Outer Bearing (1) Bolt (8) Bolt (2) Cap (9) Hub and Disc Assembly (3) Snap Ring and Shim (10) Wheel Pin (4) Hub Flange (11) ABS Sensor Ring (5) Lock Washer and Lock Screw (12) Inner Bearing (6) Hub Nut...

  • Page 298: Inspection And Repair

    DRIVE SHAFT SYSTEM 4C–9 f Place hub on a suitable work surface and remove 8. Remove lock washer and lock screw. the studs by using a hammer. 9. Use wrench J–36827, remove hub nut. 411RS004 901RW054 10. Remove hub and disc assembly. Inspection and Repair 11.

  • Page 299: Reassembly

    4C–10 DRIVE SHAFT SYSTEM Reassembly 3. Use installer J–36829 and grip J–8092, then install the inner bearing by driving it into the hub. 1. Install wheel pin. f Place the hub on a wood workbench or a block of wood approx. 6” by 6” to protect the wheel stud ends and threads.
  • Page 300 DRIVE SHAFT SYSTEM 4C–11 5. Apply grease (NLGI No.2 or equivalent) to the lip 8. Install hub nut. portion, then install oil seal by using installer J–36830 Turn to the place where there is a chamfer in the and grip J–8092. tapped hole to the outer side, then attach the nut by using front hub nut wrench J–36827.
  • Page 301 4C–12 DRIVE SHAFT SYSTEM 9. Install lock washer and lock screw in the following 10. Apply adhesive (LOCTITE 515 or equivalent) to both manner. joining flange faces then install hub flange. f Turn the side with larger diameter of the tapered 11.

  • Page 302: Front Drive Shaft Joint

    DRIVE SHAFT SYSTEM 4C–13 Front Drive Shaft Joint Front Drive Shaft Joints Replace- Inspection Of Shift On The Fly System Gear Oil ment f Refer to Front Drive Axle Assembly Replacement in this section, and refer to Front Hub and Disc Overhaul in Suspension section.

  • Page 303: Front Axle Drive Shaft

    4C–14 DRIVE SHAFT SYSTEM Front Axle Drive Shaft Front Axle Drive Shaft and Associated Parts 412RW033 Legend (12) Ball (1) Axle Case and Differential (13) Snap Ring (2) DOJ Case Assembly (14) Ball Retainer (3) Snap Ring (15) Ball Guide (4) Bearing (16) Band (5) Snap Ring...

  • Page 304: Disassembly

    DRIVE SHAFT SYSTEM 4C–15 Disassembly 4. Remove drive shaft joint assembly. 5. Remove the six balls (1) with a screwdriver or NOTE: For the left side, follow the same steps as right equivalent. side. 1. Raise the hooked end of the band with a screwdriver or equivalent.

  • Page 305: Inspection And Repair

    4C–16 DRIVE SHAFT SYSTEM 7. Remove ball retainer, ball guide and bellows. Bushing Replacement 8. Raise the hooked end of the band with a screwdriver f Remove the bushings using a remover J–39378–1 or equivalent. and hammer. 412RS014 412RS015 9. Remove band(1). f By using installer J–39378–2 and base J–39378–3, 10.
  • Page 306 DRIVE SHAFT SYSTEM 4C–17 8. Install band. Note the setting direction. After 13. Align the track on the ball (1) retainer with the window installation, check that the bellows is free from in the cage, and install the six balls into position. distortion.
  • Page 307 4C–18 DRIVE SHAFT SYSTEM 412RS020 Legend (1) Outer Case (2) Circlip (3) Open Ends 16. Install bellows. Adjust the air pressure within the bellows by inserting a screwdriver or equivalent, so that it equals atmospheric pressure. 412RS021 17. Install band. After installation, check that the bellows is free from distortion.

  • Page 308: Shift On The Fly System

    DRIVE SHAFT SYSTEM 4C–19 Shift On The Fly System Shift On The Fly System and Associated Parts 412RW031 Legend (8) Needle Bearing (1) Filler Plug (9) Clutch Gear (2) Bolt (10) Sleeve (3) Oil Seal (11) Housing (4) Snap Ring(External) (12) Front Axle Drive Shaft(LH side) with Bracket (5) Inner Shaft Bearing (13) Bolt...
  • Page 309 4C–20 DRIVE SHAFT SYSTEM 7. Remove snap ring from front axle case by using snap 10. Remove inner shaft bearing. ring pliers. NOTE: Be careful not to damage the shaft. 412RW017 8. Take out inner shaft from front axle case. 412RW015 11.

  • Page 310: Inspection And Repair

    DRIVE SHAFT SYSTEM 4C–21 Inspection And Repair Inner Shaft Run–Out With both end centers supported, rotate the shaft slowly Inspect the removed parts. If there are abnormalities and measure deflection with a dial gauge. such as wear and damage, take corrective action or replace.
  • Page 311 4C–22 DRIVE SHAFT SYSTEM Sleeve Condition Clutch Gear Condition Check and see that there is not wear damage, or cracking Check and see that there is not wear, damage, crack, or in the sleeve. any other abnormality in the clutch gear. NOTE: Close inspection of the groove and inner gear are Clutch Gear Function required because those are important parts.
  • Page 312 DRIVE SHAFT SYSTEM 4C–23 Actuator Check and see that there is no damage, cracking, or other abnormality. Functional Check 412RW007 Disconnect the shift position switch and make sure of function with a vacuum of –400 mmHg applied to Ports A and B, in accordance with the table below.

  • Page 313: Reassembly

    4C–24 DRIVE SHAFT SYSTEM 2. Force a new needle bearing into inner shaft by using a Installer J–41694 and grip J–8092. 412RS037 Reassembly 412RS051 3. Place a new snap ring(internal) in inner shaft. 1. Install the new oil seal which has been immersed in Force a new inner shaft bearing into the inner shaft.

  • Page 314: Drive Shaft System

    DRIVE SHAFT SYSTEM 4C–25 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) 12. Apply liquid gasket to the contact surface on the actuator side.

  • Page 315: Main Data And Specifications

    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 GL–5 (75W–90) Refer to chart in General Information Axle shaft type Constant velocity joint(Birfield joint type and double offset joint) Torque Specifications...
  • Page 316 DRIVE SHAFT SYSTEM 4C–27 E04RW001...

  • Page 317: Special Tools

    4C–28 DRIVE SHAFT SYSTEM Special Tools TOOL NO. TOOL NO. ILLUSTRATION ILLUSTRATION TOOL NAME TOOL NAME J–39378 Remover and Installer; J–36827 Front Axle mount Wrench; Hub nut bushing J– 26941 J–36829 Remover; Bearing Installer; Inner bearing needle J–2619–01 J–36828 Hammer; Sliding Installer;...

  • Page 318: Propeller Shaft

    DRIVE SHAFT SYSTEM 4C–29 Propeller Shaft General Description 401RX002 Legend (3) Rear Propeller Shaft; Aluminum Tube with Flange Yoke Type (1) Front Propeller Shaft (4) Rear Propeller Shaft; (2) Rear Propeller Shaft; Steel Tube Type (for 4 4, 6VD1, A/T model) Aluminum Tube with Spline Yoke Type f Alignment marks should be applied to each propeller Torque is transmitted from the transmission to the axle...

  • Page 319: Universal Joint

    4C–30 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 goes around.This vibration would be the same as a person snapping rope and watching the ”wave”...

  • Page 320: Diagnosis Of Propeller Shaft And Universal Joint

    DRIVE SHAFT SYSTEM 4C–31 Diagnosis of Propeller Shaft and Universal Joint Condition Possible cause Correction Universal Joint Noise. Worn universal joint bearings. Replace. Improper lubrication. Lubricate as directed. Loose flange bolts. Tighten to specifications. Ping, Snap, or Click in Drive Line Loose bushing bolts on the rear Tighten the bolts to specified torque.

  • Page 321: Front Propeller Shaft

    4C–32 DRIVE SHAFT SYSTEM Front Propeller Shaft Front Propeller Shaft and Associated Parts 401RW093 Legend (2) Front Propeller Shaft (1) Bolt, Nut and Washer (Front Axle Side) (3) Bolt, Nut and Washer (Transfer Side) Removal 2. Remove bolt, nut and washer (Front axle side). 3.

  • Page 322: Disassembly

    DRIVE SHAFT SYSTEM 4C–33 Disassembly 401RW032 Legend (3) Boot (1) Sleeve Yoke (4) Clamp (2) Clamp (5) Tube Assembly 1. Lay the shaft horizontally on a bench and secure. 3. Using the flat blade of a screwdriver, pry the loose end of the boot clamp upwards and away from the 2.

  • Page 323: Universal Joint Disassembly

    4C–34 DRIVE SHAFT SYSTEM Universal Joint Disassembly 401RW031 Legend (3) Spider (1) Flange Yoke (4) Needle Roller Bearing (2) Snap Ring 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.

  • Page 324: Inspection And Repair

    DRIVE SHAFT SYSTEM 4C–35 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 Support the propeller shaft on V-blocks (2) and check for run-out by holding the probe of a dial indicator (1) in...

  • Page 325: Universal Joint Reassembly

    4C–36 DRIVE SHAFT SYSTEM Spline Universal Joint Reassembly The nylon-coated spline should be free from nicks and 1. Install spider to flange yoke. Be sure to install the dings and the underlying steel spline should not be visible. spider by aligning the setting marks made during After cleaning the nylon coating spline, the coating should disassembly.

  • Page 326: Reassembly

    DRIVE SHAFT SYSTEM 4C–37 7. Install snap ring. 401RW018 Reassembly 401RW032 Legend (3) Boot (1) Sleeve Yoke (4) Clamp (2) Clamp (5) Tube Assembly...

  • Page 327: Main Data And Specifications

    4C–38 DRIVE SHAFT SYSTEM 1. Apply grease evenly to both the female and male 5. Position boot onto sleeve and yoke shaft in final splines. position over boot grooves. 2. Apply a small amount of grease by finger to the outer 6.

  • Page 328: Rear Propeller Shaft

    DRIVE SHAFT SYSTEM 4C–39 Rear Propeller Shaft Rear Propeller Shaft and Associated Parts 401RX003 Legend (2) Rear Propeller Shaft (1) Bolt, Nut and Washer (Transfer Side) (3) Bolt, Nut and Washer (Rear Axle Side) Removal Installation 1. Raise the vehicle on a hoist. NOTE: Never install the shaft assembly backwards.

  • Page 329: Slip Joint Disassembly

    4C–40 DRIVE SHAFT SYSTEM Slip Joint Disassembly 401RX004 Legend (3) Boot (1) Spline Yoke and Universal Joint Assembly (4) Clamp (2) Clamp (5) Tube and Universal Joint Assembly 1. Lay the shaft horizontally on a bench and secure. 4. When boot clamps becomes loose, remove by hand. 2.

  • Page 330: Universal Joint Disassembly

    DRIVE SHAFT SYSTEM 4C–41 Universal Joint Disassembly 401RX005 Legend (5) Flange Yoke (1) Spline Yoke (6) Bearing (2) Spider (7) Snap Ring (3) Propeller Shaft Assembly (8) Flange Yoke (4) Spider NOTE: Aluminum is softer than steel. Care must be taken not to remove excessive material or damage bearing holes.
  • Page 331 4C–42 DRIVE SHAFT SYSTEM 1. Apply alignment marks on the yokes of the universal 2. Set the yoke in the arbor press with a piece of tube joint, then remove the snap ring. stock beneath it. Place a solid plug on the upper bearing and press it through to release the lower bearing.

  • Page 332: Inspection

    DRIVE SHAFT SYSTEM 4C–43 5. Repeat this procedure on the remaining bearing to remove the spider from the yoke. Inspection f 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) f Propeller shaft for runout (Steel tube type).

  • Page 333: Universal Joint Reassembly

    4C–44 DRIVE SHAFT SYSTEM f Aluminum tube type only: Inspect the aluminum Universal Joint Reassembly tubing for surface scratches and dents. These 1. Pack the four grease cavities of the spider with a high scratches may not exceed 0.2 mm (0.008 in) in depth. quality, extreme pressure N.L.G.I.

  • Page 334: Slip Joint Reassembly

    DRIVE SHAFT SYSTEM 4C–45 Slip Joint Reassembly 401RX004 Legend (3) Boot (1) Spline Yoke and Universal Joint Assembly (4) Clamp (2) Clamp (5) Tube and Universal Joint Assembly 1. Apply grease evenly to both the female and male 7. Be sure clamp is properly seated and secure. splines.

  • Page 335: Main Data And Specifications

    4C–46 DRIVE SHAFT SYSTEM Main Data and Specifications General Specifications 2WD Model 4WD Model Engine X22SE 6VD1 (M/T) 6VD1 (A/T) 6VD1 (M/T) 6VD1 (A/T) Length (between two spiders center) 1265.1 mm 1298.5 mm 1343.8 mm 1212.5 mm 1043.0 mm (49.81 in) (51.12 in) (52.91 in) (47.73 in)

  • Page 336: Caution: Always Use The Correct Fastener In The Proper Location. When You Replace A Fastener, Use

    When you replace a fastener, use ONLY the exact part number for that application. WARNING: THIS VEHICLE HAS A SUPPLEMENTAL ISUZU will call out those fasteners that require a RESTRAINT SYSTEM (SRS). REFER TO THE SRS replacement after removal. ISUZU will also call out...

  • Page 337: General Description

    4D–2 TRANSFER CASE General Description Transfer Case (for M/T) A07RW002...
  • Page 338 TRANSFER CASE 4D–3 Transfer Case (for A/T) A07RW001 The transfer case is used to provide a means of providing power flow to the front axle. The transfer case also provides a means of disconnecting the front axle, providing better fuel economy and quieter operation when the vehicle is driven on improved roads where four wheel drive is not required.

  • Page 339: Transfer Rear Oil Seal

    4D–4 TRANSFER CASE Transfer Rear Oil Seal Transfer Rear Oil Seal and Associated Parts 220RS015 Legend (2) End Nut and Rear Companion Flange (1) Rear Propeller Shaft (3) Oil Seal Removal Installation 1. Disconnect the rear propeller shaft (1) from the 1.
  • Page 340 TRANSFER CASE 4D–5 4. Install the rear companion flange (2) and O–ring (2). 7. Connect the rear propeller shaft to the transfer case and tighten to the specified torque. 5. Use the companion flange holder J–8614–11 to install a new end nut (2) and tighten to the specified torque. Torque: 63 N·m 46 (lb ft) Torque: 167 N·m (123 lb ft) 6.

  • Page 341: Transfer Case Assembly (A

    4D–6 TRANSFER CASE Transfer Case Assembly (A/T) Transfer Case Assembly (A/T) and Associated Parts 260RW008 Legend (6) Transfer Protector (1) Transfer Control Lever Knob (7) Fairing Plate (2) Lower Cluster Assembly (8) Rear Propeller Shaft (3) Rear Console (9) Front Propeller Shaft (4) Center Console (10) Transfer Case Assembly (5) Grommet Assembly and Transfer Control...

  • Page 342: Removal

    TRANSFER CASE 4D–7 Removal 5. Remove center console (4). NOTE: Before removing transmission and transfer assembly from vehicle, change the transfer mode to 2WD using the 4WD push button switch on dash panel. 1. Disconnect battery ground cable. 2. Remove transfer control lever knob (1). 3.

  • Page 343: Installation

    4D–8 TRANSFER CASE 7. Raise and support vehicle with suitable stands. Drain Installation transfer case fluid. 1. Apply a thin coat of molybdenum disulfide grease to 8. Remove transfer protector (6) and fairing plate (7). the input shaft spline as shown in the figure. 150RW006 9.
  • Page 344 TRANSFER CASE 4D–9 2. Install transfer case (10) to the transmission. Tighten transfer bolts as shown in the figure. 261RW001 3. Remove the transmission jack from transmission side. 4. Connect harness connectors and clip. Connector: transfer switch, 2WD–4WD actuator, speed sensor. 5.
  • Page 345 4D–10 TRANSFER CASE 7. Fill transfer case fluid. 8. Lower the vehicle. Install grommet assembly and transfer control lever (5). 256RW007 9. Install center console (4), rear console (3) and lower cluster assembly (2). 10. Install transfer control lever knob (1).

  • Page 346: Transfer Rear Case Assembly (A/T)

    TRANSFER CASE 4D–11 Transfer Rear Case Assembly (A/T) Transfer Rear Case Assembly (A/T) and Associated Parts 220RW133 Legend (4) Control Box Assembly (1) Speedometer Sensor, Speedometer Driven (5) 2WD–4WD Actuator Heat Protector Gear and Plate (6) 2WD–4WD Actuator Assembly (2) Front Companion Flange (7) Transfer Rear Cover Assembly (3) Rear Companion Flange (8) Transfer Case Assembly...
  • Page 347 4D–12 TRANSFER CASE 4. Remove front companion flange (2) and rear 9. Remove the 2WD–4WD actuator assembly bolts. companion flange (3), using the flange companion 10. Pull the 2WD–4WD actuator assembly (6) with holder J–8614–11 to remove the end nut.. 2WD–4WD shift rod.

  • Page 348: Installation

    TRANSFER CASE 4D–13 11. Off set the actuator assembly. Installation 1. Apply the recommended liquid gasket (LOCTITE 17430) or its equivalent to the transfer rear cover fitting faces. 220RW028 12. Remove the actuator assembly (6). 220RS017 2. Install transfer rear cover assembly (7) to transfer case assembly (8).
  • Page 349 4D–14 TRANSFER CASE 4. Tighten the transfer rear case bolts to the specified 8. Tighten the 2WD–4WD actuator bolts to the specified torque. torque. Torque: 37 N·m (27 lb ft) Torque: 19 N·m (14 lb ft) 5. Shift the 2WD–4WD shift rod (17) to the 4WD side. 9.
  • Page 350 TRANSFER CASE 4D–15 15. Use the punch J–39209 to stake the rear companion 16. Stake the front companion flange nut (2) at one spot. flange nut (3) at two spots. NOTE: Be sure to confirm that there is no crack at the staked portion of the flange nut after staking.

  • Page 351: Transfer Rear Cover Assembly

    4D–16 TRANSFER CASE Transfer Rear Cover Assembly 226RW154 Legend (5) Bearing Snap Ring (1) Rear Output Shaft Assembly (6) Ball (2) Rear Output Shaft (7) Speedometer Drive Gear (3) Bearing Snap Ring (8) Ball Bearing (4) Ball Bearing (9) Transfer Rear Cover (with oil seal) Disassembly 1.

  • Page 352: Inspection And Repair

    TRANSFER CASE 4D–17 2. Remove the rear output shaft assembly (1) from the Reassembly transfer rear cover (with oil seal) (9). Transfer rear cover (with oil seal) (9). Oil seal 3. Remove ball bearing (8), using a bench press and the replacement.
  • Page 353 4D–18 TRANSFER CASE 2. Install bearing snap ring (5), using a pair of snap ring pliers. 3. Install ball (6). 4. Install speedometer drive gear (7). 226RS064 5. Use the ball bearing installer J–37223 to install the ball bearing (8). 226RS065 6.

  • Page 354: Detent, Shift Arm, And Interlock Pin (Transfer Case Assembly)

    TRANSFER CASE 4D–19 Detent, Shift Arm, and Interlock Pin (Transfer Case Assembly) Disassembled View 262RW005 Legend (9) Interlock Pin (1) Detent Ball, Spring and Plug (10) Spring (2) Spring Pin and Bridge (11) Select Rod Assembly (3) Spring Pin (12) Spring Pin (4) Spring (13) High–Low Shift Rod (5) 2WD–4WD Shift Rod...

  • Page 355: Disassembly

    4D–20 TRANSFER CASE Disassembly 5. Remove shift arm (6). 6. Remove shift block (7). 1. Remove detent ball, spring and plug (1). 7. Remove 4WD indicator switch (8). 2. Use a spring pin remover to remove the spring pin (2) 8.

  • Page 356: Inspection And Repair

    TRANSFER CASE 4D–21 Inspection and Repair Refer to “TRANSFER CASE ASSEMBLY” in this section for inspection and repair. Reassembly 1. Place shift block (15) in transfer case (16). 2. Set shift arm (14) on the High–Low sleeve. 3. Push High–Low shift rod (13) through shift arm (14) and block (14).
  • Page 357 4D–22 TRANSFER CASE 12. Install 4WD indicator switch and gasket (8). Tighten to the specified torque. Torque: 39 N·m (29 lb ft) 13. Install spring (4). 14. Engage the 2WD–4WD sleeve with the 4WD side and install the spring pin (3). 262RW022 15.

  • Page 358: Transfer Case Assembly

    TRANSFER CASE 4D–23 Transfer Case Assembly Disassembled View 226RW209 Legend (16) Bearing Snap Ring (1) Bearing Snap Ring (17) Ball Bearing (2) Ball Bearing (18) Bearing Collar (3) Lock Nut (19) Sub–Gear Snap Ring (M/T) (4) Snap Ring (A/T) (20) Spacer (M/T) (5) Input Shaft Assembly (A/T) (21) Belleville Spring (M/T) (6) High–Low Clutch Hub and Sleeve...

  • Page 359: Disassembly

    4D–24 TRANSFER CASE (32) Bearing Snap Ring (38) Spacer (33) Counter Gear Assembly (39) Belleville Spring (34) Snap Ring (40) Sub–Gear (anti–lash plate) (35) Ball Bearing (41) Counter Gear (36) Snap Ring (42) Transfer Case (with oil seal) (37) Ball Bearing Disassembly 5.
  • Page 360 TRANSFER CASE 4D–25 9. Remove needle bearing (8). 14. Use a pair of snap ring pliers to remove the bearing snap ring (14). 10. Remove bearing collar (9). 15. Use a plastic hammer to tap the front output gear assembly (15) free. 226RS071 11.
  • Page 361 4D–26 TRANSFER CASE 23. Disassemble the 2WD–4WD clutch hub and sleeve 30. Use a bench press and the bearing remover assembly (28). J–22912–01 to remove the ball bearing (37). f Springs (1) f Inserts (2) f Clutch Hub (3) f Sleeve (4) 226RS073 31.

  • Page 362: Inspection And Repair

    TRANSFER CASE 4D–27 f Remove the transfer case from the intermediate 3. If the measured value exceeds the specified limit, the plat with gear assembly (M/T). clutch hub must be replaced. Clutch hub spline play Inspection and Repair Standard : 0–0.1 mm (0–0.004 in) Limit : 0.2 mm (0.008 in) 1.
  • Page 363 4D–28 TRANSFER CASE Synchronizers The synchronizer hubs and sliding sleeves are a selected assembly and should be kept together as originally assembled. Clean synchronizer components with clean solvent and air dry. Inspect the components for the following: f Teeth for wear, scuffs, nicks, burrs or breaks. f Keys and springs for wear, cracks or distortion, replace if these conditions are present.
  • Page 364 TRANSFER CASE 4D–29 Detent Springs 1. Inspect the springs for distortion, cracks or wear. Replace if these conditions are present. Detent Spring Free Length 1. Use a vernier caliper to measure the detent spring free length. 2. If the measured value is less than the specified limit, the detent spring must be replaced.

  • Page 365: Reassembly

    4D–30 TRANSFER CASE Reassembly Input Shaft Oil Seal Replacement 1. Remove the oil seal from the transfer case. 2. Apply the engine oil to the oil seal outer surfaces. 3. Apply recommended grease (BESCO L2) or equivalent to the oil seal lip. 4.
  • Page 366 TRANSFER CASE 4D–31 Front Output Shaft Oil Seal Replacement 1. Install the transfer case (with oil seal) (42), performing the following steps. (M/T) 1. Remove the oil seal from the transfer case. f Cover the shaft splines with adhesive tape (43). 2.
  • Page 367 4D–32 TRANSFER CASE Install the transfer case together with intermediate plate with gear assembly to transmission case (M/T). Tighten the transfer case bolts to the specified torque a little at a time (M/T). Torque : 37 N·m (27 lb ft) 2.
  • Page 368 TRANSFER CASE 4D–33 14. Assemble the 2WD–4WD clutch hub and sleeve assembly (28). 226RW156 9. Install ball bearing (35), using a bench press. 10. Install snap ring (34). 226RW140 15. Engage the springs in the same insert with the open 11.
  • Page 369 4D–34 TRANSFER CASE 16. Install a new stopper plate (29) and the clutch hub and 21. Apply engine oil to the thrust surfaces of the sleeve assembly (28) to the front output shaft (31). sub–gear, the belleville spring, and the spacer. 226RW157 262RW014 22.
  • Page 370 TRANSFER CASE 4D–35 25. Install ball bearing (17), using a bench press. 27. Use a pair of snap ring pliers to install the snap ring (16) to the output shaft (31). 26. Select a snap ring (16) that will allow the minimum axial play.
  • Page 371 4D–36 TRANSFER CASE 31. Install plate (11), ball (10) and bearing collar (9). 38. Use the punch to stake the lock nut (3) at one spot. 32. Install needle bearing (8) and input gear (7). 39. Use a suitable drift and hammer to install the ball bearing (2).

  • Page 372: Main Data And Specifications

    TRANSFER CASE 4D–37 Main Data and Specifications General Specifications Type Synchronized type gears shifting between the 2 and 4 wheel drive mode. Constant mesh type gears shifting between “low” and “high”. Control method Remote (A/T) and direct (M/T) control with the gear shift lever on the floor for gears shifting between “low”...
  • Page 373 4D–38 TRANSFER CASE E07RX006...
  • Page 374 TRANSFER CASE 4D–39 E07RX005...

  • Page 375: Special Tools

    4D–40 TRANSFER CASE Special Tools PART NO. PART NO. ILLUSTRATION ILLUSTRATION PART NAME PART NAME J–22912–01 J–39208 Bearing Rear oil seal installer remover/installer J–38592 J–37486–A Transfer case oil seal Bearing installer adapter installer J–37219 J–8614–11 Mainshaft nut wrench Flange holder J–37223 J–37217 Rear output shaft and...
  • Page 376 SECTION BRAKE CONTROL SYSTEM 5A–1 RODEO BRAKES CONTENTS Brake Control System ....5A–1 Anti–lock Brake System ....

  • Page 377: Caution: Always Use The Correct Fastener In The Proper Location. When You Replace A Fastener, Use

    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.
  • Page 378 BRAKE CONTROL SYSTEM 5A–3 General Description The Anti-lock Brake System (ABS) works on all four This system helps the driver maintain greater control of wheels. A combination of wheel speed sensor and the vehicle under heavy braking conditions. Electronic Hydraulic Control Unit (EHCU) can determine NOTE: The Electronic Hydraulic Control Unit (EHCU) when a wheel is about to stop turning and adjust brake comprises the Hydraulic Unit (H/U) and the coil Integrated...
  • Page 379 BRAKE CONTROL SYSTEM 5A–4 Functional Description Hydraulic Unit (H/U) Solenoid Valve C05RW012 Legend (1) Isolation Valve (2) Dump valve...
  • Page 380 BRAKE CONTROL SYSTEM 5A–5 Normal Braking Brake fluid travels through the centre of the normally open isolation valve around the normally closed dump valve During normal (non anti-lock) braking, the solenoid valves and on to the brake pistons. are without current and closed due to spring force. C05RW010 Legend (1) Brake...
  • Page 381 BRAKE CONTROL SYSTEM 5A–6 Pressure Isolation (Pressure Maintain) The microprocessor in the coil integrated module sends a voltage to the coil to energize and close the isolation The electro-hydraulic control unit is activated when the valve. This prevents any additional fluid pressure applied brakes are applied which sends a signal to the coil by the brake pedal from reaching the wheel.
  • Page 382 BRAKE CONTROL SYSTEM 5A–7 Pressure Reduction The dump valves are operated independently to control the deceleration of the wheel. At this point, the brake Once the brake pressure is isolated, it must be reduced to pedal is isolated from the base brake system, the allow the wheels to unlock.
  • Page 383 BRAKE CONTROL SYSTEM 5A–8 Pressure Increase (Re-apply) If more pressure is required, more fluid is drawn from the master cylinder and applied to the brakes. The driver may The re-apply sequence is initiated to achieve optimum feel slight pedal pulsations, or pedal drop, this is normal braking.
  • Page 384 BRAKE CONTROL SYSTEM 5A–9 Brake Release The isolation valve opens and fluid may return to the master cylinder. Conventional braking is then resumed. 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.

  • Page 385: Anti-Lock Brake System

    BRAKE CONTROL SYSTEM 5A–10 System Components Wheel Speed Sensor Electronic Hydraulic Control Unit (EHCU), three Wheel It consists of a sensor and a rotor. The sensor is attached Speed Sensors, Warning Light, and G-sensor. to the knuckle on the front wheels and to the rear axle case on the rear differential.

  • Page 386: General Diagnosis

    BRAKE CONTROL SYSTEM 5A–11 Powertrain Control Module. These modules are designed Data Link Connector to withstand normal current draws associated with vehicle operation. However, care must be taken to avoid EHCU overloading any of the EHCU circuits. In testing for opens Electronic Hydraulic Control Unit or shorts, do not ground or apply voltage to any of the circuits unless instructed to do so by the appropriate...

  • Page 387: Test Driving Abs Complaint Vehicles

    BRAKE CONTROL SYSTEM 5A–12 Test Driving ABS Complaint Vehicles Normal Operation In case that there has been an abnormality in the lighting “ABS” Warning Light pattern of “ABS” warning light, the fault can be located in When the ignition is first moved from “OFF” to “RUN” , the accordance with the “DIAGNOSIS BY “ABS”...

  • Page 388: Tech 2 Scan Tool

    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 (3) DLC Cable (1) PCMCIA Card (4) Tech–2...
  • Page 389 Isuzu systems PCMCIA card. Follow the Tech 2, the following steps must be performed: operating procedure below. 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).
  • Page 390 BRAKE CONTROL SYSTEM 5A–15 060RX063...

  • Page 391: Data List

    BRAKE CONTROL SYSTEM 5A–16 DATA LIST The data displayed by DATA LIST are as follows: Display Content OK/NG Criteria for Data f Start the vehicle and make sure of linear change in Front Left Wheel Speed km/h (MPH) Front Right Wheel Speed each wheel speed.

  • Page 392: Actuator Test

    BRAKE CONTROL SYSTEM 5A–17 ACTUATOR TEST f Be sure to start ACTUATOR TEST with the engine This mode is used to exercise the ABS actuators and stopped. make sure they operate normally. Prior to the test, pay f Before testing, make sure that electrical trouble, if attention to the cautions below.
  • Page 393 BRAKE CONTROL SYSTEM 5A–18 F05RX002...
  • Page 394 BRAKE CONTROL SYSTEM 5A–19 F05RX003...
  • Page 395 BRAKE CONTROL SYSTEM 5A–20 F05RX004...

  • Page 396: Tech 2 Service Bleed

    BRAKE CONTROL SYSTEM 5A–21 Tech 2 Service Bleed F05RX005...

  • Page 397: Basic Diagnostic Flow Chart

    BRAKE CONTROL SYSTEM 5A–22 F05RX006 Basic Diagnostic Flow Chart Step Action 1. Customer complaint. 2. Questioning to customer. 3. Basic inspection (Refer to “Basic inspection procedure”) Using TECH 2? Go to Step 2 Go to Step 4 Make sure of DTC by mode “F0: Diagnostic Trouble Codes”. Clear code and check for Is EHCU including DTC?

  • Page 398: Basic Inspection Procedure

    BRAKE CONTROL SYSTEM 5A–23 Basic Inspection Procedure 1. Basic Inspection of Service Brake Step Action Is the fluid level normal? Replenish with fluid Go to Step 2 Go to Step 2 Does fluid leak? Repair Go to Step 3 Go to Step 3 Is the booster function normal? Repair Go to Step 4...

  • Page 399: Ehcu Connector Pin-Out Checks

    BRAKE CONTROL SYSTEM 5A–24 EHCU Connector Pin-out Checks f Disconnect Electronic Hydraulic Control Module. f Perform checks with high impedance digital multimeter J-39200 or equivalent. Circuit to be Tested Ignition Multimeter Measure be- Nominal Value Note Switch Scale/Range tween Pin Position Number Power supply...

  • Page 400: Circuit Diagram

    BRAKE CONTROL SYSTEM 5A–25 Circuit Diagram D08RX108...
  • Page 401 BRAKE CONTROL SYSTEM 5A–26 D08RX110...
  • Page 402 BRAKE CONTROL SYSTEM 5A–27 D08RX109...

  • Page 403: Connector List

    BRAKE CONTROL SYSTEM 5A–28 Connector List Connector face Connector face H-13 B-19 H-14 H-26 C-13 I-18 C-33 C-16 C-36 E-28 E-30 C-34 H-12 H-15 H-25...

  • Page 404: Part Location

    BRAKE CONTROL SYSTEM 5A–29 Part Location D08RX107 Legend (11) F–4 (1) Battery (12) H–26 (2) Fuse & Relay Box (13) H–25 (3) C–36 (14) H–15 (4) C–5 (15) C–16 (5) C–4 (16) C–13 (6) H–12, 13, 14 (17) H–5 (7) I–18 (18) B–19 (8) Starter Switch (19) E–30 (6VD1)

  • Page 405: Symptom Diagnosis

    BRAKE CONTROL SYSTEM 5A–30 Symptom Diagnosis 4. Brake pedal feel is abnormal. 5. Braking sound (from EHCU) is heard while not The symptoms that cannot be indicated by warning light braking. can be divided in the following five categories: These are all attributable to problems which cannot be de- 1.

  • Page 406: Chart A-2 Uneven Braking Occurs While Abs Works

    BRAKE CONTROL SYSTEM 5A–31 Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2) Step Action 1. Connect TECH 2. Replace wheel 2. Make sure of the output conditions of each sensor. speed sensor. Is the output of each sensor normal? Go to Step 3 Go to Step 2 Return to Chart A-1.

  • Page 407: Chart A-3, Ta-3 The Wheels Are Locked

    BRAKE CONTROL SYSTEM 5A–32 Chart A-3, TA-3 The Wheels Are Locked Step Action Is ABS working? Go to Step 2 Go to Step 6 Is vehicle speed under 10 km/h (6mph)? Normal. Go to Step 3 Is sensor output normal? (Chart C-1 or TC-1) Replace sensor or repair harness.
  • Page 408 BRAKE CONTROL SYSTEM 5A–33 Chart A-4 Brake Pedal Feed Is Abnormal Step Action Is the stop light actuated when the brake pedal is depressed? Go to Step 2 Go to Step 3 1. Turn the ignition switch off. Harness NG 2.

  • Page 409: Chart A-5, Ta-5 Braking Sound

    BRAKE CONTROL SYSTEM 5A–34 Chart A-5, TA-5 Braking Sound (From EHCU) Is Heard While Not Braking Step Action Is this the first vehicle start after engine start? It is self checking sound Normal. Go to Step 2 Is vehicle speed under 10 km/h (6 mph)? It is self checking sound Normal.

  • Page 410: Diagnostic Trouble Codes

    BRAKE CONTROL SYSTEM 5A–35 Diagnostic Trouble Codes Choose and trace an appropriate flowchart by the numbers listed below to find fault and repair. Code Chart Chart Diagnosis Item Flash out Serial Communications — — — — C0285 2 WD Controller in 4WD Vehicle Controller Wiring C0271 RAM read/write error...
  • Page 411 BRAKE CONTROL SYSTEM 5A–36 Code Chart Chart Diagnosis Item Flash out Serial Communications C0225 FL Open or shorted sensor B-17 C0221 FR Open or shorted sensor B-18 C0235 Rear Open or shorted sensor B-19 C0226 FL Missing sensor signal B-20 B-20 C0227 FL Sensor signal dropout...

  • Page 412: Diagnosis By "Abs" Warning Light Illumination Pattern

    BRAKE CONTROL SYSTEM 5A–37 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 during driving, trouble should be diagnosed on a illumination pattern basis as follows: Condition...

  • Page 413: Diagnostic Trouble Codes (Dtcs)

    BRAKE CONTROL SYSTEM 5A–38 Diagnostic Trouble Codes (DTCs) 1. How to start DTC display: f Confirm that the vehicle has come to a complete When the warning light in the meter remains ON, the stop (with the wheels standing still) and that the EHCU stores the fault identification and disables the brake pedal is not depressed.
  • Page 414 BRAKE CONTROL SYSTEM 5A–39 B05RW005 4. Notes f If the following should occurs during Diagnostic Trouble Code (DTC) display the display will be discontinued. After initial check, the status that is under the control of ABS will be returned : –...

  • Page 415: Chart B-1 With The Key In The On Position (Before Starting The Engine). Warning Light (W/L) Is Not Activated

    BRAKE CONTROL SYSTEM 5A–40 B05RS005 The DTC 12 is displayed repeatedly. (display is discontinued after about 5 minutes after) Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated. Step Action Is W/L fuse disconnected? Replace fuse.

  • Page 416: Chart B-2 Cpu Error (Dtc 14 (Flash Out) / C0271, C0272, C0273, C0284 (Serial Communications))

    BRAKE CONTROL SYSTEM 5A–41 Chart B-2 CPU Error (DTC 14 (Flash out) / C0271, C0272, C0273, C0284 (Serial communications)) Step Action 1. Turn the key off. 2. Disconnected coil integrated module connector. 3. Inspect coil integrated module ground. Repair the body ground harness.

  • Page 417: Chart B-5 Excessive Isolation Time (Dtc 18 (Flash Out) / C0274 (Serial Communications))

    BRAKE CONTROL SYSTEM 5A–42 Chart B-5 Excessive Isolation Time (DTC 18 (Flash out) / C0274 (Serial communications)) Step Action Check for anything causing extended ABS activation, such as locked brakes or an erratic speed sensor signal. Repair or Was a problem found? Replace Go to Step 2 1.

  • Page 418: Chart B-8 2Wd Controller In 4Wd Vehicle

    BRAKE CONTROL SYSTEM 5A–43 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 Action Remove coil integrated module connector. Repair.

  • Page 419: Chart B-10 Ehcu Valve Relay Failure (Dtc 35 (Flash Out) / C0265, C0266 (Serial Communications))

    BRAKE CONTROL SYSTEM 5A–44 Chart B-10 EHCU Valve Relay Failure (DTC 35 (Flash out) / C0265, C0266 (Serial communications)) Step Action 1. Turn the key off. Repair fuse and 2. Disconnect coil integrated module connector. harness coil 3. Measure the voltage between terminal 1 of the coil integrated integrated module connector (C-5) and body ground.

  • Page 420: Chart B-13 Fr Isolation Solenoid Coil Failure (Dtc 43 (Flash Out) / C0241, C0243 (Serial Communications))

    BRAKE CONTROL SYSTEM 5A–45 Chart B-13 FR Isolation Solenoid Coil Failure (DTC 43 (Flash out) / C0241, C0243 (Serial communications)) Step Action Was the “EHCU Connector Pin–out Checks” performed? Go to “EHCU Connector Go to Step 2 Pin–out Checks.” 1. Turn the key switch to off. Repair the 2.

  • Page 421: Chart B-16 Rear Dump Solenoid Coil Failure (Dtc 46 (Flash Out) / C0252, C0254 (Serial Communications))

    BRAKE CONTROL SYSTEM 5A–46 Chart B-16 Rear Dump Solenoid Coil Failure (DTC 46 (Flash out) / C0252, C0254 (Serial communications)) Step Action Was the “EHCU Connector Pin–out Checks” performed? Go to “EHCU Connector Go to Step 2 Pin–out Checks.” 1. Turn the key switch to off. Repair the 2.

  • Page 422: Chart B-18 Fr Speed Sensor Open Or Shorted (Dtc 52 (Flash Out) / C0221 (Serial Communications))

    BRAKE CONTROL SYSTEM 5A–47 Chart B-18 FR Speed Sensor Open or Shorted (DTC 52 (Flash out) / C0221 (Serial communications)) Step Action 1. Turn the key off. Check for faults 2. Disconnect coil integrated module connector. in harness 3. Measure the resistance between coil integrated module between speed connector (C-4) terminals 3 and 11.

  • Page 423: Chart B-19 Rear Speed Sensor Open Or Shorted (Dtc 53 (Flash Out) / C0235 (Serial Communications))

    BRAKE CONTROL SYSTEM 5A–48 Chart B-19 Rear Speed Sensor Open or Shorted (DTC 53 (Flash out) / C0235 (Serial communications)) Step Action 1. Turn the key off. Check for faults 2. Disconnect coil integrated module connector. in harness 3. Measure the resistance between coil integrated module between speed connector (C-4) terminals 4 and 12.

  • Page 424: Chart B-20 Fl Speed Sensor Missing (Dtc 61 (Flash Out) / C0226, C0227 (Serial Communications))

    BRAKE CONTROL SYSTEM 5A–49 Chart B-20 FL Speed Sensor Missing (DTC 61 (Flash out) / C0226, C0227 (Serial communications)) Step Action 1. Turn the key off. 2. Disconnect coil integrated module connector. 3. Measure the FL speed sensor resistance between coil integrated module connector (C-4) terminals 2 and 10.

  • Page 425: Chart B-21 Fr Speed Sensor Missing (Dtc 62 (Flash Out) / C0222, C0223 (Serial Communications))

    BRAKE CONTROL SYSTEM 5A–50 Chart B-21 FR Speed Sensor Missing (DTC 62 (Flash out) / C0222, C0223 (Serial communications)) Step Action 1. Turn the key off. 2. Disconnect coil integrated module connector. 3. Measure the FR speed sensor resistance between coil integrated module connector (C-4) terminals 3 and 11.

  • Page 426: Chart B-22 Rear Speed Sensor Missing (Dtc 63 (Flash Out) / C0236, C0237 (Serial Communications))

    BRAKE CONTROL SYSTEM 5A–51 Chart B-22 Rear Speed Sensor Missing (DTC 63 (Flash out) / C0236, C0237 (Serial communications)) Step Action 1. Turn the key off. 2. Disconnect coil integrated module connector. 3. Measure the Rear speed sensor resistance between coil integrated module connector (C-4) terminals 4 and 12.

  • Page 427: Chart B-23 Simultaneous Drop-Out Of Front Speed Sensor Signal (Dtc 64 (Flash Out) / C0229 (Serial Communications))

    BRAKE CONTROL SYSTEM 5A–52 Chart B-23 Simultaneous Drop-out of Front Speed Sensor Signal (DTC 64 (Flash out) / C0229 (Serial communications)) Step Action 1. Turn the key off. 2. Disconnect coil integrated module connector. 3. Measure the FL speed sensor resistance between coil integrated module connector (C-4) terminals 2 and 10.

  • Page 428: Chart B-24 Wheel Speed Input Abnormality (Dtc 65 (Flash Out) / C0238 (Serial Communications))

    BRAKE CONTROL SYSTEM 5A–53 Chart B-24 Wheel Speed Input Abnormality (DTC 65 (Flash out) / C0238 (Serial communications)) Step Action Using TECH 2? Go to Step 2 Go to Step 3 1. Connect TECH 2. 2. Select Snap shot manual trigger. Go to Step 3 3.

  • Page 429: Unit Inspection Procedure

    BRAKE CONTROL SYSTEM 5A–54 Unit Inspection Procedure This section describes the following inspection proce- dures referred to during “SYMPTOM DIAGNOSIS” and “DIAGNOSIS BY ‘ABS’ WARNING LIGHT ILLUMINA- TION PATTERN” : without TECH 2 with TECH 2 Sensor Output Inspection Chart C-1-1 to C-1-3 Chart TC-1 Chart C-1-1 FL Sensor Output Inspection Procedure Step...

  • Page 430: Chart C-1-2 Fr Sensor Output Inspection Procedure

    BRAKE CONTROL SYSTEM 5A–55 Chart C-1-2 FR Sensor Output Inspection Procedure Step Action 1. Turn the key off. 2. Disconnect coil integrated module connector. 3. Jack up the vehicle with all four wheels off the ground. Measure the AC voltage between coil integrated module connector terminals while turning FR wheel at a speed of 1 RPS: Is the check between coil integrated module connector (C-4)

  • Page 431: Chart Tc-1 Sensor Output Inspection Procedure

    BRAKE CONTROL SYSTEM 5A–56 Chart TC-1 Sensor Output Inspection Procedure Step Action 1. Connect TECH 2. 2. Check the wheel speed of each sensor by Data List. Is the vehicle speed normal? Go to Step 6 Go to Step 2 Check the sensor harness for suspected disconnection (check Replace speed while shaking harness/connector).

  • Page 432: Special Tools

    BRAKE CONTROL SYSTEM 5A–57 Special Tools TOOL NO. ILLUSTRATION TOOL NAME J–35616 Connector test adapter J–39200 High impedance multimeter 7000086–ISU Tech 2 Set (1) PCMCIA Card (2) SAE 16/19 Adapter (3) DLC Cable (4) Tech 2...

  • Page 433: Anti-Lock Brake System

    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.

  • Page 434: Removal

    ANTI–LOCK BRAKE SYSTEM 5B–2 Electronic Hydraulic Control Unit Electronic Hydraulic Control Unit and Associated Parts 350RW017 Legend (3) Bracket (1) EHCU (4) Bolt and Nut (2) Bolt Removal 1. Remove brake pipes. f After disconnecting brake pipe, cap or tape the openings of the brake pipe to prevent the entry of foreign matter.

  • Page 435: Installation

    ANTI–LOCK BRAKE SYSTEM 5B–3 4. Remove harness connector. Disassembly 5. Remove EHCU ASM. 1. Remove fixing bolts from EHCU. 6. Remove EHCU. 2. Remove coil integrated module from hydraulic unit. Disassembled View 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)

  • Page 436: Installation

    ANTI–LOCK BRAKE SYSTEM 5B–4 Front Wheel Speed Sensor Front Wheel Speed Sensor and Associated Parts 350RS033 Legend (3) Sensor Cable Fixing Bolt (Lower side) (1) Speed Sensor Connector (4) Sensor Cable Fixing Bolt (Sensor side) (2) Sensor Cable Fixing Bolt (Upper side) (5) Speed Sensor Removal Installation...

  • Page 437: Installation

    ANTI–LOCK BRAKE SYSTEM 5B–5 Rear Wheel Speed Sensor Removal Installation 1. Disconnect harness connector (1). 1. Install speed sensor (3). 2. Remove sensor fixing bolt (2) . 2. Tighten the sensor fixing bolt (2) to the specified torque. 3. Remove speed sensor (3). Torque : 11 N·m (95 lb in) 3.
  • Page 438 SECTION POWER–ASSISTED BRAKE SYSTEM 5C–1 RODEO BRAKES POWER-ASSISTED BRAKE SYSTEM CONTENTS Service Precaution ..... . 5C–2 Master Cylinder Assembly ....

  • Page 439: Service Precaution

    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.
  • Page 440 POWER–ASSISTED BRAKE SYSTEM 5C–3 The master cylinder contains two pistons that supply the CAUTION: hydraulic pressure for a dual–circuit braking system. The 1. The master cylinder is not repairable. If found primary piston provides the fluid pressure to the front defective, it must be replaced as a complete brakes, while the secondary piston provides the fluid assembly.
  • Page 441 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, 4. Replace pads in axle sets only. rotor, pad assembly and support bracket. The caliper 5.
  • Page 442 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 move both shoes out contact the drum.

  • Page 443: Diagnosis

    5C–6 POWER–ASSISTED BRAKE SYSTEM Diagnosis Warning Light Operation When the ignition switch is in the START position, the Road Testing The Brakes “BRAKE” warning light should turn on and go off when the ignition switch returns to the ON position. Brake Test The following conditions will activate the “BRAKE”...

  • Page 444: General Diagnosis

    POWER–ASSISTED BRAKE SYSTEM 5C–7 General Diagnosis Condition Possible cause Correction Brake Pull 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.
  • Page 445 5C–8 POWER–ASSISTED BRAKE SYSTEM Condition Possible cause Correction Excessive Brake Pedal Travel Air in hydraulic circuit. Bleed the hydraulic circuit. Level of brake fluid in the reservoir Replenish brake fluid reservoir to too low. specified level and bleed hydraulic circuit as necessary. Master cylinder push rod clearance Adjust excessive.
  • Page 446 POWER–ASSISTED BRAKE SYSTEM 5C–9 Condition Possible cause Correction Poor Brake Action Master cylinder faulty. Correct or replace. Vacuum booster faulty. Correct or replace. Level of brake fluid in reservoir too Replenish and bleed. low. Air in hydraulic circuit. Bleed Disc brake caliper faulty. Clean or replace.

  • Page 447: Hydraulic Brakes

    5C–10 POWER–ASSISTED BRAKE SYSTEM Hydraulic Brakes Filling Master Cylinder Reservoir disconnected at any fitting located between the master cylinder and brakes, then the brake system served by the CAUTION: Use only specified brake fluid. Do not disconnected pipe must be bled. use any fluid which contains a petroleum base.

  • Page 448: Flushing Brake Hydraulic System

    POWER–ASSISTED BRAKE SYSTEM 5C–11 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.

  • Page 449: Front Caliper Brake Hose

    5C–12 POWER–ASSISTED BRAKE SYSTEM Front Caliper Brake Hose Front Caliper Brake Hose Removal Associated Parts 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.

  • Page 450: Rear Axle Brake Hose

    POWER–ASSISTED BRAKE SYSTEM 5C–13 Rear Axle Brake Hose Rear Axle Brake Hose and Associated Removal Parts 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.

  • Page 451: Brake Pipe

    5C–14 POWER–ASSISTED BRAKE SYSTEM Brake Pipe Removal Installation To install, follow the removal steps in the reverse order, 1. Raise the vehicle and support it with suitable safety noting the following points. stands. 1. Tighten the brake pipes to the specified torque. 2.

  • Page 452: P & B (Proportioning And Bypass) Valve

    POWER–ASSISTED BRAKE SYSTEM 5C–15 P & B (Proportioning and Bypass) Valve P & B (Proportioning and Bypass) Valve Sectional View 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 350RW026 different function.

  • Page 453: Main Data And Specifications

    5C–16 POWER–ASSISTED BRAKE SYSTEM Main Data and Specifications Torque Specifications E05RW014...

  • Page 454: Brake Pedal

    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 310RW011 NOTE: While adjusting the stoplight switch, make sure that the threaded part of the stoplight switch does not push the brake pedal.

  • Page 455: Brake Pedal And Associated Parts

    5C–18 POWER–ASSISTED BRAKE SYSTEM Brake Pedal and Associated Parts 310RW007 Legend (6) Peadl Assembly (1) Brake Pedal Bracket Assembly (7) Push Rod Pin (2) Fulcrum Pin and Nut (8) Lower Cover (3) Connector (9) Bolts and Nut (4) Snap Pin (10) Driver Knee Bolster (5) Return Spring Removal...

  • Page 456: Stoplight Switch

    POWER–ASSISTED BRAKE SYSTEM 5C–19 7. Tighten the steering column fixing nut (9) (Cross 12. Connect the stop light switch connector (3). Beam) to the specified torque. 13. Install driver knee bolster (10) and lower cover (8). Torque: 20 N·m (14 lb ft) 14.

  • Page 457: Main Data And Specifications

    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 E05RW013...

  • Page 458: Fluid Reservoir Tank

    POWER–ASSISTED BRAKE SYSTEM 5C–21 Fluid Reservoir Tank Fluid Reservoir Tank and Associated Parts 330RW003 Legend (3) O–ring (1) Fluid Reservoir (4) Retainer (2) Electrical Connector Removal Installation To install, follow the removal steps in the reverse order, NOTE: Before removing the fluid reservoir, remove the noting the following points: brake fluid from the fluid reservoir.

  • Page 459: Master Cylinder Assembly

    5C–22 POWER–ASSISTED BRAKE SYSTEM Master Cylinder Assembly Master Cylinder Assembly and Associated Parts 330RW010 Legend (4) P&B Valve and Bracket (1) Electrical Connector (5) Brake Pipes (2) Master Cylinder (6) Spacer and 2 gaskets (3) 2 attaching Nuts Removal 5. Remove master cylinder. 6.

  • Page 460: Installation

    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.

  • Page 461: Main Data And Specifications

    5C–24 POWER–ASSISTED BRAKE SYSTEM 5. Install brake pipes and tighten the brake pipe to the Special Tools specified torque. Master cylinder and P&B valve sides TOOL NO. ILLUSTRATION TOOL NAME Torque: 12 N·m (104 lb in) Others Torque: 16 N·m (12 lb in) J-39242 6.

  • Page 462: Vacuum Booster Assembly

    POWER–ASSISTED BRAKE SYSTEM 5C–25 Vacuum Booster Assembly Vacuum Booster Assembly and Associated Parts 331RW005 Legend (4) Master Cylinder (1) Pin (5) Vacuum Booster (2) Vacuum Booster Fixing Nut (6) Snap Pin (3) Vacuum Hose Removal Outside surface of the piston is the surface on which seals are to slide.

  • Page 463: Installation

    5C–26 POWER–ASSISTED BRAKE SYSTEM 3. Air should not pass from the engine (1) to the vacuum 3. Set push rod gauge J–39216 on vacuum booster, and booster (3). If it does, the check valve is inoperative apply negative pressure by means of vacuum pump and must be replaced.
  • Page 464 POWER–ASSISTED BRAKE SYSTEM 5C–27 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.

  • Page 465: Exterior Components

    5C–28 POWER–ASSISTED BRAKE SYSTEM Exterior Components Exterior Components and Associated Parts 331RW006 Legend (6) Filter (1) Yoke Clevis (7) 2 Gaskets and Spacer (2) Lock Nut (8) Vacuum Booster (3) Retaining Clip (9) Retainer (4) Valve Body Guard (10) Plate and Seal Assembly (5) Silencer (11) Master Cylinder Removal...

  • Page 466: Inspection And Repair

    POWER–ASSISTED BRAKE SYSTEM 5C–29 Inspection and Repair 3. Install 2 gaskets and spacer. 4. Install filter. Visual Check 5. Install silencer. Make necessary parts replacement if cuts, nicks, 6. Install valve body guard. excessive wear, or other abnormal conditions are found 7.

  • Page 467: Main Data And Specifications

    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...

  • Page 468: Special Tools

    POWER–ASSISTED BRAKE SYSTEM 5C–31 Special Tools TOOL NO. ILLUSTRATION TOOL NAME J-39216 Push Rod Gauge J-23738-A Vacuum Pump J-39241 Push Rod Support...

  • Page 469: Front Disc Brake Pads

    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 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.

  • Page 470: Removal

    POWER–ASSISTED BRAKE SYSTEM 5C–33 Removal Installation 1. Install clip. 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. f Draw out two–thirds of the brake fluid from the reservoir.
  • Page 471 5C–34 POWER–ASSISTED BRAKE SYSTEM 4. Install lock bolt (5) and tighten the bolt to the specified torque. Torque: 74 N·m (54 lb ft) 302RW006 3. Use adjustable pliers to bottom the piston into the caliper bore. Be careful do not damage the piston boot and do not damage the flexible hose by twisting or pulling it.

  • Page 472: Front Disc Brake Rotor

    POWER–ASSISTED BRAKE SYSTEM 5C–35 Front Disc Brake Rotor Inspection Parallelism Parallelism is the measurement of thickness of the rotor In the manufacturing of the brake rotor, all the tolerances at four or more points around the circumference of the regarding surface finish, parallelism and lateral runout are rotor.

  • Page 473: Front Disc Brake Caliper Assembly

    5C–36 POWER–ASSISTED BRAKE SYSTEM 411RW003 Front Disc Brake Caliper Assembly Front Disc Brake Caliper Assembly and Associated Parts 302RW008 Legend (4) Caliper Assembly (1) Guide Bolt (5) Clip (2) Brake Flexible Hose (6) Support Bracket with Pad Assembly (3) Lock Bolt (7) Pad Assembly...

  • Page 474: Removal

    POWER–ASSISTED BRAKE SYSTEM 5C–37 Removal 9. Remove pad assembly with shim and mark the lining locations if they are to be reinstalled. 1. Raise the vehicle and support with suitable safety 10. Remove clip. stands. 2. Concernig wheel and tire assembly, refer to “Wheels Installation and Tires System”...
  • Page 475 5C–38 POWER–ASSISTED BRAKE SYSTEM 3. Install support bracket and tighten the bolt (7) to the 6. Install brake flexible hose, always use new gaskets specified torque. and be sure to put the hooked edge of the flexible hose end into the anti–rotation cavity then tighten the Torque: 155 N·m (115 lb ft) I–bolt (10) to the specified torque.

  • Page 476: Front Disc Brake Caliper

    POWER–ASSISTED BRAKE SYSTEM 5C–39 Front Disc Brake Caliper Front Disc Brake Caliper Disassembled View 302RW015 Legend (5) Dust Boot: Guide Bolt and Lock Bolt (1) Guide Bolt (6) Piston Seal (2) Lock Bolt (7) Piston (3) Bleeder with Cap (8) Dust Boot: Piston (4) Caliper Body (9) Dust Boot Ring Disassembly...

  • Page 477: Inspection And Repair

    5C–40 POWER–ASSISTED BRAKE SYSTEM 5. Insert a block of wood into the caliper and force out Reassembly the piston by blowing compressed air into the caliper 1. Install caliper body. at the flexible hose attachment. This procedure must be done prior to removal of the dust boot. 2.
  • Page 478 POWER–ASSISTED BRAKE SYSTEM 5C–41 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.

  • Page 479: Main Data And Specifications

    5C–42 POWER–ASSISTED BRAKE SYSTEM Main Data and Specifications General Specifications Type Floating, pin slide Pad dimension 55 cm@ (8.52 in@) Adjusting method Self–adjusting Piston diameter 60.33 mm (2.38 in) Disc type Ventilated Disc thickness 26 mm (1.02 in) Disc effective diameter 222 mm (8.74 in) Torque Specifications E05RW004...

  • Page 480: Rear Disc Brake Pads (4 4 Model)

    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.

  • Page 481: Removal

    5C–44 POWER–ASSISTED BRAKE SYSTEM Removal Installation 1. Install clip (2). 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. f Draw out two–thirds of the brake fluid from the reservoir.
  • Page 482 POWER–ASSISTED BRAKE SYSTEM 5C–45 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, referring to “Wheels and Tires System” in Section 3E. 6. Pump the brake pedal several times to make sure that the pedal is firm.

  • Page 483: Rear Disc Brake Rotor (4 4 Model)

    5C–46 POWER–ASSISTED BRAKE SYSTEM Rear Disc Brake Rotor (4 4 Model) Inspection Parallelism Parallelism is the measurement of thickness of the rotor In the manufacturing of the brake rotor, all the tolerances at four or more points around the circumference of the regarding surface finish, parallelism and lateral runout are rotor.

  • Page 484: Rear Drum (In Disc) Inside Diameter Check 5C-47

    POWER–ASSISTED BRAKE SYSTEM 5C–47 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.

  • Page 485: Rear Disc Brake Caliper Assembly (4 4 Model)

    5C–48 POWER–ASSISTED BRAKE SYSTEM Rear Disc Brake Caliper Assembly (4 4 Model) Rear Disc Brake Caliper Assembly and Associated Parts 306RW007 Legend (4) Support Bracket (1) Brake Flexible Hose (5) Guide Bolt (2) Clip (6) Pad Assembly with Shim (3) Lock Bolt (7) Caliper Assembly Removal 4.

  • Page 486: Installation

    POWER–ASSISTED BRAKE SYSTEM 5C–49 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 4. Install caliper assembly. 306RW010 5. Install lock bolt and guide bolt (8) and tighten the bolt 2.

  • Page 487: Rear Disc Brake Caliper (4 4 Model)

    5C–50 POWER–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 (5) Piston Seal...

  • Page 488: Disassembly

    POWER–ASSISTED BRAKE SYSTEM 5C–51 Disassembly 6. Remove dust boot: piston. 7. Remove piston seal. 1. Remove guide bolt. 8. Remove bleeder with cap. 2. Remove lock bolt. 9. Remove caliper body. 3. Remove dust boot; guide bolt and lock bolt. 4.
  • Page 489 5C–52 POWER–ASSISTED BRAKE SYSTEM 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.
  • Page 490 POWER–ASSISTED BRAKE SYSTEM 5C–53 Main Data and Specifications (4 4 Model) General Specifications Type Floating, pin slide Pad dimension 33 cm@ (5.11 in@) Adjusting method Self–adjusting Piston diameter 41.3 mm (1.63 in) Disc type Ventilated Disc thickness 18 mm (0.71 in) Disc effective diameter 269.2 mm (10.60 in) Torque Specifications...

  • Page 491: Brake Lining

    5C–54 POWER–ASSISTED BRAKE SYSTEM Brake Lining Brake Lining and Associated Parts 305RW001 Legend (9) Upper (inner) Return Spring (1) Wheel and Tire Assembly (10) Auto Adjuster Lever (2) Drum (11) Parking Brake Lever (3) Hold-down Spring and Cup (12) Adjuster Assembly (4) Hold-down Spring and Cups (13) Wave Washer (5) Lower Return Spring...

  • Page 492: Brake Lining Inspection

    POWER–ASSISTED BRAKE SYSTEM 5C–55 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). 305RW002 10. Remove hold-down spring and cup (3) and hold-down Legend pin (16).

  • Page 493: Drum Brake Adjustment (4 2 Model)

    5C–56 POWER–ASSISTED BRAKE SYSTEM 10. Install lower return spring (5). Servicing The Brake Drum f Use brake spring tool. Whenever the brake drums are removed, they should be 11. Install auto adjuster lever (10). thoroughly cleaned and inspected for cracks, scores, deep grooves and out-of-round.

  • Page 494: Wheel Cylinder Assembly (4 2 Model)

    POWER–ASSISTED BRAKE SYSTEM 5C–57 Machining The Drum affect dissipation of heat and may cause distortion of the drum. If a drum is to be machined, only enough metal should be After refinishing, replace any drum that exceeds a removed to obtain a true, smooth braking surface. If a maximum inside diameter of 296.5 mm (11.673 in).

  • Page 495: Disassembled View

    5C–58 POWER–ASSISTED BRAKE SYSTEM Disassembled View NOTE: Replace the piston cups and boots each time the wheel cylinder is overhauled. Discard these used rubber parts and replace with new ones. Reassembly 1. Lubricate the cylinder bore with clean rubber grease. 305RS006 Legend (1) Boot...
  • Page 496 POWER–ASSISTED BRAKE SYSTEM 5C–59 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.

  • Page 497: Main Data And Specifications

    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 25.4 mm (1 in) Torque Specifications E05RW010...
  • Page 498 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.
  • Page 499 5D1–2 PARKING BRAKE SYSTEM (4x4 Model) Operation primary shoe is transmitted again to the secondary shoe through the fulcrum “B”. The secondary shoe contacts the When pulled in the direction “A”, the parking lever presses drum thereby producing braking effect. Clearance which the secondary shoe against the brake drum using the may result from worn parking brake shoe lining can be lever/shoe joint “B”...

  • Page 500: Removal

    PARKING BRAKE SYSTEM (4x4 Model) 5D1–3 Parking Brake Lever and Front Cable Parking Brake Lever Assembly and Associated Parts 311RW008 Legend (5) Trunnion Pin (1) Rear Console (6) Equalizer (2) Switch Connector (7) Parking Brake Rear Cable (3) Bolt (8) Parking Brake Lever (4) Adjust Nut and Lock Nut Removal Installation...

  • Page 501: Parking Brake Rear Cable

    5D1–4 PARKING BRAKE SYSTEM (4x4 Model) Parking Brake Rear Cable Parking Brake Rear Cable and Associated Parts 311RW010 Legend (8) Cable Fixing Bolt (1) Rear Wheels (9) Bolt (2) Caliper Assembly (10) Bolt (3) Rotor (Drum) (11) Bolt (Only Long Wheel Base Model) (4) Holding Spring (12) Nut (5) Upper Return Spring...

  • Page 502: Removal

    PARKING BRAKE SYSTEM (4x4 Model) 5D1–5 Removal 6. Install shoe assembly (7). After installation of the shoe and cable assembly, 1. Remove rear wheels (1). apply special grease (included in the repair kit) to the 2. Remove 2 bolts to remove the caliper assembly (2) following portions indicated in the figure.

  • Page 503: Inspection And Repair

    5D1–6 PARKING BRAKE SYSTEM (4x4 Model) Inspection and Repair 7. When poor braking effect possibly resulting from insufficient break–in is felt, or just after replacement Parking Brake Lining Inspection of parking brake shoe, be sure to conduct break–in as follows: Check the shoe assemblies for wear by removing the 8.

  • Page 504: Main Data And Specifications

    PARKING BRAKE SYSTEM (4x4 Model) 5D1–7 Main Data and Specifications General Specifications Model Type Duo–servo Drum inside diameter 210 mm(8.27 in) Parking brake lever stroke 6–8 notches When pulled with a force of 30 kg (66 lb) Torque Specifications E05RW011...
  • Page 505 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.

  • Page 506: Removal

    5D2–2 PARKING BRAKE SYSTEM (4X2 Model) Parking Brake Lever Parking Brake Lever Assembly and Associated Parts 311RW008 Legend (5) Trunnion Pin (1) Rear Console (6) Equalizer (2) Switch Connector (7) Parking Brake Rear Cable (3) Bolt (8) Parking Brake Lever (4) Adjust Nut and Lock Nut Removal Installation...

  • Page 507: Parking Brake Rear Cable And Associated Parts

    PARKING BRAKE SYSTEM (4X2 Model) 5D2–3 Parking Brake Rear Cable Parking Brake Rear Cable and Associated Parts 311RW011 Legend (5) Clip and Bolt (Only Long Wheel Base Model) (1) Rear Wheels (6) Nut (2) Drums (7) Nut (3) Clip and Bolt (8) Retainer (4) Clip and Bolt (9) Rear Cable...

  • Page 508: Removal

    5D2–4 PARKING BRAKE SYSTEM (4X2 Model) Removal Parking Brake Adjustment 1. Remove rear wheels (1) and drums (2). NOTE: All brakes are self adjusting. Brakes are adjusted by repeated stepping on the brake pedal. (After stepping 2. Remove bolt (3) (4) (5). on the pedal and releasing it, the rear auto–adjuster, in the 3.

  • Page 509: Main Data And Specifications

    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 E05RW012...
  • Page 510 SECTION ENGINE MECHANICAL (X22SE 2.2L) 6A–1 RODEO ENGINE CONTENTS Engine Mechanical ..... . 6A–1 Driveability and Emissions ....

  • Page 511: Engine Mechanical

    This will ONLY the exact part number for that application. protect against accidental entrance of foreign ISUZU will call out those fasteners that require a material into the cylinder which could cause extensive replacement after removal. ISUZU will also call out damage when the engine is started.

  • Page 512: Engine Diagnosis

    ENGINE MECHANICAL (X22SE 2.2L) 6A–3 Engine Diagnosis Hard Starting 1. Starting Motor Does Not Turn Over Trouble Shooting Procedure Turn on headlights and starter switch. Condition Possible cause Correction Headlights Battery run down or under charged Recharge or replace battery considerably considerably Terminals poorly connected...
  • Page 513 6A–4 ENGINE MECHANICAL (X22SE 2.2L) 3. Trouble In Fuel System Condition Possible cause Correction Starting motor turns over and spark Fuel tank empty Fill occurs but engine does not start occurs but engine does not start. Water in fuel system Clean Fuel filter clogged Replace filter...
  • Page 514 ENGINE MECHANICAL (X22SE 2.2L) 6A–5 Rough Engine Idling or Engine Stalling Condition Possible cause Correction Trouble in fuel injection system Idle air control valve defective Replace Throttle shutting off incomplete Correct or replace Throttle position sensor circuit open Correct or replace or shorted Fuel injector circuits open or shorted Correct or replace...
  • Page 515 6A–6 ENGINE MECHANICAL (X22SE 2.2L) Rough Engine Running Condition Possible cause Correction Engine misfires regularly 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 Engine control module faulty Replace Engine knocks regularly Spark plugs running too hot...
  • Page 516 ENGINE MECHANICAL (X22SE 2.2L) 6A–7 Hesitation Condition Possible cause Correction Hesitation on acceleration Throttle Position Sensor adjustment Replace throttle valve assembly incorrect Throttle Position Sensor circuit open Correct or replace or shorted Excessive play in accelerator linkage Adjust or replace Manifold Absolute Pressure (MAP) Correct or replace Sensor circuit open or shorted...
  • Page 517 6A–8 ENGINE MECHANICAL (X22SE 2.2L) Engine Lacks Power Condition Possible cause Correction Trouble in fuel system Fuel Pressure Control Valve not Replace working normally Fuel injector clogged Clean or replace Fuel pipe clogged Clean Fuel filter clogged or fouled Replace Fuel pump drive circuit not working Correct or replace normally...
  • Page 518 ENGINE MECHANICAL (X22SE 2.2L) 6A–9 Condition Possible cause Correction Engine overheating Level of Engine Coolant too low Replenish Thermo switch or fan motor defective 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...
  • Page 519 6A–10 ENGINE MECHANICAL (X22SE 2.2L) Troubleshooting Procedure Short out each spark plug in sequence using insulated spark plug wire removers. Locate cylinder with defective bearing by listening for abnormal noise that stops when spark plug is shorted out. Condition Possible cause Correction Noise from connecting rods or from Bearing or crankshaft pin worn...
  • Page 520 ENGINE MECHANICAL (X22SE 2.2L) 6A–11 Troubleshooting Procedure The slapping sound stops when spark plug on bad cylin- der is shorted out. Condition Possible cause Correction Timing belt noise Timing belt tension is incorrect Replace pusher or adjust the tension pulley or replace timing belt Tensioner bearing defective Replace Timing belt defective...
  • Page 521 6A–12 ENGINE MECHANICAL (X22SE 2.2L) Abnormal Combustion Condition Possible cause Correction Trouble in fuel injection system 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...
  • Page 522 ENGINE MECHANICAL (X22SE 2.2L) 6A–13 Engine Oil Consumption Excessive Condition Possible cause Correction Oil leaking Oil pan drain plug loose Retighten or replace gasket Oil pan setting bolts loosened Retighten Oil pan gasket broken Replace gasket Front cover retaining bolts loose or Retighten or replace gasket gasket broken Head cover retaining bolts loose or...
  • Page 523 6A–14 ENGINE MECHANICAL (X22SE 2.2L) Fuel Consumption Excessive Condition Possible cause Correction Trouble in fuel system Mixture too rich or too lean due to Refer to “Abnormal Combustion” trouble in fuel injection system Fuel cut function does not act Refer to “Abnormal Combustion” Trouble in ignition system Misfiring or abnormal combustion Refer to Hard Start or Abnormal...
  • Page 524 ENGINE MECHANICAL (X22SE 2.2L) 6A–15 Malfunction Indicator Lamp The instrument panel “CHECK ENGINE” Malfunction In- dicator Lamp (MIL) illuminates by self diagnostic system when the system checks the starting of engine, or senses malfunctions. Condition Possible cause Correction “CHECK ENGINE” MIL does not Bulb defective Replace illuminate at the starting of engine...

  • Page 525: Cylinder Head Cover

    6A–16 ENGINE MECHANICAL (X22SE 2.2L) Cylinder Head Cover Removal 13. Remove four bolts and remove the crankshaft pulley 1. Disconnect battery ground cable. 2. Disconnect PCV hose from cylinder head cover. 3. Remove intake duct. 4. Remove left side ground cable from cylinder head cover and disconnect ground cable connector on the left side wheel arch.

  • Page 526: Installation

    ENGINE MECHANICAL (X22SE 2.2L) 6A–17 Installation 5. Move drive belt tensioner to loose side using wrench then install the drive belt to normal position. 1. Install the camshaft position sensor and tighten timing rear cover bolt. Torque: 8 N·m (5.9 lb ft) 033RW001 6.

  • Page 527: Exhaust Manifold

    6A–18 ENGINE MECHANICAL (X22SE 2.2L) 10. Connect cooling fan wire harness connector to 12. Connect three(black, green and blue colors) engine cooling fan on left side top of fan shroud. wire harness connector to chassis harness of left rear side of engine compartment. 11.

  • Page 528: Crankshaft Pulley

    ENGINE MECHANICAL (X22SE 2.2L) 6A–19 5. Install intake duct bracket with ground cable. 7. Connect PCV hose to air intake duct. 6. Install intake duct assembly to throttle body and air 8. Connect battery ground cable. cleaner then tighten nut to the intake duct bracket and clamp on the throttle body side, also clamp air cleaner cover.

  • Page 529: Intake Manifold

    6A–20 ENGINE MECHANICAL (X22SE 2.2L) Intake Manifold Removal 11. Remove water pipe fixing bolt then remove water pipe. 1. Disconnect battery ground cable. 12. Remove fixing bolt from bracket (Between cylinder 2. Remove PCV hose from air intake duct. block and intake manifold) of intake manifold side. 3.

  • Page 530: Installation

    ENGINE MECHANICAL (X22SE 2.2L) 6A–21 Installation 1. Install intake manifold with gasket to cylinder head, tighten bolt and nuts to the specified torque. Torque: 22 N·m (16 lb ft) 065RW025 6. Install fuel rail assembly to intake manifold and connect hose between fuel pressure regulator and throttle body.

  • Page 531: Cylinder Head Assembly

    6A–22 ENGINE MECHANICAL (X22SE 2.2L) Cylinder Head Assembly Removal 13. Remove heater hose from adapter side. 14. Remove heater hose from water pipe side. 1. Disconnect battery ground cable. 15. Remove water hose between water pipe and throttle 2. Disconnect connector of intake air temperature body.
  • Page 532 ENGINE MECHANICAL (X22SE 2.2L) 6A–23 f Do not allow oil or other chemical substances to come in contact with the belt. They will shorten the life. f Do not attempt to pry or stretch the belt with a screw driver or any other tool during installation. f Store timing belt in cool and dark place.

  • Page 533: Installation

    6A–24 ENGINE MECHANICAL (X22SE 2.2L) Installation 1. Put cylinder head gasket on the cylinder block. 015RW014 4. Connect engine oil pressure switch connector. 5. Install camshaft angle sensor. 6. Install the timing belt rear cover and tighten three 012RW011 2. Install the cylinder head assembly, tighten cylinder bolts to the specified torque.
  • Page 534 ENGINE MECHANICAL (X22SE 2.2L) 6A–25 020RW016 014RW066 8. Install timing belt tensioner then tighten it temporarily until make alignment timing belt. 9. Install the cylinder head cover and tighten fixing bolt temporally. 10. Install the timing belt and perform timing belt setting procedure as follows.
  • Page 535 6A–26 ENGINE MECHANICAL (X22SE 2.2L) 3. Set the timing belt shown in the illustration, For new timing belt: The pointer must be at the ensure that tension side of the timing belt is taut center of “V” notch when viewed from the front of and move the timing belt tension adjustment lever the engine.
  • Page 536 ENGINE MECHANICAL (X22SE 2.2L) 6A–27 17. Install crankshaft pulley and tighten four bolts. 24. Install fuel pipe joint eye bolts to fuel rail assembly and install fuel pipe bracket with electric ground cable. Torque: 20 N·m (14 lb ft) Torque: 25 N·m (18 lb ft) 020RW014 18.

  • Page 537: Timing Belt

    6A–28 ENGINE MECHANICAL (X22SE 2.2L) 31. Install exhaust front pipe to exhaust manifold and tighten four nuts to the specified torque. Torque: 25 N·m (18 lb ft) 033RW001 34. Install intake air duct bracket to cylinder head. 35. Install air intake duct assembly with air cleaner cover to throttle body and tighten nut to the air intake duct 027RW005 bracket then tighten hose clamp.

  • Page 538: Installation

    ENGINE MECHANICAL (X22SE 2.2L) 6A–29 5. Disconnect three connectors of engine harness from Installation chassis harness of left rear side of engine 1. Install timing belt tensioner then tighten it temporarily compartment. until make alignment timing belt. 6. Remove nut and remove engine harness cover from front of engine.
  • Page 539 6A–30 ENGINE MECHANICAL (X22SE 2.2L) 014RW065 014RW066 3. Set the timing belt shown in the illustration, ensure that tension side of the timing belt is taut and move the timing belt tension adjustment lever clockwise, until the pointer of the tensioner is flowing.
  • Page 540 ENGINE MECHANICAL (X22SE 2.2L) 6A–31 For new timing belt: The pointer must be at the center of “V” notch when viewed from the front of the engine. 014RW062 3. Tighten fixing bolt (1) of timing belt tensioner to the specified torque. Torque: 25 N·m (18 lb ft) 014RW070 For used timing belt(over 60 minutes from new):...

  • Page 541: Camshaft

    6A–32 ENGINE MECHANICAL (X22SE 2.2L) 6. Install crankshaft pulley and tighten four bolts. Torque: 20 N·m (14 lb ft) 033RW001 8. Connect engine harness three connector to chassis harness of left rear side of engine compartment. 9. Connect battery ground cable. 020RW014 7.

  • Page 542: Installation

    ENGINE MECHANICAL (X22SE 2.2L) 6A–33 6. Remove twenty fixing bolts from intake and exhaust camshaft bracket on the cylinder head, then remove camshafts. 014RW052 011RW015 CAUTION: f Do not damage camshaft lobe and journal. f Do not damage hydraulic lash adjuster(HLA) and do not allow into foreign materials into cylinder head.
  • Page 543 6A–34 ENGINE MECHANICAL (X22SE 2.2L) Camshaft oil seal installation area on the cylinder body of No.1, No.6 and camshaft bracket rear side plug portion must be applied HN1023 or equivalent as in the illustration. 014RW071 7. Install the camshaft drive gear. Align the timing mark between notch on the camshaft drive gear(1) and lug on the camshaft bracket(2).

  • Page 544: Engine Assembly

    ENGINE MECHANICAL (X22SE 2.2L) 6A–35 Also align a guide hole on the camshaft drive gear marked “IN” for intake and “EX” for exhaust to guide pin on the camshaft when instaling the camshaft drive gear. 015RW014 9. Install timing belt. Refer to installation procedure for Timing Belt in this manual.

  • Page 545: Removal

    6A–36 ENGINE MECHANICAL (X22SE 2.2L) Removal 16. Remove transmission mounting fixing bolts and nut from cross member. 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.

  • Page 546: Installation

    ENGINE MECHANICAL (X22SE 2.2L) 6A–37 022RW005 022RW005 022RW006 022RW006 30. Lift up the engine assembly. 3. Install harness clip behind right horn. 4. Install the radiator grille and install flasher lamp assembly. Installation 5. Install two heater hoses to right side panel. CAUTION: When assembling the engine and 6.
  • Page 547 6A–38 ENGINE MECHANICAL (X22SE 2.2L) 14. Install transmission front under cover to front portion 22. Connect three engine harness connectors to chassis of clutch housing. harness of left rear side of engine compartment. 15. Install transmission mounting fixing bolts and nuts to 23.

  • Page 548: Cylinder Head

    ENGINE MECHANICAL (X22SE 2.2L) 6A–39 Cylinder Head Cylinder Head and Associated Parts 011RW010 Legend (6) Camshaft Exhaust (1) Cylinder Head Bolt (7) Camshaft Intake (2) Camshaft Pulley Fixing Bolt (8) Tappet (HLA) (3) Camshaft Pulley (9) Split Collar (4) Camshaft Oil Seal (10) Valve Spring and Spring Upper Seat (5) Camshaft Bracket Bolt (11) Valve...

  • Page 549: Inspection And Repair

    6A–40 ENGINE MECHANICAL (X22SE 2.2L) 3. Remove cylinder head. Inspection and Repair Use J–42623. 1. Check length and width of cylinder head sealing 4. Valve spring, valve spring caps, compress valve surfaces for deformation and diagonals for warpage spring — use J–8062 (1) and Adapter J–42619 (2). —...

  • Page 550: Reassembly

    ENGINE MECHANICAL (X22SE 2.2L) 6A–41 Reassembly 1. Valves, valve stem seals. Refer to Valve Spring, Oil Controller, Valve, Valve Guide in this section. 2. Valve spring, valve spring caps. Refer to Valve Spring, Oil Controller, Valve, Valve Guide in this section.

  • Page 551: Valve Spring, Valve, Valve Guide

    6A–42 ENGINE MECHANICAL (X22SE 2.2L) Valve Spring, Valve, Valve Guide Valve Spring, Valve, Valve Guide and Associated Parts 011RW024 Legend (8) Tappet (1) Camshaft Pulley Fixing Bolts (9) Split Collar (2) Camshaft Pulley (10) Spring Upper Seat (3) Camshaft Bracket Fixing Bolt (11) Valve Spring (4) Camshaft Assembly Intake (12) Oil Seal...
  • Page 552 ENGINE MECHANICAL (X22SE 2.2L) 6A–43 6. Use J–8062 valve spring compressor and J–42619 Inspection and Repair adapter to remove split collar (9). 1. Use a internal micrometer to measure the diameter valve guide. Valve stem play Intake : 0.03 to 0.057 mm (0.0012 to 0.0022 in) Exhaust : 0.04 to 0.067 mm (0.0016 to 0.0026 in) 011RW014 7.

  • Page 553: Reassembly

    6A–44 ENGINE MECHANICAL (X22SE 2.2L) Valve Seat Insert Replacement Reassembly 1. Arc weld the rod at several points. Be careful not to 1. Install oil controller (3) and spring lower seat (2). damage the aluminum section. Using oil controller replacer J–42622, drive in a new oil controller.

  • Page 554: Camshaft

    ENGINE MECHANICAL (X22SE 2.2L) 6A–45 Camshaft Camshaft and Associated Parts 011RW023 Legend (4) Camshaft Bracket (1) Camshaft Pulley Fixing Bolt (5) Camshaft Bracket Fixing Bolt (2) Camshaft Pulley (6) Camshaft Assembly Exhaust (3) Oil Seal (7) Camshaft Assembly Intake Disassembly 1.

  • Page 555: Reassembly

    6A–46 ENGINE MECHANICAL (X22SE 2.2L) 3. Remove oil seal (3). Reassembly 4. Remove twenty fixing bolts (5) from inlet and exhaust 1. Install camshaft drive gear assembly and tighten camshaft bracket, then camshaft brackets (4). three bolts to specified torque. Torque: 50 N·m (37 lb ft) + 60°...

  • Page 556: Crankshaft

    ENGINE MECHANICAL (X22SE 2.2L) 6A–47 Crankshaft Crankshaft and Associated Parts 015RW008 Legend (6) Balance Unit Assembly (1) Cylinder Head Assembly (7) Piston and Connecting Rod Assembly (2) Oil Pump Assembly (8) Main Bearing Cap (3) Pan (9) Crankshaft (4) Pan Support (10) Cylinder Block Assembly (5) Oil Strainer Disassembly...

  • Page 557: Inspection And Repair

    6A–48 ENGINE MECHANICAL (X22SE 2.2L) 10. Remove main bearing cap (8). 11. Remove crankshaft (9). 12. Remove crankshaft pulse pickup sensor disc. Inspection and Repair 1. Crankshaft Set the dial indicator as shown in the illustration and measure the crankshaft thrust clearance. If the thrust clearance exceeds the specified limit, replace the thrust bearings as a set.

  • Page 558: Inspection And Repair

    ENGINE MECHANICAL (X22SE 2.2L) 6A–49 Crankshaft (12) Inspection Inspect the surface of the crankshaft journal and crank pins for excessive wear and damage. Inspect the oil seal fitting surfaces for excessive wear and damage. Inspect the oil ports for obstructions. Inspection and Repair 1.

  • Page 559: Reassembly

    6A–50 ENGINE MECHANICAL (X22SE 2.2L) Crankshaft Bearing Selection When installing new crankshaft bearings or replacing bearings, refer to the selection table below. Select and install the new crankshaft bearings. Crankshaft grinding dimensions mm (in) Production and Service Crankshaft bearing journal dia. Standard size white 57.974 to 57.981 (2.260–2.261)
  • Page 560 ENGINE MECHANICAL (X22SE 2.2L) 6A–51 2. Rear oil seal (10). NOTE: Do not reuse the bolt. f Coat lip of seal rings thinly with protective grease. 4. Piston and connecting rod assembly (8) f Install seal ring into cylinder block, use J–42616 (1) f Apply engine oil to the cylinder bores, the and J–42613 (2).
  • Page 561 6A–52 ENGINE MECHANICAL (X22SE 2.2L) f Tighten the bolts in 3 steps: 1st step: 35 N·m (25 lb ft) 2nd step: 45° 3rd step: 15° 5. Install the balance unit assembly and tighten the bolts in 2 steps: 1st step: 20 N·m (14 lb ft) 2nd step: 45°...

  • Page 562: Piston And Connecting Rod

    ENGINE MECHANICAL (X22SE 2.2L) 6A–53 Piston and Connecting Rod Piston, Connecting Rod and Associate Parts 015RW037 Legend (7) Piston and Connecting Rod Assembly (1) Cylinder Head Assembly (8) Piston Ring (2) Cylinder Head Gasket (9) Piston Pin (3) Oil Pan Assembly (10) Piston (4) Pan Support (11) Connecting Rod...

  • Page 563: Inspection And Repair 6A-54

    6A–54 ENGINE MECHANICAL (X22SE 2.2L) 7. Remove piston and connecting rod assembly (7). Piston Rings (8) Any worn or damaged part discovered during engine NOTE: Before removing piston and connecting rod assembly, measure thrust clearance. overhaul must be replaced with a new one. f Remove any ridge or carbon build up from the top 1.
  • Page 564 ENGINE MECHANICAL (X22SE 2.2L) 6A–55 Piston Pin (9) Connecting Rods (11) 1. Measure the oil clearance between the connecting NOTE: Do not reuse the old piston pin. rod and the crankshaft. 1. Use a micrometer to measure the new piston pin 1.

  • Page 565: Reassembly

    6A–56 ENGINE MECHANICAL (X22SE 2.2L) Crankshaft grinding dimensions mm (in) (continued) Production and Service Con–rod bearing journal dia. Standard size (no color code) 48.970 to 48.988 (1.9098–1.9105) Undersize 0.25 (0.0097) blue 48.720 to 48.738 (1.9001–1.9008) Undersize 0.5 (0.0195) white 48.470 to 48.488 (1.8903–1.891) Con–rod bearing journal width Standard size (no color code)

  • Page 566: Cylinder Block

    ENGINE MECHANICAL (X22SE 2.2L) 6A–57 NOTE: Do not apply engine oil to the bearing back faces. 9. Install oil pan support assembly, refer to “Oil Pan and Oil Pan Support” in this manual. 6. Oil gallery, refer to “Crankshaft and Main Bearing” in 10.

  • Page 567: Disassembly

    6A–58 ENGINE MECHANICAL (X22SE 2.2L) Disassembly 1. Remove cylinder head assembly. 2. Remove cylinder head gasket. 3. Remove oil pan assembly. 4. Remove oil pan support. 5. Remove oil strainer. 6. Remove oil pump assembly. 7. Remove balance unit assembly. 8.

  • Page 568: Reassembly

    ENGINE MECHANICAL (X22SE 2.2L) 6A–59 Reassembly 1. Install cylinder block. 2. Install crankshaft. f Install the main bearings to the cylinder block and the main bearing caps. f Be sure that they are positioned correctly. f Apply new engine oil to the upper and lower main bearing faces.

  • Page 569: Cylinder Head Cover

    6A–60 ENGINE MECHANICAL (X22SE 2.2L) 1. Completely remove all residual sealant, lubricant 4. Tighten the bolts and nuts to the specified torque and moisture from the sealing surfaces. The in 2 steps: surfaces must be perfectly dry. 1st step : 8 N·m (5.8 lb ft) 2.

  • Page 570: Removal

    ENGINE MECHANICAL (X22SE 2.2L) 6A–61 Removal Installation 1. Remove two bolts and remove ignition cable cover (1) 1. Install the camshaft angle sensor and tighten timing from cylinder head cover (3). rear cover bolt. 2. Disconnect ignition cable and remove spark plag (2). Torque: 8 N·m (5.9 lb ft) 3.
  • Page 571 6A–62 ENGINE MECHANICAL (X22SE 2.2L) 5. Move drive belt tensioner to loose side using wrench then install the drive belt to normal position. 033RW001 6. Connect ignition cable to ignition plug. 7. Install ignition cable cover to cylinder head cover and tighten two bolts to the specified torque.

  • Page 572: Balance Unit Assembly

    ENGINE MECHANICAL (X22SE 2.2L) 6A–63 Balance Unit Assembly Balance Unit Assembly Associated Parts 051RW012 Legend (3) Oil Strainer (1) Oil Pan (4) Balance Unit Assembly (2) Oil Pan Support (5) Shim...

  • Page 573: Disassembly

    6A–64 ENGINE MECHANICAL (X22SE 2.2L) Disassembly 2. In this crankshaft position, the flattened side (arrows) of both balancer shafts must face downward and 1. Remove the oil pan. must be on a horizontal line. 2. Remove the oil pan support. 3.
  • Page 574 ENGINE MECHANICAL (X22SE 2.2L) 6A–65 4. Place pre tensioned probe (6) of gauge on measuring 6. The tooth backlash must be measured in 4 different arm of measuring device J–43038. The probe must positions — turn the crankshaft further at the be set precisely between the notch marks, square to fastening bolt of the timing belt drive gear by 45°...

  • Page 575: Reassembly

    6A–66 ENGINE MECHANICAL (X22SE 2.2L) 9. Remove balance unit from cylinder block/crankshaft 2. Turn balancer shafts until the flattened sides (arrows) bearing caps and remove with balancer piece. The of both balancer shafts face downward and are on a balancer piece has a number (code), for easy horizontal line.
  • Page 576 ENGINE MECHANICAL (X22SE 2.2L) 6A–67 6. Install oil pan support. Torque: 20 N·m (14 lb ft) f Adjust surfaces of the cylinder block and the oil pan support. 035RW026 7. Install oil pan. 1st step: 8 N·m (5.8 lb ft) 2nd step: 30°...

  • Page 577: Main Data And Specifications

    6A–68 ENGINE MECHANICAL (X22SE 2.2L) Main Data and Specifications Torque Specifications Camshaft bracket, Timing gear camshaft side, Cylinder head 011RW021...
  • Page 578 ENGINE MECHANICAL (X22SE 2.2L) 6A–69 Timing gear crankshaft (center bolt), Timing belt cover front, Timing belt cover rear, Timing belt tensioner, Camshaft angle sensor 020RW011...
  • Page 579 6A–70 ENGINE MECHANICAL (X22SE 2.2L) Crankshaft main bearing, Oil pan support, Oil pan, Balance unit assembly, Connrod Cap, Oil pump, Oil strainer 015RW023...
  • Page 580 ENGINE MECHANICAL (X22SE 2.2L) 6A–71 Spark plug, Throttle body, EGR valve adaptor assembly, Bypass housing assembly, Thermostat assembly, inlet manifold assembly, Exhaust manifold assembly, heat shield, Ignition cable cover 011RW022...
  • Page 581 6A–72 ENGINE MECHANICAL (X22SE 2.2L) Engine mount 022RW010...

  • Page 582: Special Tools

    ENGINE MECHANICAL (X22SE 2.2L) 6A–73 Special Tools TOOL NO. TOOL NO. ILLUSTRATION ILLUSTRATION TOOL NAME TOOL NAME J–42613 J–42619 Installer; Rear Adapter; Valve spring crankshaft seal ring J–42609 J–42622 Remover/Installer; Installer sleeve; Valve Crankshaft carrier seal stem seal J–8062 Compressor; Valve J–42623 spring Socket wrench;...
  • Page 583 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.
  • Page 584 6B–2 ENGINE COOLING (X22SE 2.2L) General Description 111RW001 Legend (5) Coolant Distributor (1) Water Pump (6) Cylinder Block and Head (2) Thermostat (7) Throttle Body (3) Radiator (8) Heater (4) Reserve Tank The Cooling System is a pressurized type, where the water pump, which is cambelt driven, forces the circulation of the coolant through the cylinder block and head.
  • Page 585 Proper mixing ratio can be determined by referring to the chart. Supplemental inhibitors or additives claiming to increase cooling capability that have not been specifically approved by Isuzu are not recommended for addition to the cooling system. 111RW002 f Mixing ratio Check the specific gravity of engine coolant in the cooling system temperature ranges from 0°C to 50°C...
  • Page 586 6B–4 ENGINE COOLING (X22SE 2.2L) Diagnosis Engine Cooling Trouble Condition Possible cause Correction Engine overheating Low Engine Coolant level Replenish Thermo mater unit faulty Replace Faulty thermostat Replace Faulty Engine Coolant temperature Repair or replace sensor Clogged radiator Clean or replace Faulty radiator cap Replace Low engine oil level or use of...
  • Page 587 ENGINE COOLING (X22SE 2.2L) 6B–5 Water Pump Water Pump and Associated Parts 030RW004 Legend (2) O Ring (1) Water Pump Assembly (3) Bolt Removal Installation 1. Disconnect battery ground cable. 1. Before installing water pump, coat sealing surface with silicon grease. 2.
  • Page 588 6B–6 ENGINE COOLING (X22SE 2.2L) Thermostat Removal Installation 1. Disconnect battery ground cable. 1. Before installing thermostat, coat sealing surface with silicon grease. 2. Drain engine coolant from the radiator and engine. 2. Install gasket. 3. Disconnect radiator hose from the inlet pipe. 3.
  • Page 589 ENGINE COOLING (X22SE 2.2L) 6B–7 Radiator Radiator and Associated Parts 110RX004 Legend (4) Radiator Cap (1) Radiator (5) Radiator Hose (2) Bracket (6) Lower Fan Guide (3) Cooling Fan Assembly Removal 1. Disconnect battery ground cable. 2. Disconnect cooling fan motor connector. 3.
  • Page 590 6B–8 ENGINE COOLING (X22SE 2.2L) f Leakage from the radiator 8. Lift out the radiator assembly with hose, taking care not to damage the radiator core with fan blade. f Leakage from the coolant pump 9. Remove rubber cushions on both sides at the bottom. f Leakage from the water hoses f Check the rubber hoses for swelling.

  • Page 591: Special Tool

    ENGINE COOLING (X22SE 2.2L) 6B–9 D If air bubbles come up to the radiator filler neck, 7. Connect battery ground cable. replenish with EC. Repeat until the EC level does 8. Pour engine coolant up to filler neck of radiator, and not drop any further.
  • Page 592 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.
  • Page 593 6C–2 ENGINE FUEL (X22SE 2.2L) General Description 140RX008 Legend (7) Intake Manifold (1) Fuel Filter Cap (8) Fuel Pressure Control Valve (2) Fuel Tank (9) Duty Solenoid Valve (3) Rollover Valve (10) Throttle Valve (4) Fuel Pump and Sender Assembly (11) Canister (5) Fuel Filter (12) Evapo Pipe...

  • Page 594: Fuel Metering

    6C–3 ENGINE FUEL (X22SE 2.2L) When working on the fuel system, there are several Fuel Metering things to keep in mind: The Powertrain Control Module (PCM) is in complete f Any time the fuel system is being worked on, control of this fuel delivery system during normal driving disconnect the negative battery cable except for conditions.

  • Page 595: Fuel Filter

    6C–4 ENGINE FUEL (X22SE 2.2L) Fuel Filter Fuel Filter and Associated Parts 140RX007 Legend (3) Fuel Filter Holder (1) Fuel Hose (4) Fuel Hose (2) Fuel Filter Removal Installation 1. Install the fuel filter in the proper direction. CAUTION: When repair to the fuel system has been completed, start engine and check the fuel system 2.
  • Page 596 6C–5 ENGINE FUEL (X22SE 2.2L) Fuel Pump Flow Test If reduction of fuel supply is suspected, perform the following checks. 1. Make sure that there is fuel in the tank. 2. With the engine running, check the fuel feed pipe and hose from fuel tank to injector for evidence of leakage.

  • Page 597: Fuel Pump

    6C–6 ENGINE FUEL (X22SE 2.2L) Fuel Pump Fuel Pump and Associated Parts 140RX004 Legend (6) Connector; Fuel Level Sensor (1) Fuel Feed Port (7) Snap Ring (or Fuel pump lock) (2) Fuel Tube/Quick Connector (8) Hose; Evaporative Fuel (3) Fuel Return Port (9) Hose;...

  • Page 598: Cautions During Work

    6C–7 ENGINE FUEL (X22SE 2.2L) Fuel Tube / Quick – Connector Fittings Precautions Removal f Lighting of Fires Prohibited. 1. Open the fuel cap to relieve the fuel pressure in the f Keep flames away from your work area to prevent the tank.
  • Page 599 6C–8 ENGINE FUEL (X22SE 2.2L) 2. For removal of the delivery pipe (feeding fuel to the NOTE: This work should be done by hands. Do not use engine), hold the connector in one hand, and hold the any tools. Should the pipe can hardly be removed from retainer tab with the other hand and pull out the the connector, use a lubricant (light oil) and/or push and connector, as illustrated.

  • Page 600: Assembling Advice

    6C–9 ENGINE FUEL (X22SE 2.2L) Reuse of Quick–Connector (Delivery Pipe) f Replace the pipe and connector if scratch, dent or crack is found. f Remove mud and dust from the pipe and make sure that the end including spool is free of defects, such as scratch, rust, and dent, which may cause poor sealability.

  • Page 601: Fuel Pump Relay

    6C–10 ENGINE FUEL (X22SE 2.2L) Fuel Pump Relay General Description When it is turned to “START” position, the Engine Control Module receives the reference pulse from the Ignition In order to control the FPAS operation, the FPAS relay is Control Module and it operates the relay, again causing provided.

  • Page 602: Fuel Gage Unit

    6C–11 ENGINE FUEL (X22SE 2.2L) Removal Installation 1. Install protectors (15,19) and tighten the six fixing CAUTION: When repair to the fuel system has been bolts to the specified torque. completed, start engine and check the fuel system for loose connection or leakage. For the fuel system Torque: 68 N·m (50 lb ft) diagnosis, see Section “Driveability and Emission”.

  • Page 603: Fuel Filler Cap

    6C–12 ENGINE FUEL (X22SE 2.2L) Fuel Filler Cap General Description Fuel filler cap includes vacuum valve. In case any high vacuum happen in tank, the valve works to adjust the pressure to prevent the tank from being damaged. 140RW014 Legend (1) Vacuum Valve (2) Fuel Filler Cap Inspection...
  • Page 604 6C–13 ENGINE FUEL (X22SE 2.2L) Main Data and Specifications Torque Specification 140RX009 Special Tool TOOL NO. ILLUSTRATION TOOL NAME J–39763 Remover; fuel pump lock (For S/W)
  • Page 605 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.
  • Page 606 6D1–2 ENGINE ELECTRICAL (X22SE 2.2L) Battery General Description 3. Fluid Level Check The fluid level should be between the upper level line(2) There are six battery fluid caps on top of the battery. and lower level line(3) on side of battery. These are covered by a paper label.
  • Page 607 6D1–3 ENGINE ELECTRICAL (X22SE 2.2L) a. VOLTAGE DOES NOT DROP BELOW THE Jump Starting MINIMUM LISTED IN THE TABLE – The battery is Jump Starting with an Auxiliary (Booster) good and should be returned to service. Battery b. VOLTAGE IS LESS THAN MINIMUM LISTED – Replace battery.

  • Page 608: Battery Installation

    6D1–4 ENGINE ELECTRICAL (X22SE 2.2L) 3. Attach the end of one jumper cable to the positive Battery Installation terminal of the booster battery. 1. Install battery (5). Attach the other end of the same cable to the positive terminal of the discharged battery. 2.
  • Page 609 6D1–5 ENGINE ELECTRICAL (X22SE 2.2L) Main Data and Specifications General Specifications Model 24–600 Voltage (V) Cold Cranking Performance (Amp) Reserve Capacity (Min) Load Test (Amp) BCI Group No.
  • Page 610 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.
  • Page 611 6D2–2 IGNITION SYSTEM (X22SE 2.2L) Ignition Module Removal Installation 1. Disconnect battery ground cable. 1. Install the ignition module (1). Connect ignition module connector and ignition 2. Ignition module connector. coil,then tighten bolt to the specified torque. 3. Removal ignition module (1). Torque: 20 N·m (15 lb ft) 080RW001 080RW001...
  • Page 612 IGNITION SYSTEM (X22SE 2.2L) 6D2–3 f Replace spark plugs if measured value is out of f Clean threads and metal body with a wire brush. standard. f File the electrode tip if electrode is extremely worn. f Bend the ground electrode to adjust the spark plug Insulation resistance: 50 MW or more gap.
  • Page 613 6D2–4 IGNITION SYSTEM (X22SE 2.2L) Main Data and Specifications General Specifications Ignition System Ignition Form Electronic Ignition System (El system) with Crankshaft angle Sensor Spark Plug Type Electronic Spark Control No. of Coils and Type 2 Solid State Coil Location Engine–mounted Torque 20 N·m (14 lb ft)
  • Page 614 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.
  • Page 615 6D3–2 STARTING AND CHARGING SYSTEM (X22SE 2.2L) Starting System General Description Cranking Circuit The cranking system consists of a battery, starter, starter switch, starter relay, etc. These main components are connected. Starter The cranking system employs a magnetic type reduction starter in which the motor shaft is also used as a pinion shaft.
  • Page 616 6D3–3 STARTING AND CHARGING SYSTEM (X22SE 2.2L) Starter Removal Installation 1. Battery ground cable. 1. Install starter assembly(6). 2. Remove harness connectors (1) and (2). 2. Install mounting bolts and tighten bolts to specified torque (1), (2). Torque: 25 N·m (18 lb ft) 065RW022 3.
  • Page 617 6D3–4 STARTING AND CHARGING SYSTEM (X22SE 2.2L) Disassembled View 065RW023 Legend (7) Armature (1) Bolt (8) Yoke Assembly (2) Magnetic Switch (9) Brush and Brush Holder (3) Gear Case (10) Washer (4) Piston (11) Rear Cover (5) Piston Shaft (12) Through Bolt (6) Center Bracket...
  • Page 618 6D3–5 STARTING AND CHARGING SYSTEM (X22SE 2.2L) Inspection and Repair Brush Measure the length of brush. Repair or replace necessary parts if extreme wear or Replace with a new one, if it is below the limit. damage is found during inspection. Armature Brush Holder Check for continuity between commutator and segment.
  • Page 619 6D3–6 STARTING AND CHARGING SYSTEM (X22SE 2.2L) Continuity of Series Coil Check for continuity between terminals S and M. Replace, if there is no continuity (i.e., coil is disconnected). 065RS025 Characteristic Test For easily confirming the characteristics, conduct the noload test as follows: 065RW017 Rating as short as 30 seconds requires rapid testing.
  • Page 620 6D3–7 STARTING AND CHARGING SYSTEM (X22SE 2.2L) Charging System General Description General On–Vehicle Inspection The operating condition of charging system is indicated The charging system is an IC integral regulator charging by the charge warning lamp. The warning lamp comes on system and its main components are connected as when the starter switch is turned to “ON”...
  • Page 621 6D3–8 STARTING AND CHARGING SYSTEM (X22SE 2.2L) Generator Removal Inspection 1. Disconnect battery ground cable. Generator Power and Circuit Diagram 2. Move drive belt tensioner to loose side using wrench then remove drive belt. 3. Disconnect terminal “B” wiring connector and connector.
  • Page 622 6D3–9 STARTING AND CHARGING SYSTEM (X22SE 2.2L) Generator Power Installation 1. Adjust load resistor, if the required load currents are 1. Install generator assembly and bring generator not attained. assembly to the position to be installed. 2. The shape of the voltage curves on oscilloscope 2.
  • Page 623 6D3–10 STARTING AND CHARGING SYSTEM (X22SE 2.2L) 2. Spring ring, washer, belt pulley halves, spacing ring, 7. Clawpole armature from drive bearing. fan pinion, pulley spring. 8. Lay suitable pipe piece (1) underneath. 3. Voltage regulator with brush holder. 066RW013 9.
  • Page 624 6D3–11 STARTING AND CHARGING SYSTEM (X22SE 2.2L) 11. Ball bearing from armature shaft. 16. Spray sleeve (if present). 17. Carefully bend off diode plate. 18. Unsolder stator winding from diode plate. 066RW012 12. Nut from connecting pins “B+” and “D+”. 13.
  • Page 625 6D3–12 STARTING AND CHARGING SYSTEM (X22SE 2.2L) 2. Measure the slip ring diameter, and replace if it 4. Check for continuity between slip ring and rotor core. exceeds the limit. In case of continuity, replace the rotor assembly. 066RS015 066RS017 3.
  • Page 626 6D3–13 STARTING AND CHARGING SYSTEM (X22SE 2.2L) Brush Reassembly Measure the brush length. To reassemble, follow the disassembly steps in the If more than limit, replace the brush. reverse order, noting the following points: Standard: 5 mm (0.20 in) 1. Install pulley on the rotor. Clamp pulley to the vise, and tighten nut to the specified torque.
  • Page 627 6D3–14 STARTING AND CHARGING SYSTEM (X22SE 2.2L) Main Data and Specifications General Specifications Battery voltage Rated output Direction of rotation (as viewed from pulley side) Clockwise Maximum speed 18000...
  • Page 628 SECTION RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–1 RODEO CONTROL SYSTEM RODEO 2.2L ENGINE DRIVEABILITY AND EMISSIONS CONTENTS SPECIFICATIONS ..... .
  • Page 629 6E1–2 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION ON–BOARD DIAGNOSTIC (OBD II) DIAGNOSTIC TROUBLE CODE (DTC) P0112 SYSTEM CHECK ..... . .
  • Page 630 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–3 DIAGNOSTIC TROUBLE CODE (DTC) P0201 DIAGNOSTIC TROUBLE CODE (DTC) P0404 INJECTOR CIRCUIT MALFUNCTION EXHAUST GAS RECIRCULATION (EGR) – CYLINDER 1 ......
  • Page 631 6E1–4 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P0533 DIAGNOSTIC TROUBLE CODE (DTC) P1441 A/C REFRIGERANT PRESSURE SENSOR EVAPORATIVE EMISSION (EVAP) SYSTEM CIRCUIT HIGH INPUT ....
  • Page 632 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–5 EVAP Canister Vent Solenoid ... . . 6E1–417 Accelerator Controls ....

  • Page 633: Specifications

    6E1–6 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION SPECIFICATIONS TIGHTENING SPECIFICATIONS Application N–m Lb Ft Lb In Crankshaft Position Sensor Mounting Bolt — EGR Nut — Engine Coolant Temperature Sensor — Fuel Drain Plug — Fuel Pressure Regulator Attaching Screw —...

  • Page 634: Diagrams And Schematics

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–7 DIAGRAMS AND SCHEMATICS PCM WIRING DIAGRAM (1 of 10) D06RX026...

  • Page 635: Pcm Wiring Diagram (2 Of 10)

    6E1–8 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION PCM WIRING DIAGRAM (2 of 10) D06RX029...

  • Page 636: Pcm Wiring Diagram (3 Of 10)

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–9 PCM WIRING DIAGRAM (3 of 10) D06RX027...

  • Page 637: Pcm Wiring Diagram (4 Of 10)

    6E1–10 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION PCM WIRING DIAGRAM (4 of 10) D06RX030...

  • Page 638: Pcm Wiring Diagram (5 Of 10)

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–11 PCM WIRING DIAGRAM (5 of 10) D06RX028...

  • Page 639: Pcm Wiring Diagram (6 Of 10)

    6E1–12 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION PCM WIRING DIAGRAM (6 of 10) D06RX032...

  • Page 640: Pcm Wiring Diagram (7 Of 10)

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–13 PCM WIRING DIAGRAM (7 of 10) D06RX031...

  • Page 641: Pcm Wiring Diagram (8 Of 10)

    6E1–14 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION PCM WIRING DIAGRAM (8 of 10) D06RX033...

  • Page 642: Pcm Wiring Diagram (9 Of 10)

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–15 PCM WIRING DIAGRAM (9 of 10) D06RX034...

  • Page 643: Pcm Wiring Diagram (10 Of 10)

    6E1–16 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION PCM WIRING DIAGRAM (10 of 10) D06RX035...

  • Page 644: Pcm Pinouts

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–17 PCM PINOUTS PCM Pinout Table, 32–Pin Red Connector – Row ”A” TS23344 PIN Function Wire Color IGN ON ENG RUN Refer To 5 Volt Reference Signal 5.0 V 5.0 V Appropriate Sensor Knock Sensor Input —...

  • Page 645: Pcm Pinout Table, 32-Pin Red Connector - Row "B

    6E1–18 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION PCM Pinout Table, 32–Pin Red Connector – Row ”B” TS23344 PIN Function Wire Color IGN ON ENG RUN Refer To 5 Volt Reference Signal BLU/ORG 5.0 V 5.0 V Appropriate Sensor Not Used —...
  • Page 646 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–19 PCM Pinout Table, 32–Pin White Connector – Row ”C” TS23345 PIN Function Wire Color IGN ON ENG RUN Refer To Injector Cylinder #2 GRN/RED B+ Varies B+ Varies General Description and Operation, Fuel Injector Not Used —...

  • Page 647: Pcm Pinout Table, 32-Pin White Connector - Row "D

    6E1–20 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION PCM Pinout Table, 32–Pin White Connector – Row ”D” TS23345 PIN Function Wire Color IGN ON ENG RUN Refer To Injector Cylinder #3 GRN/ORN General Description and Operation, Fuel Injector Not Used —...

  • Page 648: Pcm Pinout Table, 32-Pin White Connector - Row "E

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–21 PCM Pinout Table, 32–Pin White Connector – Row ”E” TS23346 PIN Function Wire Color IGN ON ENG RUN Refer To Not Used — — — — Fan Control RED/GRN 0.0V Chassis Electrical Not Used —...

  • Page 649: Pcm Pinout Table, 32-Pin White Connector - Row "F

    6E1–22 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION PCM Pinout Table, 32–Pin White Connector – Row ”F” TS23346 PIN Function Wire Color IGN ON ENG RUN Refer To Not Used — — — — Not Used — — — —...

  • Page 650: Component Locator

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–23 COMPONENT LOCATOR 755RX008...
  • Page 651 6E1–24 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 010RX001 028RX001...

  • Page 652: Undercarriage Component Locator Table . 6E1-25

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–25 Engine Component Locator Table Number Name Location Engine Coolant Temperature (ECT) Sensor Rear of engine, near ignition coils Linear Exhaust Gas Recirculation (EGR) Valve On the left rear of the engine at the bulkhead...
  • Page 653 6E1–26 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 755RX009...

  • Page 654: Diagnosis Strategy-Based Diagnostics

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–27 DIAGNOSIS Strategy–Based 3. Use a check sheet or other method to identify the circuit or electrical system component. Diagnostics 4. Follow the suggestions for intermittent diagnosis found in the service documentation. Strategy–Based Diagnostics Most Scan Tools, such as the Tech 2, have The strategy–based diagnostic is a uniform approach to...

  • Page 655: General Service Information

    This label is located in the engine compartment of every If the ignition system is rain–soaked, it can temporarily vehicle. If the label has been removed it should be cause engine misfire and turn on the MIL (”Check Engine” replaced, it can be ordered from Isuzu Dealer ship. lamp).

  • Page 656: Maintenance Schedule

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–29 Maintenance Schedule ON–BOARD DIAGNOSTIC (OBD II) Refer to the Maintenance Schedule. Visual/Physical Engine Compartment On–Board Diagnostic Tests Inspection A diagnostic test is a series of steps, the result of which is Perform...

  • Page 657: System Status And Drive Cycle For Satisfying Federal Inspection/Maintenance (I/M 240) Regulations

    6E1–30 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION Output Components: System Status And Drive Cycle For Satisfying Federal Output components are diagnosed for proper response to control module commands. Components where Inspection/Maintenance (I/M 240) functional monitoring is not feasible will be monitored for Regulations circuit continuity and out–of–range values if applicable.

  • Page 658: The Diagnostic Executive

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–31 Trip There is a continuous self–diagnosis on certain control functions. This diagnostic capability is complimented by Technically, a trip is a key on–run–key off cycle in which all the diagnostic procedures contained in this manual. The...

  • Page 659: Dtc Types

    6E1–32 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION f When the MIL remains ON while the engine is f Does not store a Freeze Frame running, or when a malfunction is suspected due to a f Stores Fail Record when test fails...

  • Page 660: Decimal/Binary/Hexadecimal Conversions 6E1-33

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–33 f Fuel Trim information which will aid in repairing the vehicle. Some f Engine Speed Scan Tools will display encoded messages which will aid in determining the nature of the concern. The method of...
  • Page 661 6E1–34 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION f The negative battery cable. (Disconnecting the When a Tech 2 is not available, DTCs can also be cleared by disconnecting one of the following sources for at least negative battery cable will result in the loss of other on–board memory data, such as preset radio tuning).

  • Page 662: Tech 2 Features

    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 (5). 2. Connect the SAE 16/19 adapter (3) to the DLC cable (4).

  • Page 663: Operating Procedure (Example)

    6E1–36 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION Operating Procedure (Example) The power up screen is displayed when you power up the tester with the Isuzu system PCMCIA card. Follow the operating procedure below. 060RX058 060RX060...

  • Page 664: Dtc Modes

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–37 Menu f The following table shows which functions are used for the available equipment versions. 060RW223 The following is a brief description of each of the sub menus in DTC Info and DTC. The order in which they...

  • Page 665: Miscellaneous Test

    6E1–38 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION History This selection will display only DTCs that are stored in the PCM’s history memory. It will display all type A and B DTCs that have requested the MIL and have failed within the last 40 warm-up cycles.

  • Page 666: Relays Test

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–39 5. Select F0:Malfunction Indicator Lamp. Select F2:Low Fuel Lamp 060RX019 060RX020 6. Push “On” soft key. 10. Push “On” soft key. 7. Make sure Lamp illuminates. 11. Make sure Lamp illuminates. 8. If lamp illuminates, the Lamp is operating correctly.
  • Page 667 6E1–40 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 4. Select F1:Relay Test in the Miscellaneous Test. 6. Push “On” soft key. 060RX046 060RX022 5. Select F0:Fuel Pump Relay. 7. Control Fuel Pump Relay and check a data list. 8. If the data list chenges, the Fuel Pump Relay is normal.

  • Page 668: Evap Test

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–41 15. Select F2: Low Fan Relay. EVAP Test This test is conducted check EVAP system for its working. Tech 2 must be used for this test. Test Procedure: 1. Connect Tech 2 to the vehicle DLC.

  • Page 669: Idle Air Control System Test

    6E1–42 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 5. Select F0: Purge Solenoid. 10. Select F1:EVAP Vent Solenoid. 060RX025 060RX025 6. Push “Decrease” or “Increase” soft key. 11. Push “On” or “Off” of soft key. 060RX026 060RX027 7. Control EVAP Purge Solenoid and check a data list.
  • Page 670 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–43 3. Select F3: Miscellaneous Test in the Application 5. Select F1: IAC Control Test. Menu. 060RX052 6. Push “Increase” or “Decrease” soft key. 060RW228 4. Select F3: IAC System Test in the Miscellaneous 7.

  • Page 671: Fuel System Test

    6E1–44 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 11. If data list changes, the IAC has been Reset. 4. Select F4: Fuel System in the Miscellaneous Menu. 060RW231–1 060RX053 5. Select F1: Fuel Gauge Level Fuel System Test This test is conducted check Fuel Level Gauge for proper operation.

  • Page 672: Egr Control Test

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–45 6. Push “Decrease” or “Increase” of soft key. 10. Push “Reset” of soft key. 060RX030 060RX029 7. Control Fuel Level and check data list. EGR Control Test 8. If data list changes, the Fuel Gauge Level is normal.

  • Page 673: Injector Balance Test

    6E1–46 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 4. Select F5: EGR Control Test in the Miscellaneous 3. Select F3: Miscellaneous Test in the Application Test. Menu. 060RX054 060RW228 5. Control EGR Valve and check data list. 4. Select F6: Injector Balance Test in the Miscellaneous Test.

  • Page 674: Plotting Snapshot Graph

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–47 5. Select injector number and push “injector off” of soft Plotting Snapshot Graph key. This test selects several necessary items from the data list to plot graphs and makes data comparison on a long term basis.

  • Page 675: Plotting Graph Flow Chart (Plotting Graph After Obtaining Vehicle Information)

    6E1–48 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information) 060RX041...

  • Page 676: Flow Chart For Snapshot Replay (Plotting Graph)

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–49 Flow Chart for Snapshot Replay (Plotting Graph) 060RX040...

  • Page 677: Primary System-Based Diagnostics

    6E1–50 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION PRIMARY SYSTEM–BASED operation and to allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of DIAGNOSTICS time required for fuel control sensor (HO2S 1) to become active. Oxygen sensor heaters are required by the Primary System–Based Diagnostics...

  • Page 678: Misfire Monitor Diagnostic Operation

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–51 f Exhaust leaks MISFIRE MONITOR DIAGNOSTIC f HO2S contamination OPERATION f Alternate fuels Exhaust system leaks may cause the following: Misfire Monitor Diagnostic Operation f Preventing a degraded catalyst from failing the The misfire monitor diagnostic is based on crankshaft diagnostic.

  • Page 679: Fuel Trim System Monitor Diagnostic Operation

    6E1–52 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION emission system malfunction. Examples include the Fuel Trim Cell Diagnostic Weights following items: No fuel trim DTC will set regardless of the fuel trim counts f Contaminated fuel in cell 0 unless the fuel trim counts in the weighted cells f Low fuel are also outside specifications.

  • Page 680: On-Board Diagnostic (Obd Ii) System Check

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–53 ON–BOARD DIAGNOSTIC (OBD II) SYSTEM CHECK D06RX036 damaged terminals, poor terminal–to–wire connection, Circuit Description and damaged harness. The on–board diagnostic system check is the starting point for any driveability complaint diagnosis. Before...
  • Page 681 6E1–54 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 7. A Tech 2 parameter which is not within the typical 10. This vehicle is equipped with a PCM which utilizes range may help to isolate the area which is causing an electrically erasable programmable read only the problem.
  • Page 682 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–55 On–Board Diagnostic (OBD II) System Check (Cont'd) Step Action Value(s) 1. Attempt to reprogram the PCM. Refer to Powertrain Control Module (PCM) in On–Vehicle Service. 2. Attempt to display PCM data with the Tech 2.

  • Page 683: A/C Clutch Control Circuit Diagnosis

    6E1–56 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION A/C CLUTCH CONTROL CIRCUIT DIAGNOSIS D06RX037 f The throttle is greater than 90%. Circuit Description f The ignition voltage is below 10.5 volts. When air conditioning and blower fan are selected, and if f The engine speed is greater than 4500 RPM for 5 the system has a sufficient refrigerent charge, a 12–volt...
  • Page 684 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–57 f Damaged harness – Inspect the wiring harness for be used in diagnosing the system. The Tech 2 has the damage; shorts to ground, shorts to battery voltage, ability to read the A/C request input to the PCM. The Tech and open circuits.
  • Page 685 6E1–58 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION A/C Clutch Control Circuit Diagnosis (Cont'd) Step Action Value(s) 1. Reinstall the A/C Compressor Clutch Relay. 2. Using a fused jumper, ground the A/C Compressor Clutch Relay control circuit at the PCM connector.

  • Page 686: Electronic Ignition System Diagnosis

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–59 ELECTRONIC IGNITION SYSTEM IDLE AIR CONTROL (IAC) VALVE DIAGNOSIS If the engine cranks but will not run or immediately stalls, the Engine Cranks But Will Not Start chart must be used to determine if the failure is in the ignition system or the fuel system.

  • Page 687: Fuel Injector Coil Test Procedure And Fuel Injector Balance Test Procedure

    6E1–60 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION monitored with a Tech 2. Ideal long term fuel trim values CAUTION: In order to reduce the risk of fire and are around 0%; for a lean HO2S signal, the PCM will add personal injury, wrap a shop towel around the fuel fuel, resulting in a fuel trim value above 0%.

  • Page 688: Injector Coil Test Procedure (Steps 1-6) And Injector Balance Test Procedure (Steps 7-11)

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–61 Injector Coil Test Procedure (Steps 1–6) And Injector Balance Test Procedure (Steps 7–11) R262001 CYLINDER 1st Reading 296 kPa 296 kPa 296 kPa 296 kPa (43psi) (43psi) (43psi) (43psi) 2nd Reading 131 kPa...
  • Page 689 6E1–62 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION Injector Coil Test Procedure (Steps 1–6) And Injector Balance Test Procedure (Steps 7–11) Step Action Value(s) Go to OBD Was the ”On–Board Diagnostic (OBD) System Check” performed? System Check — Go to Step 2 1.
  • Page 690 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–63 Injector Coil Test Procedure (Steps 1–6) And Injector Balance Test Procedure (Steps 7–11) (Cont'd) Step Action Value(s) 1. Set the injector switch box to injector #1. 2. Press the ”Push to Start Test” button on the fuel injector tester.
  • Page 691 6E1–64 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION Injector Coil Test Procedure (Steps 1–6) And Injector Balance Test Procedure (Steps 7–11) (Cont'd) Step Action Value(s) 1. Connect the J 39021–5V Fuel Injector Tester and J39021–90 Injector Switch Box to the fuel injector harness connector.

  • Page 692: Powertrain Control Module (Pcm) Diagnosis

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–65 f There is a problem with the PCM terminal POWERTRAIN CONTROL MODULE connections. The terminals may have to be removed (PCM) DIAGNOSIS from the connector in order to check them properly. f EEPROM program is not correct for the application.
  • Page 693 6E1–66 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION will continue to indicate a high or low voltage after the af- fected circuit has been repaired. If the sensor has been damaged, replace it. An open in the sensor ground circuit between the PCM...
  • Page 694 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–67 Multiple PCM Information Sensor DTCs Set Step Action Value(s) Go to OBD Was the ”On–Board Diagnostic (OBD) System Check” performed? System Check — Go to Step 2 1. Turn the ignition OFF, disconnect the PCM.
  • Page 695 6E1–68 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION Multiple PCM Information Sensor DTCs Set (Cont'd) Step Action Value(s) 1. Disconnect the EGR valve. 2. Measure the voltage between the EGR pintle position sensor signal circuit at the PCM harness connector and ground.

  • Page 696: Exhaust Gas Recirculation (Egr) Diagnosis

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–69 EXHAUST GAS RECIRCULATION DECEL FUEL MODE – Tech 2 Displays ACTIVE or INACTIVE (EGR) DIAGNOSIS ”ACTIVE” displayed indicates that the PCM has detected conditions appropriate to operate in deceleration fuel mode. The PCM will command the deceleration fuel mode when it detects a closed throttle position while the vehicle is traveling over 20 mph.
  • Page 697 6E1–70 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION EVAP PURGE PWM – Tech 2 Range 0%–100% HO2S WARM UP TIME BANK 1, SEN. 1 – Tech 2 Represents the PCM commanded PWM duty cycle of the Range 00:00:00–99:99:99 HRS:MIN:SEC EVAP purge solenoid valve. ”0%” displayed indicates no Indicates warm–up time for each HO2S.
  • Page 698 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–71 MAP – Tech 2 Range 10–105 kPa (0.00–4.97 Volts) SHORT TERM FT BANK 1 The manifold absolute pressure (MAP) sensor measures Short term fuel trim to a bank represents a short term...

  • Page 699: Typical Scan Data Values

    6E1–72 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION TYPICAL SCAN DATA VALUES Only the parameters listed below are referred to in this service manual for use in diagnosis. For further Use the Typical Scan Data Values Table only after the information on using the Tech 2 to diagnose the PCM and On–Board...
  • Page 700 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–73 Tech 2 Data List Units Typical Data Typical Data Refer To Parameter Displayed Values (IDLE) Values (2500 RPM) Throttle Position Engine 0.35 – 0.39 0.55 – 0.59 General Discription and Sensor Opreration, Throttle Position Sensor.
  • Page 701 6E1–74 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION Tech 2 Data List Units Typical Data Typical Data Refer To Parameter Displayed Values (IDLE) Values (2500 RPM) EVAP Purge Engine 17 – 19 35 – 37 Diagnosis, EVAP Emission Solenoid Canister Purge Valve Check...
  • Page 702 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–75 Tech 2 Data List Units Typical Data Typical Data Refer To Parameter Displayed Values (IDLE) Values (2500 RPM) Weak Cylinder Engine Cylinder # – – Misfire P0300,P0301,P0302,P0303, P0304 Misfire Delay Engine Counts...

  • Page 703: No Malfunction Indicator Lamp (Mil)

    6E1–76 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION NO MALFUNCTION INDICATOR LAMP (MIL) D06RX038 f If the engine cranks but will not run, check for an open Circuit Description PCM ignition or battery feed, or a poor PCM to engine The ”Check Engine”...
  • Page 704 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–77 17. This vehicle is equipped with a PCM which utilizes an electrically erasable programmable read only memory (EEPROM). When the PCM is replaced, the new PCM must be programmed. Refer to PCM Replacement and Programming Procedures in Powertrain Control Module (PCM) and Sensors.
  • Page 705 6E1–78 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION No Malfunction Indicator Lamp (MIL) (Cont'd) Step Action Value(s) Repair the open in the ignition feed circuit. Is the action complete? — Verify repair — Locate and repair the open PCM battery feed circuit.

  • Page 706: Malfunction Indicator Lamp (Mil) On Steady

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–79 MALFUNCTION INDICATOR LAMP (MIL) ON STEADY D06RX039 f Poor connection or damaged harness – Inspect the Circuit Description PCM harness and connectors for improper mating, The malfunction indicator lamp (MIL) should always be...
  • Page 707 6E1–80 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION Malfunction Indicator Lamp (MIL) ON Steady Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to OBD performed? System — Go to Step 2 Check 1. Ignition OFF, disconnect the PCM.

  • Page 708: Engine Cranks But Will Not Run

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–81 ENGINE CRANKS BUT WILL NOT RUN D06RX027...
  • Page 709 6E1–82 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION D06RX029...
  • Page 710 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–83 Circuit Description present at start–up, the PCM will begin sequential fuel delivery with a 1–in–4 chance that fuel delivery is correct. The electronic ignition system uses a dual coil method of The engine will run without a CMP signal, but will set a spark distribution.
  • Page 711 6E1–84 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION Engine Cranks But Will Not Run (Cont'd) Step Action Value(s) 1. Disconnect the ignition module harness connector. 2. Check for an open or short circuit between the ignition control module and the PCM?
  • Page 712 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–85 Engine Cranks But Will Not Run (Cont'd) Step Action Value(s) Replace the coil–to–spark plug secondary ignition wire and any other secondary wires which exceed the specified value. 10,000 W per Go to Step 21...
  • Page 713 6E1–86 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION Engine Cranks But Will Not Run (Cont'd) Step Action Value(s) 1. Ignition ON. 2. At the CKP harness connector, connect a test lamp between the ignition and ground terminals. Go to Step 31...

  • Page 714: Fuel System Electrical Test

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–87 FUEL SYSTEM ELECTRICAL TEST D06RX040 Circuit Description Diagnostic Aids When the ignition switch is first turned ON, the powertrain An intermittent may be caused by a poor connection, control module (PCM) energizes the fuel pump relay rubbed–through wire insulation, or a wire broken inside...
  • Page 715 6E1–88 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION CAUTION: To reduce the risk of fire and personal 2. Remove the fuel pump relay from the underhood injury: relay center. f It is necessary to relieve fuel system pressure 3. Start the engine and allow it to stall.
  • Page 716 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–89 Fuel System Electrical Test (Cont'd) Step Action Value(s) Check for short or open between the PCM and the fuel pump relay. Go to Step 10 Was a problem found? — Verify repair 1.

  • Page 717: Fuel System Diagnosis

    6E1–90 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION FUEL SYSTEM DIAGNOSIS D06RX040 Circuit Description Test Description When the ignition switch is turned ON, the powertrain Number(s) below refer to the step number(s) on the control module (PCM) will turn ON the in–tank fuel pump.
  • Page 718 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–91 f The valve or valve seat within the fuel pressure 20. This test determines if the high fuel pressure is due regulator. to a restricted fuel return line or if the high fuel pressure is due to a faulty fuel pressure regulator.
  • Page 719 6E1–92 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION Fuel System Diagnosis Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to OBD performed? System — Go to Step 2 Check 1. Turn the ignition OFF. 2. Turn the air conditioning system OFF.
  • Page 720 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–93 Fuel System Diagnosis (Cont'd) Step Action Value(s) Locate and repair the loss of vacuum to the fuel pressure regulator. Is the action complete? — Verify repair — Replace the fuel pressure regulator.
  • Page 721 6E1–94 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION Fuel System Diagnosis (Cont'd) Step Action Value(s) Is the fuel pressure indicated by the fuel pressure Go to Step 22 Go to Step 23 0 kPa (0 psi) gauge above the specified value? 1.

  • Page 722: Idle Air Control (Iac) System Check 6E1-95

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–95 IDLE AIR CONTROL (IAC) SYSTEM CHECK D06RX041 high. The following checks should be made to repair a Circuit Description non–IAC system problem: The powertrain control module (PCM) controls engine f Vacuum leak (high idle) – If idle is too high, stop the idle speed with the idle air control (IAC) valve.
  • Page 723 6E1–96 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION f Rich heated oxygen sensor signal (low air/fuel ratio) – 1. The IAC motor analyzer J 39027–A is used to The idle speed will be too low. Tech 2 IAC counts will extend and retract the IAC valve.
  • Page 724 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–97 Idle Air Control (IAC) System Check (Cont'd) Step Action Value(s) 1. Install the appropriate IAC noid light from J 39027–A into the powertrain control module harness. 2. Cycle the IAC motor analyzer J 39027–A and observe the noid lights.

  • Page 725: Exhaust Gas Recirculation (Egr) System Check

    6E1–98 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION EXHAUST GAS RECIRCULATION (EGR) SYSTEM CHECK D06RX055 Circuit Description Diagnostic Aids A properly operating exhaust gas recirculation (EGR) The EGR valve chart is a check of the EGR system. An system will directly affect the air/fuel requirements of the EGR pintle constantly in the closed position could cause engine.
  • Page 726 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–99 Exhaust Gas Recirculation (EGR) System Check Step Action Value(s) Check the EGR valve for looseness. Is the EGR valve loose? — Go to Step 2 Go to Step 3 Tighten the EGR valve.

  • Page 727: Manifold Absolute Pressure (Map) Output Check

    6E1–100 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION MANIFOLD ABSOLUTE PRESSURE (MAP) OUTPUT CHECK D06RX042 Circuit Description 1. When you compare the Tech 2 readings to a known good vehicle, it is important to compare vehicles The manifold absolute pressure (MAP) sensor measures...
  • Page 728 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–101 Manifold Absolute Pressure (MAP) Output Check Step Action Value(s) 1. Turn the ignition OFF and leave it OFF for 15 seconds. 2. Ignition ON. Do not crank engine. 3. The Tech 2 should indicate a manifold absolute pressure (MAP) sensor voltage.

  • Page 729: Evaporative (Evap) Emissions Canister Purge Valve Solenoid Check

    6E1–102 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION EVAPORATIVE (EVAP) EMISSIONS CANISTER PURGE VALVE SOLENOID CHECK D06RX056 Circuit Description Diagnostic Aids f Make a visual check of vacuum hoses. Canister purge is controlled by a solenoid valve that allows manifold vacuum to purge the canister. The f Check the throttle body for possible cracked.
  • Page 730 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–103 Evaporative (EVAP) Emissions Canister Purge Valve Solenoid Check Step Action Value(s) 1. Ignition OFF. 2. Ignition ON, engine OFF. 3. At the throttle body, disconnect the hose that goes to the pump solenoid.
  • Page 731 6E1–104 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION Evaporative (EVAP) Emissions Canister Purge Valve Solenoid Check (Cont'd) Step Action Value(s) 1. Turn the ignition OFF. 2. At the throttle body, install a vacuum gauge where the hose from the purge solenoid was disconnected for testing.

  • Page 732: Upshift Lamp System Check (Manual Transmission Only)

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–105 Upshift Lamp System Check (Manual Transmission Only) D06RX063 Circuit Description Diagnostic Aids The shift lamp indicates the best transmission shift point An intermittent may be caused by a poor connection, for maximum fuel economy.
  • Page 733 6E1–106 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION Up-Shift Lamp System Check Step Action Value(s) 1. Verify the customer complaints in accordance with mentioned below: Go to the adequate Step Chart first. At the 1 gear position, the lamp doesn’t...
  • Page 734 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–107 Up-Shift Lamp System Check (Cont'd) Step Action Value(s) 1. Check for an open or short in the Alarmer and Relay Control Unit. 2. Check for an open of BLU/ORN wiring harness between Transmission Switches and Alarmer Relay Control Unit.

  • Page 735: Pcm Diagnostic Trouble Codes

    6E1–108 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION PCM DIAGNOSTIC TROUBLE CODES The following table lists the diagnostic trouble codes may be faulty; notify the Tech 2 manufacturer of any supported by this vehicle application. If any DTCs not DTCs displayed that are not included in the following listed here are displayed by a Scan Tool, the Tech 2 data table.
  • Page 736 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–109 Description Type Illuminate MIL P0352 Ignition Coil ”B” Primary/Secondary P0401 EGR Flow Insufficient Detected P0402 EGR Excessive Flow Detected P0404 EGR Circuit Range/Performance P0405 EGR Sensor Circuit Low P0406 EGR Sensor Circuit High...
  • Page 737 6E1–110 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION Description Type Illuminate MIL P1627 PCM A/D Conversion Malfunction P1635 5 Volt Reference Voltage Circuit Malfunction P1640 ODM Output Circuit Fault...

  • Page 738: Diagnostic Trouble Code (Dtc) P0106 Manifold Absolute Pressure (Map) Circuit/Range Performance Problem

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–111 DIAGNOSTIC TROUBLE CODE (DTC) P0106 MANIFOLD ABSOLUTE PRES- SURE (MAP) CIRCUIT/RANGE PERFORMANCE PROBLEM D06RX042 f Throttle position is steady, throttle angle changes less Circuit Description than 5%. The manifold absolute pressure (MAP) sensor responds f EGR flow rate is steady, changing less than 2%.
  • Page 739 6E1–112 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION Conditions for Clearing the MIL/DTC If these codes are also set, it could indicate a problem with the 5 Volt reference circuit. f The PCM will turn the MIL OFF on the third consecutive...
  • Page 740 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–113 DTC P0106 MAP Circuit/Range Performance Problem (Cont'd) Step Action Value(s) Check the 5 volt signal circuit, between the MAP sensor and the PCM, for the following conditions: An open circuit A short to ground...

  • Page 741: Diagnostic Trouble Code (Dtc) P0107 Manifold Absolute Pressure (Map) Sensor Circuit Low Input

    6E1–114 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P0107 MANIFOLD ABSOLUTE PRES- SURE (MAP) SENSOR CIRCUIT LOW INPUT D06RX042 f System voltage greater than 11 volts. Circuit Description f Throttle angle is above 0% if engine speed is less than The manifold absolute pressure (MAP) sensor responds or equal to 1300 RPM.
  • Page 742 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–115 Diagnostic Aids observe the MAP display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. Check for the following conditions: A change in the display will indicate the location of the f Poor connection at PCM –...
  • Page 743 6E1–116 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0107 – MAP Sensor Circuit Low Input (Cont'd) Step Action Value(s) 1. Ignition OFF. 2. Disconnect the PCM and check the 5 volt reference circuit for an open or short to ground.

  • Page 744: Diagnostic Trouble Code (Dtc) P0108 Manifold Absolute Pressure (Map) Circuit High Input

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–117 DIAGNOSTIC TROUBLE CODE (DTC) P0108 MANIFOLD ABSOLUTE PRES- SURE (MAP) CIRCUIT HIGH INPUT D06RX042 f Throttle position is below 2.7% if engine speed is below Circuit Description 1000 RPM. The manifold absolute pressure (MAP) sensor responds f Throttle position is below 10% if engine speed is above to changes in intake manifold pressure.
  • Page 745 6E1–118 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION f Poor connection at PCM – Inspect harness connectors f Damaged harness – Inspect the wiring harness for for backed–out terminals, improper mating, broken damage; an open circuit, a short to ground, or a short locks, improperly formed or damaged terminals, and to voltage.
  • Page 746 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–119 DTC P0108 MAP Sensor Circuit High Input (Cont'd) Step Action Value(s) 1. Ignition OFF. 2. Place a fused jumper between the MAP sensor circuit and the 5 volt signal circuit, both at the wiring harness’...

  • Page 747: Diagnostic Trouble Code (Dtc) P0112 Intake Air Temperature (Iat) Sensor Circuit Low Input

    6E1–120 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P0112 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT LOW INPUT D06RX043 f The PCM will store conditions which were present Circuit Description when the DTC was set as Freeze Frame and in the The intake air temperature (IAT) sensor is a thermistor Failure Records data.
  • Page 748 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–121 Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart: 2. Verifies that the fault is present. 3. If Diagnostic Trouble Code P0112 can be repeated only by duplicating the Failure Records condition, refer to the Temperature vs.
  • Page 749 6E1–122 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0112 Intake Air Temperature (IAT) Sensor Circuit Low Input Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to OBD performed? System — Go to Step 2 Check 1. Ignition ON, engine OFF.

  • Page 750: Diagnostic Trouble Code (Dtc) P0113 Intake Air Temperature (Iat) Sensor Circuit High Input

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–123 DIAGNOSTIC TROUBLE CODE (DTC) P0113 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT HIGH INPUT D06RX043 f The PCM will store conditions which were present Circuit Description when the Diagnostic Trouble Code was set as Freeze The intake air temperature (IAT) sensor is a thermistor Frame and in the Failure Records data.
  • Page 751 6E1–124 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION be useful in determining vehicle mileage since the Intake Air Temperature Sensor Diagnostic Trouble Code was last set. °C °F OHMS Test Description Temperature vs. Resistance Values (approximate) Number(s) below refer to the step number(s) on the Diagnostic Chart: 2.Verifies that the fault is present.
  • Page 752 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–125 DTC P0113 Intake Air Temperature (IAT) Sensor Circuit High Input (Cont'd) Step Action Value(s) Check for poor connections at the IAT sensor and replace terminals if necessary. Go to Step 10 Did any terminals require replacement? —...

  • Page 753: Diagnostic Trouble Code (Dtc) P0117 Engine Coolant Temperature (Ect) Sensor Circuit Low Input

    6E1–126 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P0117 ENGINE COOLANT TEMPERA- TURE (ECT) SENSOR CIRCUIT LOW INPUT D06RX044 f The PCM will store conditions which were present Circuit Description when the Diagnostic Trouble Code was set as Freeze The engine coolant temperature (ECT) sensor is a Frame and in the Failure Records data.
  • Page 754 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–127 Diagnostic Trouble Code was last set. If it is determined that the Diagnostic Trouble Code occurs intermittently, performing Diagnostic Trouble Code P1114 Diagnostic Chart may isolate the cause of the fault. Test Description...
  • Page 755 6E1–128 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0117 – Engine Coolant Temperature (ECT) Sensor Circuit Low Input Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to OBD performed? System — Go to Step 2 Check 1.

  • Page 756: Diagnostic Trouble Code (Dtc) P0118 Engine Coolant Temperature (Ect) Sensor Circuit High Input

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–129 DIAGNOSTIC TROUBLE CODE (DTC) P0118 ENGINE COOLANT TEMPERA- TURE (ECT) SENSOR CIRCUIT HIGH INPUT D06RX044 f The PCM will store conditions which were present Circuit Description when the DTC was set as Freeze Frame and in the The engine coolant temperature (ECT) sensor is a Failure Records data.
  • Page 757 6E1–130 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION Diagnostic Trouble Code was last set. If it is determined Intake Air Temperature Sensor that the Diagnostic Trouble Code occurs intermittently, °C °F performing the DTC P1115 Diagnostic Chart may isolate OHMS the cause of the fault.
  • Page 758 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–131 DTC P118 – ECT Sensor Circuit High Input (Cont'd) Step Action Value(s) 1. Ignition OFF. 2. Disconnect the PCM, and check the ECT sensor ground circuit for an open. 3. If the ECT sensor ground circuit is open, repair it as necessary.

  • Page 759: Diagnostic Trouble Code (Dtc) P0121 Throttle Position (Tp) Sensor Circuit Range/Performance Problem

    6E1–132 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P0121 THROTTLE POSITION (TP) SEN- SOR CIRCUIT RANGE/PERFORMANCE PROBLEM D06RX045 f Actual TP value is greater than the PCM’s estimated Circuit Description TP value (Estimated TP value is based on MAP and The throttle position (Throttle Position) sensor circuit RPM).
  • Page 760 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–133 Diagnostic Aids locks, improperly formed or damaged terminals, and poor terminal–to–wire connection. Check for the following conditions: f Damaged harness – Inspect the wiring harness for f Skewed MAP signal or faulty MAP sensor – An damage;...
  • Page 761 6E1–134 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0121 TP Sensor/Range Performance Problem (Cont'd) Step Action Value(s) Check the 5 volt signal circuit, between the TP sensor and the PCM, for the following conditions: An open circuit A short to ground...

  • Page 762: Diagnostic Trouble Code (Dtc) P0122 Throttle Position (Tp) Sensor Circuitlow Input

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–135 DIAGNOSTIC TROUBLE CODE (DTC) P0122 THROTTLE POSITION (TP) SEN- SOR CIRCUITLOW INPUT D06RX045 Circuit Description Conditions for Clearing the MIL/DTC f The PCM will turn the MIL OFF on the third consecutive The throttle position (TP) sensor circuit provides a voltage signal that changes relative to throttle blade angle.
  • Page 763 6E1–136 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION If Diagnostic Trouble Code P0122 cannot be duplicated, that the Diagnostic Trouble Code occurs intermittently, the information included in the Failure Records data can performing Diagnostic Trouble Code P1122 be useful in determining vehicle mileage since the Diagnostic Chart may isolate the cause of the fault.
  • Page 764 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–137 DTC P0122 – TP Sensor Circuit Low Input (Cont'd) Step Action Value(s) 1. Ignition OFF. 2. Disconnect the PCM, and check the TP signal circuit for an open, short to ground, or short to the sensor ground circuit.

  • Page 765: Diagnostic Trouble Code (Dtc) P0123 Throttle Position (Tp) Sensor Circuit High Input

    6E1–138 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P0123 THROTTLE POSITION (TP) SEN- SOR CIRCUIT HIGH INPUT D06RX045 Circuit Description Conditions for Clearing the MIL/DTC f The PCM will turn the MIL OFF on the third consecutive The throttle position (TP) sensor circuit provides a voltage signal that changes relative to throttle blade angle.
  • Page 766 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–139 f Faulty Throttle Position sensor – With the ignition key Test Description ON engine OFF observe the TP sensor display on the Number(s) below refer to the step number(s) on the Tech 2 while slowly depressing the accelerator to wide Diagnostic Chart: open throttle.
  • Page 767 6E1–140 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0123 – TP Sensor Circuit High Input (Cont'd) Step Action Value(s) 1. Ignition ON. 2. Monitor the ”Throttle Position Sensor” Tech 2 display while disconnecting each components that share the 5 volt reference circuit (one at a time).

  • Page 768: Diagnostic Trouble Code (Dtc) P0125 Insufficient Coolant Temperature For Closed Loop Fuel Control

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–141 DIAGNOSTIC TROUBLE CODE (DTC) P0125 INSUFFICIENT COOLANT TEM- PERATURE FOR CLOSED LOOP FUEL CONTROL D06RX044 f Time for coolant to reach stabilized ”Closed Loop” Circuit Description value is less than 120 seconds.
  • Page 769 6E1–142 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION f A history Diagnostic Trouble Code P0125 will clear 2. Comparing the engine coolant temperature after 40 consecutive warm–up cycles have occurred displayed on a Tech 2 with actual coolant without a fault.
  • Page 770 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–143 DTC P0125 Insufficient Coolant Temperature for Closed Loop Fuel Control (Cont'd) Step Action Value(s) Compare engine coolant temperature displayed on the Tech 2 to the actual coolant temperature measured with a thermometer. (Observe normal precautions when opening the cooling system.)

  • Page 771: Diagnostic Trouble Code (Dtc) P0131 O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1)

    6E1–144 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P0131 O2 SENSOR CIRCUIT LOW VOLT- AGE (BANK 1 SENSOR 1) D06RX046 Circuit Description Action Taken When the DTC Sets f The PCM will illuminate the malfunction indicator lamp...
  • Page 772 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–145 Trouble Code P0131 may be set. Refer to Fuel System Test Description Diagnosis. Number(s) below refer to the step number(s) on the f Lean injector(s) – Perform ”Injector Balance Test.” Diagnostic Chart: f Vacuum leaks –...
  • Page 773 6E1–146 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0131 – O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1) (Cont'd) Step Action Value(s) 1. Turn the ignition OFF HO2S 1 and PCM disconnected. 2. Check for continuity between the high and low signal circuits.

  • Page 774: Diagnostic Trouble Code (Dtc) P0132 O2 Sensor Circuit High Voltage (Bank 1 Sensor 1)

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–147 DIAGNOSTIC TROUBLE CODE (DTC) P0132 O2 SENSOR CIRCUIT HIGH VOLT- AGE (BANK 1 SENSOR 1) D06RX046 Circuit Description f Bank 1 HO2S 1 signal voltage remains above 500 mV The powertrain control module (PCM) supplies a bias during ”deceleration fuel cutoff mode”...
  • Page 775 6E1–148 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION Diagnostic Trouble Code P0132 may be set. Refer to range between 300 mV to 600 mV, check the HO2S Fuel System Diagnosis. high and low circuit wiring and associated terminal connections. If the wiring and connections are OK, f Perform ”Injector Balance Test”...
  • Page 776 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–149 DTC P0132 – O2 Sensor Circuit High Voltage (Bank 1 Sensor 1) (Cont'd) Step Action Value(s) 1. Ignition OFF. 2. Disconnect the PCM connector. 3. Check for damage to the PCM pins and terminals.

  • Page 777: Diagnostic Trouble Code (Dtc) P0133 O2 Sensor Circuit Slow Response (Bank 1 Sensor 1)

    6E1–150 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P0133 O2 SENSOR CIRCUIT SLOW RE- SPONSE (BANK 1 SENSOR 1) D06RX046 Circuit Description All above conditions are met for 1 second and the following condition is met: The powertrain control module (PCM) continuously f 90 seconds after ”Closed Loop”...
  • Page 778 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–151 Diagnostic Aids the condition that caused the Diagnostic Trouble Code to be set occurs. This may assist in diagnosing the Check for the following conditions: condition. f Poor connection at PCM – Inspect harness connectors for backed–out terminals, improper mating, broken...
  • Page 779 6E1–152 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0133 – O2 Sensor Circuit Slow Response (Bank 1 Sensor 1) (Cont'd) Step Action Value(s) 1. Disconnect Bank 1 HO2S 1. 2. Ignition ON. 3. Using a Digital Voltmeter (DVM) at the PCM side of the HO2S 1 connector, measure the voltage between the high signal circuit and ground.

  • Page 780: Diagnostic Trouble Code (Dtc) P0134 O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1)

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–153 DIAGNOSTIC TROUBLE CODE (DTC) P0134 O2 SENSOR CIRCUIT NO ACTIV- ITY DETECTED (BANK 1 SENSOR 1) D06RX046 Circuit Description Action Taken When the DTC Sets f The PCM will illuminate the malfunction indicator lamp...
  • Page 781 6E1–154 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION signal line shorted to ground or signal lines shorted and related connectors. If the fault is induced, the together. Disconnect the HO2S and connect a test light HO2S signal voltage will change. This may help isolate between the HO2S ignition feed and heater ground the location of the malfunction.
  • Page 782 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–155 DTC P0134 – O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1) (Cont'd) Step Action Value(s) 1. Ignition OFF. 2. With the PCM disconnected, check continuity of the Bank 1 HO2S 1 low circuit.

  • Page 783: Diagnostic Trouble Code (Dtc) P0135 O2 Sensor Heater Circuit Malfunction (Bank 1 Sensor 1)

    6E1–156 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P0135 O2 SENSOR HEATER CIRCUIT MALFUNCTION (BANK 1 SENSOR 1) D06RX046 f Engine coolant temperature (ECT) is less than 32°C Circuit Description (90°F) at start–up. Heated oxygen sensors are used to minimize the amount f IAT and ECT are within 5°C (9°F) of each other at...
  • Page 784 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–157 f A history Diagnostic Trouble Code P0135 will clear Test Description after 40 consecutive warm–up cycles have occurred Number(s) below refer to the step number(s) on the without a fault. Diagnostic Chart: f Diagnostic Trouble Code P0135 can be cleared by 2.
  • Page 785 6E1–158 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0135 – O2 Sensor Heater Circuit Malfunction (Bank 1 Sensor 1) (Cont'd) Step Action Value(s) 1. Allow the HO2S to cool for at least 10 minutes. 2. Using a Digital Voltmeter (DVM), measure the...

  • Page 786: Diagnostic Trouble Code (Dtc) P0137 O2 Sensor Circuit Low Voltage (Bank 1 Sensor 2)

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–159 DIAGNOSTIC TROUBLE CODE (DTC) P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2) D06RX047 f Engine coolant temperature is above 60°C (140°F). Circuit Description f ”Closed Loop” commanded air/fuel ratio is between To control emissions of hydrocarbons (HC), carbon 14.5 and 14.8.
  • Page 787 6E1–160 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION f A history Diagnostic Trouble Code P0137 will clear HO2S, causing the Diagnostic Trouble Code P0137 to after 40 consecutive warm–up cycles have occurred set. Check for exhaust leaks near the Bank 1 HO2S 2 without a fault.
  • Page 788 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–161 DTC P0137 – O2 Sensor Circuit Low Voltage (Bank 1 Sensor 2) (Cont'd) Step Action Value(s) 1. Ignition OFF. 2. Leave the PCM and HO2S 2 disconnected. 3. Check for continuity between the high and low signal circuits.

  • Page 789: Diagnostic Trouble Code (Dtc) P0138 O2 Sensor Circuit High Voltage (Bank 1 Sensor 2)

    6E1–162 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2) D06RX047 f ”Closed Loop” commanded air/fuel ratio is between Circuit Description 14.5 and 14.8. To control emissions of hydrocarbons (HC), carbon f Engine coolant temperature is above 60°C (140°F).
  • Page 790 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–163 f Diagnostic Trouble Code P0138 can be cleared by f Open HO2S Signal, Low Circuit or Faulty HO2S – A using the Scan Tool’s ”Clear Info” function. poor connection or open in the HO2S signal or low...
  • Page 791 6E1–164 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0138 – O2 Sensor Circuit High Voltage (Bank 1 Sensor 2) (Cont'd) Step Action Value(s) 1. Ignition OFF. 2. Disconnect Bank 1 HO2S 2. 3. Ignition ON. 4. At HO2S 2 connector (PCM side) use a DVM to measure voltages at the high and low signal terminals.

  • Page 792: Diagnostic Trouble Code (Dtc) P0140 O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 2)

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–165 DIAGNOSTIC TROUBLE CODE (DTC) P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 2) D06RX047 f Oxygen sensor heater is functioning properly, and the Circuit Description oxygen sensor has reached operating temperature.
  • Page 793 6E1–166 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION damaged terminals, poor terminal–to–wire HO2S signal voltage will change. This may help isolate connection, shorts to ground, shorts to battery positive the location of the malfunction. and open circuits. Test Description f Faulty HO2S heater or heater circuit – With the ignition...
  • Page 794 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–167 DTC P0140 – O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 2) (Cont'd) Step Action Value(s) 1. Reconnect the PCM harness. 2. Ignition ON. 3. With the Bank 1 HO2S 2 sensor harness...
  • Page 795 6E1–168 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P0141 O2 SENSOR HEATER CIRCUIT MALFUNCTION (BANK 1 SENSOR 2) D06RX047 f Engine coolant temperature (ECT) is less than 32°C Circuit Description (90°F) at start–up. Heated oxygen sensors are used to minimize the amount f IAT and ECT are within 5°C (9°F) of each other at...
  • Page 796 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–169 f A history Diagnostic Trouble Code P0141 will clear Test Description after 40 consecutive warm–up cycles have occurred Number(s) below refer to the step number(s) on the without a fault. Diagnostic Chart: f Diagnostic Trouble Code P0141 can be cleared by 2.The HO2S should be allowed to cool before...
  • Page 797 6E1–170 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0141 – O2 Sensor Heater Circuit Malfunction (Bank 1 Sensor 2) (Cont'd) Step Action Value(s) 1. Allow the HO2S to cool for at least 10 minutes. 2. Using a Digital Voltmeter (DVM), measure the...

  • Page 798: Diagnostic Trouble Code (Dtc) P0171 System Too Lean (Bank 1)

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–171 DIAGNOSTIC TROUBLE CODE (DTC) P0171 SYSTEM TOO LEAN (BANK 1) D06RX048 Circuit Description Codes, IAT Diagnostic Trouble Codes, canister purge Diagnostic Trouble Codes, EVAP Diagnostic Trouble To provide the best possible combination of driveability, Codes, injector circuit Diagnostic Trouble Codes, or fuel economy, and emission control, a ”Closed Loop”...
  • Page 799 6E1–172 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION Conditions for Clearing the MIL/DTC Test Description f The PCM will turn the MIL OFF on the third consecutive Number(s) below refer to the step number(s) on the trip cycle during which the diagnostic has been run and Diagnostic Chart: the fault condition is no longer present.
  • Page 800 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–173 DTC P0171 – System Too Lean (Bank 1) Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to OBD performed? System — Go to Step 2 Check Are any DTCs set other than P0171?
  • Page 801 6E1–174 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0171 – System Too Lean (Bank 1) (Cont'd) Step Action Value(s) Perform the ”Idle Air Control (IAC) Valve Check” and correct any IAC problem as necessary. Go to Step Did this test isolate a problem requiring repair? —...

  • Page 802: Diagnostic Trouble Code (Dtc) P0172 System Too Rich (Bank 1)

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–175 DIAGNOSTIC TROUBLE CODE (DTC) P0172 SYSTEM TOO RICH (BANK 1) D06RX048 Circuit Description Diagnostic Trouble Codes, canister purge Diagnostic Trouble Codes, EVAP Diagnostic Trouble Codes, To provide the best possible combination of driveability, injector circuit Diagnostic Trouble Codes, or misfire fuel economy, and emission control, a ”Closed Loop”...
  • Page 803 6E1–176 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION f A history Diagnostic Trouble Code P0172 will clear Test Description after 40 consecutive warm–up cycles have occurred Number(s) below refer to the step number(s) on the without a fault. Diagnostic Chart: f Diagnostic Trouble Code P0172 can be cleared by 2.
  • Page 804 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–177 DTC P0172 – System Too Rich (Bank 1) Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to OBD performed? System — Go to Step 2 Check Are any Diagnostic Trouble Codes set other than...
  • Page 805 6E1–178 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0172 – System Too Rich (Bank 1) (Cont'd) Step Action Value(s) 1. Perform the ”Idle Air Control (IAC) Valve Check.” 2. If a problem is found, repair as necessary. Go to Step Did the test isolate a problem requiring repair? —...

  • Page 806: Diagnostic Trouble Code (Dtc) P0201 Injector Circuit Malfunction - Cylinder

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–179 DIAGNOSTIC TROUBLE CODE (DTC) P0201 INJECTOR CIRCUIT MALFUNCTION – CYLINDER 1 D06RX049 f The PCM will store conditions which were present Circuit Description when the Diagnostic Trouble Code was set as Freeze The powertrain control module (PCM) has four individual Frame and in the Failure Records data.

  • Page 807: Cylinder 2

    6E1–180 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 3.This step determines if Diagnostic Trouble Code P0201 is the result of a hard failure or an intermittent condition. 5. This step tests the harness wiring and PCM control of the injectors using a test light.
  • Page 808 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–181 DTC P0201 – Injector Circuit Malfunction – Cylinder 1 (Cont'd) Step Action Value(s) 1. Disconnect the PCM connector for the affected injectors. 2. With a test light connected to B+, probe the affected injector driver circuit.

  • Page 809: Diagnostic Trouble Code (Dtc) P0203 Injector Circuit Malfunction - Cylinder

    6E1–182 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P0202 INJECTOR CIRCUIT MALFUNCTION – CYLINDER 2 D06RX049 f The PCM will store conditions which were present Circuit Description when the Diagnostic Trouble Code was set as Freeze The powertrain control module (PCM) has four individual Frame and in the Failure Records data.

  • Page 810: Cylinder 3

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–183 3.This step determines if Diagnostic Trouble Code P0202 is the result of a hard failure or an intermittent condition. 5.This step tests the harness wiring and PCM control of the injectors using a test light.
  • Page 811 6E1–184 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0202 – Injector Circuit Malfunction – Cylinder 2 (Cont'd) Step Action Value(s) 1. Disconnect the PCM connector for the affected injectors. 2. With a test light connected to B+, probe the affected injector driver circuit.
  • Page 812 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–185 DIAGNOSTIC TROUBLE CODE (DTC) P0203 INJECTOR CIRCUIT MALFUNCTION – CYLINDER 3 D06RX049 f The PCM will store conditions which were present Circuit Description when the DTC was setas Freeze Frame and in the The powertrain control module (PCM) has four individual Failure Records data.

  • Page 813: Cylinder 4

    6E1–186 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 3. This step determines if Diagnostic Trouble Code P0203 is the result of a hard failure or an intermittent condition. 5. This step tests the harness wiring and PCM control of the injectors using a test light.
  • Page 814 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–187 DTC P0203 – Injector Circuit Malfunction – Cylinder 3 (Cont'd) Step Action Value(s) 1. Disconnect the PCM connector for the affected injectors. 2. With a test light connected to B+, probe the affected injector driver circuit.
  • Page 815 6E1–188 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P0204 INJECTOR CIRCUIT MALFUNCTION – CYLINDER 4 D06RX049 f The PCM will store conditions which were present Circuit Description when the Diagnostic Trouble Code was set as Freeze The powertrain control module (PCM) has four individual Frame and in the Failure Records data.
  • Page 816 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–189 3. This step determines if Diagnostic Trouble Code P0204 is the result of a hard failure or an intermittent condition. 5. This step tests the harness wiring and PCM control of the injectors using a test light.
  • Page 817 6E1–190 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0204 – Injector Circuit Malfunction – Cylinder 4 (Cont'd) Step Action Value(s) 1. Disconnect the PCM connector for the affected injectors. 2. With a test light connected to B+, probe the affected injector driver circuit.

  • Page 818: Diagnostic Trouble Code (Dtc) P0300 Random/Multiple Cylinder Misfire Detected

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–191 DIAGNOSTIC TROUBLE CODE (DTC) P0300 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED D06RX050 Circuit Description Action Taken When the DTC Sets f The PCM will illuminate the malfunction indicator lamp If the PCM determines that the engine is misfiring and cannot determine the actual cylinder that is misfiring then (MIL) the first time the fault is detected.
  • Page 819 6E1–192 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION f Substitute a known good coil – Swap the ignition coils and retest. If misfire follows the coil, replace the ignition coil. If the misfire is random, check for the following conditions: f System grounds –...
  • Page 820 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–193 DTC P0300 – Random/Multiple Cylinder Misfire Detected Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to OBD performed? System — Go to Step 2 Check 1. Start and idle the engine.
  • Page 821 6E1–194 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0300 – Random/Multiple Cylinder Misfire Detected (Cont'd) Step Action Value(s) 1. Remove the spark plugs from the cylinders that were indicated as misfiring. 2. Visually inspect the spark plug electrodes. Go to Engine...

  • Page 822: Diagnostic Trouble Code (Dtc) P0301 Random/Multiple Cylinder Misfire Detected

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–195 DIAGNOSTIC TROUBLE CODE (DTC) P0301 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED D06RX050 Circuit Description Action Taken When the DTC Sets f The PCM will illuminate the malfunction indicator lamp If the PCM determines that the engine is misfiring and can determine the actual cylinder that is misfiring then it will (MIL) the first time the fault is detected.
  • Page 823 6E1–196 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION f Substitute a known good coil – Swap the ignition coils and retest. If misfire follows the coil, replace the ignition coil. If the misfire is random, check for the following conditions: f System grounds –...
  • Page 824 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–197 DTC P0301 – Random/Multiple Cylinder Misfire Detected Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to OBD performed? System — Go to Step 2 Check 1. Start and idle the engine.
  • Page 825 6E1–198 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0301 – Random/Multiple Cylinder Misfire Detected (Cont'd) Step Action Value(s) 1. Visually inspect the spark plug insulators for cracks, carbon tracking, or other damage. 2. If a problem is found, replace the faulty spark plug(s) as necessary.

  • Page 826: Diagnostic Trouble Code (Dtc) P0302 Random/Multiple Cylinder Misfire Detected

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–199 DIAGNOSTIC TROUBLE CODE (DTC) P0302 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED D06RX050 Circuit Description Action Taken When the DTC Sets f The PCM will illuminate the malfunction indicator lamp If the PCM determines that the engine is misfiring and can determine the actual cylinder that is misfiring then it will (MIL) the first time the fault is detected.
  • Page 827 6E1–200 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION f Substitute a known good coil – Swap the ignition coils and retest. If misfire follows the coil, replace the ignition coil. If the misfire is random, check for the following conditions: f System grounds –...
  • Page 828 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–201 DTC P0302 – Random/Multiple Cylinder Misfire Detected Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to OBD performed? System — Go to Step 2 Check 1. Start and idle the engine.
  • Page 829 6E1–202 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0302 – Random/Multiple Cylinder Misfire Detected (Cont'd) Step Action Value(s) 1. Visually inspect the spark plug insulators for cracks, carbon tracking, or other damage. 2. If a problem is found, replace the faulty spark plug(s) as necessary.

  • Page 830: Diagnostic Trouble Code (Dtc) P0303 Random/Multiple Cylinder Misfire Detected

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–203 DIAGNOSTIC TROUBLE CODE (DTC) P0303 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED D06RX050 Circuit Description Action Taken When the DTC Sets f The PCM will illuminate the malfunction indicator lamp If the PCM determines that the engine is misfiring and can determine the actual cylinder that is misfiring then it will (MIL) the first time the fault is detected.
  • Page 831 6E1–204 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION f Substitute a known good coil – Swap the ignition coils and retest. If misfire follows the coil, replace the ignition coil. If the misfire is random, check for the following conditions: f System grounds –...
  • Page 832 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–205 DTC P0303 – Random/Multiple Cylinder Misfire Detected Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to OBD performed? System — Go to Step 2 Check 1. Start and idle the engine.
  • Page 833 6E1–206 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0303 – Random/Multiple Cylinder Misfire Detected (Cont'd) Step Action Value(s) 1. Visually inspect the spark plug insulators for cracks, carbon tracking, or other damage. 2. If a problem is found, replace the faulty spark plug(s) as necessary.

  • Page 834: Diagnostic Trouble Code (Dtc) P0304 Random/Multiple Cylinder Misfire Detected

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–207 DIAGNOSTIC TROUBLE CODE (DTC) P0304 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED D06RX050 Circuit Description Action Taken When the DTC Sets f The PCM will illuminate the malfunction indicator lamp If the PCM determines that the engine is misfiring and can determine the actual cylinder that is misfiring then it will (MIL) the first time the fault is detected.
  • Page 835 6E1–208 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION f Substitute a known good coil – Swap the ignition coils and retest. If misfire follows the coil, replace the ignition coil. If the misfire is random, check for the following conditions: f System grounds –...
  • Page 836 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–209 DTC P0304 – Random/Multiple Cylinder Misfire Detected Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to OBD performed? System — Go to Step 2 Check 1. Start and idle the engine.
  • Page 837 6E1–210 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0304 – Random/Multiple Cylinder Misfire Detected (Cont'd) Step Action Value(s) 1. Visually inspect the spark plug insulators for cracks, carbon tracking, or other damage. 2. If a problem is found, replace the faulty spark plug(s) as necessary.

  • Page 838: Diagnostic Trouble Code (Dtc) P0325 Knock Sensor (Ks) Circuit Malfunction

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–211 DIAGNOSTIC TROUBLE CODE (DTC) P0325 KNOCK SENSOR (KS) CIRCUIT MALFUNCTION D06RX051 f The PCM will use a calculated spark retard value in Circuit Description order to minimize the knock during the conditions when The knock sensor (KS) system is used to detect engine the knock is likely to occur.
  • Page 839 6E1–212 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 2. If the conditions for the test as described above are 8. If the KS module was previously replaced and the met, a Diagnostic Trouble Code P0325 will set and Diagnostic Trouble Code resets, a malfunctioning MIL will illuminate.
  • Page 840 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–213 DTC P0325 KS Circuit Malfunction (Cont'd) Step Action Value(s) Replace the PCM. IMPORTANT: The replacement must programmed. Refer to On–Vehicle Service in Powertrain Control Module Sensors procedures. And also refer to latest Service Bulletin.

  • Page 841: Diagnostic Trouble Code (Dtc) P0327 Knock Sensor (Ks) Circuit Low Input

    6E1–214 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P0327 KNOCK SENSOR (KS) CIRCUIT LOW INPUT D06RX051 f A/D Voltage is less than or equal to 0.0977 Volts. Circuit Description Gain Test The PCM uses the Knock Sensor (KS) in order to detect engine detonation.
  • Page 842 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–215 A poor connection at the PCM. Inspect the knock sensor Review the Fail Records vehicle mileage since the and the PCM connectors for: , broken locks, improperly diagnostic test last failed in order to help determine how formed or damaged terminals.
  • Page 843 6E1–216 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0327 KS Circuit Low Input (Cont'd) Step Action Value(s) 1. Check the KS signal circuit for a poor terminal connection at the knock sensor. 2. If a problem is found, repair as necessary. Refer to Wiring Repairs in Engine Electrical.

  • Page 844: Diagnostic Trouble Code (Dtc) P0336 Crankshaft Position (Ckp) Sensor Circuit Range/Performance

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–217 DIAGNOSTIC TROUBLE CODE (DTC) P0336 CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT RANGE/PERFORMANCE D06RX052 Circuit Description Conditions for Clearing the MIL/DTC f The PCM will turn the MIL OFF on the third consecutive The 58X reference signal is produced by the crankshaft position (CKP) sensor.
  • Page 845 6E1–218 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION be set occurs. This may assist in diagnosing the condition. DTC P0336 – CKP Sensor Circuit Range/Performance Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to OBD performed? System Check —...

  • Page 846: Diagnostic Trouble Code (Dtc) P0337 Crankshaft Position (Ckp) Sensor Circuit Low Input

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–219 DIAGNOSTIC TROUBLE CODE (DTC) P0337 CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT LOW INPUT D06RX052 Circuit Description Conditions for Clearing the MIL/DTC f The PCM will turn the MIL OFF on the third consecutive The 58X reference signal is produced by the crankshaft position (CKP) sensor.
  • Page 847 6E1–220 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION be set occurs. This may assist in diagnosing the condition. DTC P0337 – CKP Sensor Circuit Low Input Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to OBD performed?
  • Page 848 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–221 DTC P0337 – CKP Sensor Circuit Low Input (Cont'd) Step Action Value(s) Check the connections at the PCM and replace the terminals if necessary. Go to Step Did any terminals require replacement? —...

  • Page 849: Diagnostic Trouble Code (Dtc) P0341 Camshaft Position (Cmp) Sensor Circuit Range/Performance

    6E1–222 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P0341 CAMSHAFT POSITION (CMP) SENSOR CIRCUIT RANGE/PERFORMANCE D06RX053 f The PCM will initiate injector sequence without the Circuit Description CMP signal with a one in four chance that injector The camshaft position (CMP) sensor signal is produced sequence is correct.
  • Page 850 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–223 f Poor connection – Inspect the PCM harness and PCM harness connector while moving connectors and connectors for improper mating, broken locks, wiring harnesses related to the CMP sensor. A change improperly formed or damaged terminals, and poor in voltage will indicate the location of the fault.
  • Page 851 6E1–224 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0341 – CMP Sensor Circuit Range/Performance (Cont'd) Step Action Value(s) Repair the open circuit. Is the repair complete? — Verify repair — 1. Ignition ON. 2. Use a DVM to measure at the CMP connector between the battery + and the CMP ground wire.

  • Page 852: Diagnostic Trouble Code (Dtc) P0342 Camshaft Position (Cmp) Sensor Circuit Low Input

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–225 DIAGNOSTIC TROUBLE CODE (DTC) P0342 CAMSHAFT POSITION (CMP) SENSOR CIRCUIT LOW INPUT D06RX053 f The PCM will initiate injector sequence without the Circuit Description CMP signal with a one in four chance that injector The camshaft position (CMP) sensor signal is produced sequence is correct.
  • Page 853 6E1–226 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION f Poor connection – Inspect the PCM harness and PCM harness connector while moving connectors and connectors for improper mating, broken locks, wiring harnesses related to the CMP sensor. A change improperly formed or damaged terminals, and poor in voltage will indicate the location of the fault.
  • Page 854 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–227 DTC P0342 – Camshaft Position Sensor Circuit Low Input (Cont'd) Step Action Value(s) 1. Ignition ON. 2. Use a DVM to measure at the CMP connector between the battery + and the CMP ground wire.

  • Page 855: Diagnostic Trouble Code (Dtc) P0351 Ignition Coil "A" Primary/Secondary Circuit Malfunction

    6E1–228 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P0351 IGNITION COIL ”A” PRIMARY/ SECONDARY CIRCUIT MALFUNCTION D06RX054 Circuit Description Action Taken When the DTC Sets f The PCM will illuminate the malfunction indicator lamp The ignition control circuit provides a zero volt or a 5 volt signal to the ignition control module.
  • Page 856 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–229 Reviewing the Failure Records vehicle mileage since the the condition that caused the DTC to be set occurs. This diagnostic test last failed may help determine how often may assist in diagnosing the condition.

  • Page 857: Diagnostic Trouble Code (Dtc) P0352 Ignition Coil "B" Primary/Secondary Circuit Malfunction

    6E1–230 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P0352 IGNITION COIL ”B” PRIMARY/ SECONDARY CIRCUIT MALFUNCTION D06RX054 Circuit Description Action Taken When the DTC Sets f The PCM will illuminate the malfunction indicator lamp The ignition control circuit provides a zero volt or a 5 volt signal to the ignition control module.
  • Page 858 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–231 Reviewing the Failure Records vehicle mileage since the the condition that caused the DTC to be set occurs. This diagnostic test last failed may help determine how often may assist in diagnosing the condition.

  • Page 859: Diagnostic Trouble Code (Dtc) P0401 Exhaust Gas Recirculation (Egr) Flow Insufficient Detected

    6E1–232 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P0401 EXHAUST GAS RECIRCULATION (EGR) FLOW INSUFFICIENT DETECTED D06RX055 f Engine coolant temperature is greater than 60°C Circuit Description (140°F). The powertrain control module (PCM) tests the exhaust f System voltage is between 11.5 and 16 volts.
  • Page 860 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–233 difference between the two values exceeds the PCM’s Diagnostic Aids internal limit, a Diagnostic Trouble Code P0401 will set. Check for the following conditions: DTC P0401 is a type A code. f Poor connection or damaged harness – Inspect the NOTE: Several deceleration cycles will be necessary to wiring harness for damage.
  • Page 861 6E1–234 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0401 – Exhaust Gas Recirculation Flow Insufficient Detected Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to OBD performed? System — Go to Step 2 Check 1. Start the engine.

  • Page 862: Diagnostic Trouble Code (Dtc) P0402 Exhaust Gas Recirculation (Egr) Excessive Flow Detected

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–235 DIAGNOSTIC TROUBLE CODE (DTC) P0402 EXHAUST GAS RECIRCULATION (EGR) EXCESSIVE FLOW DETECTED D06RX055 f Poor connection or damaged harness – Inspect the Circuit Description wiring harness for damage. If the harness appears to...
  • Page 863 6E1–236 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0402 EGR Excessive Flow Detected Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to OBD performed? System — Go to Step 2 Check 1. Review and record the Tech 2 Failure Records data.

  • Page 864: Diagnostic Trouble Code (Dtc) P0404 Exhaust Gas Recirculation (Egr) Circuit Range/Performance

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–237 DIAGNOSTIC TROUBLE CODE (DTC) P0404 EXHAUST GAS RECIRCULATION (EGR) CIRCUIT RANGE/PERFORMANCE D06RX055 Circuit Description If the PCM detects a large difference between the desired EGR position and actual EGR position, then An Exhaust Gas Recirculation (EGR) system is used to Diagnostic Trouble Code P0404 will set.
  • Page 865 6E1–238 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION Diagnostic Aids 17. All circuits to the EGR valve are OK at this point. The fault lies internally in the EGR valve and Due to the moisture associated with exhaust systems, the therefore must be replaced.
  • Page 866 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–239 DTC P0404 EGR Circuit Range/Performance Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to performed? Powertrain OBD System — Go to Step 2 Check 1. Turn the ignition switch ON, with the engine OFF.
  • Page 867 6E1–240 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0404 EGR Circuit Range/Performance (Cont'd) Step Action Value(s) Replace the PCM. IMPORTANT: The replacement must programmed. Refer to On–Vehicle Service in Powertrain Control Module Sensors procedures. And also refer to latest Service Bulletin.

  • Page 868: Diagnostic Trouble Code (Dtc) P0405 Exhaust Gas Recirculation (Egr) Sensor Circuit Low

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–241 DIAGNOSTIC TROUBLE CODE (DTC) P0405 EXHAUST GAS RECIRCULATION (EGR) SENSOR CIRCUIT LOW D06RX055 Circuit Description If the PCM detects a continuous short to ground in the signal circuit or the sensor, then Diagnostic Trouble Code An Exhaust Gas Recirculation (EGR) system is used to P0405 will set.
  • Page 869 6E1–242 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION Diagnostic Aids 4. Jumping the 5 volt reference circuit to the signal circuit checks the signal circuit and PCM. The Tech Due to the moisture associated with exhaust systems, the 2 should display the Actual EGR Position as 100% if EGR valve may freeze and stick in colder weather at the signal circuit and PCM are OK.
  • Page 870 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–243 DTC P0405 – EGR Sensor Circuit Low (Cont'd) Step Action Value(s) Check the 5 V reference and signal circuit’s for a poor connection or proper terminal tension and repair as necessary. Go to Step...

  • Page 871: Diagnostic Trouble Code (Dtc) P0406 Exhaust Gas Recirculation (Egr) Sensor Circuit High

    6E1–244 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P0406 EXHAUST GAS RECIRCULATION (EGR) SENSOR CIRCUIT HIGH D06RX055 Circuit Description If the PCM detects a continuous short to ground in the signal circuit or the sensor, then DTC P0406 will set.
  • Page 872 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–245 times. After the vehicle is brought into a warm shop for repairs, the valve warms and the problem disappears. By watching the Actual EGR and Desired EGR Positions on a cold vehicle with a Tech 2, the fault can be verified easily.
  • Page 873 6E1–246 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0406 EGR Sensor Circuit High Step Action Value(s) Was the Powertrain ”On–Board Diagnostic (OBD) Go to System Check” performed? Powertrain OBD System — Go to Step 2 Check 1. Turn the ignition switch ON, with the engine OFF.
  • Page 874 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–247 DTC P0406 EGR Sensor Circuit High (Cont'd) Step Action Value(s) 1. Ignition ON, Engine OFF. 2. Using a Digital Voltmeter (DVM), check for voltage on the 5 volt Reference signal circuit at the Linear Exhaust Gas Recirculation (EGR) Valve wiring harness connector.

  • Page 875: Diagnostic Trouble Code (Dtc) P0420 Catalyst System Efficiency Below Threshold

    6E1–248 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD D06RX048 f The PCM determines that the catalyst’s oxygen Circuit Description storage capacity is below the acceptable threshold. The PCM uses the Bank 1 HO2S 1 and the Bank 1 HO2S 2 heated oxygen sensors.
  • Page 876 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–249 connectors and wiring harnesses related to the sensor. Test Description A change in the display will indicate the location of the Number(s) below refer to the step number(s) on the fault. Diagnostic Chart: Reviewing the Failure Records vehicle mileage since the 7.
  • Page 877 6E1–250 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0420 – Catalyst System Efficiency Below Threshold Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to OBD performed? System — Go to Step 2 Check Are any other O2 Sensor Diagnostic Trouble Codes...

  • Page 878: Diagnostic Trouble Code (Dtc) P0440 Evaporative Emission (Evap) Control System Malfunction

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–251 DIAGNOSTIC TROUBLE CODE (DTC) P0440 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM MALFUNCTION D06RX056 f Disconnected, damaged, pinched, or blocked fuel tank Circuit Description vapor line evaporative system includes following f Disconnected or faulty EVAP canister purge valve...
  • Page 879 6E1–252 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION f The difference between the actual Fuel Tank Pressure Test Description and the expected Fuel Tank Pressure is less than the Number(s) below refer to the step number(s) on the PCM’s expectations.
  • Page 880 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–253 DTC P0440 EVAP Control System Malfunction Step Action Value(s) Was the Powertrain On–Board Diagnostic (OBD) Go to System Check performed? Powertrain OBD System — Go to Step 2 Check Is Diagnostic Trouble Code P0461, P0462 or P0463...
  • Page 881 6E1–254 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0440 EVAP Control System Malfunction (Cont'd) Step Action Value(s) 1. Disconnect the fuel tank vapor line and the EVAP purge line from the EVAP canister. 2. Block the canister fitting for the fuel tank vapor line.
  • Page 882 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–255 DTC P0440 EVAP Control System Malfunction (Cont'd) Step Action Value(s) 1. Using the Tech 2, command the EVAP vent solenoid 2. With the cart connected to the EVAP service port continuously attempt to pressurize the EVAP system by leaving the cart control knob in the pressurized position.

  • Page 883: Diagnostic Trouble Code (Dtc) P0442 Evaporative Emission (Evap) Control System Small Leak Detected

    6E1–256 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P0442 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM SMALL LEAK DETECTED D06RX056 Circuit Description Conditions for Setting the DTC f The BARO is greater the 72.3 kPa. evaporative system includes...
  • Page 884 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–257 f The PCM will record operating conditions at the time fuel tank pressure sensor for an intermittent open or the diagnostic fails. The Freeze Frame and Failure intermittent short circuit. Records buffers will store this information.
  • Page 885 6E1–258 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0442 EVAP Control System Small Leak Detected (Cont'd) Step Action Value(s) Disconnect the battery, wait 20 seconds then reconnect the battery. Is the action complete? — Go to Step 4 —...
  • Page 886 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–259 DTC P0442 EVAP Control System Small Leak Detected (Cont'd) Step Action Value(s) 1. Visually/physically check following conditions: Malfunctioning fuel cap. Leaking fuel tank vapor line. Damaged EVAP purge line. 2. If a problem is found, repair as necessary...

  • Page 887: Diagnostic Trouble Code (Dtc) P0443 Evaporative Emission (Evap) Control System Purge Control Valve Circuit Malfunction

    6E1–260 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P0443 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT MALFUNCTION D06RX056 f The PCM will store the conditions that were present Circuit Description when the DTC was set as Freeze Frame and in Failure The Powertrain Control Module (PCM) controls the Records.
  • Page 888 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–261 DTC P0443 EVAP Control System Purge Control Valve Circuit Malfunction Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to OBD performed? System — Go to Step 2 Check 1. Ignition ON, Engine OFF.
  • Page 889 6E1–262 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0443 EVAP Control System Purge Control Valve Circuit Malfunction (Cont'd) Step Action Value(s) Replace the EVAP Canister Purge Solenoid. Verify Repair. — — — Replace the PCM. IMPORTANT: The replacement must programmed.

  • Page 890: Diagnostic Trouble Code (Dtc) P0446 Evaporative Emission (Evap) Control System Vent Control Circuit Malfunction

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–263 DIAGNOSTIC TROUBLE CODE (DTC) P0446 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM VENT CONTROL CIRCUIT MALFUNCTION D06RX056 Circuit Description sensor input. With the EVAP vent solenoid open, any vacuum in the system should decrease quickly unless the...
  • Page 891 6E1–264 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION f Fuel Tank vacuum is greater than 39 cm (15.35 inches) Test Description of water. Number(s) below refer to the step number(s) on the Diagnostic Chart: Action Taken When the DTC Sets 1.
  • Page 892 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–265 DTC P0446 EVAP Control System Vent Control Circuit Malfunction Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to performed? Powertrain OBD System — Go to Step 2 Check Is Diagnostic Trouble Code P0461, P0462, or P0463...
  • Page 893 6E1–266 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0446 EVAP Control System Vent Control Circuit Malfunction (Cont'd) Step Action Value(s) 1. Disconnect the large vent hose (marked air) from the EVAP canister. 2. Switch the rotary switch on the cart J41413 to PURGE.

  • Page 894: Diagnostic Trouble Code (Dtc) P0449 Evaporative Emission (Evap) Control System Vent Valve/Solenoid Circuit Malfunction

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–267 DIAGNOSTIC TROUBLE CODE (DTC) P0449 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM VENT VALVE/SOLENOID CIRCUIT MALFUNCTION D06RX056 f The PCM will store the conditions that were present Circuit Description when the DTC was set as Freeze Frame and in Failure The Powertrain Control Module (PCM) controls the Records.
  • Page 895 6E1–268 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0449 EVAP Control System Vent Valve/Solenoid Circuit Malfunction Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to OBD performed? System — Go to Step 2 Check 1. Ignition ON, Engine OFF.
  • Page 896 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–269 DTC P0449 EVAP Control System Vent Valve/Solenoid Circuit Malfunction (Cont'd) Step Action Value(s) Replace the EVAP Canister Purge Solenoid. — Verify repair. Go to Step 7 Replace the PCM. IMPORTANT: The replacement must programmed.

  • Page 897: Diagnostic Trouble Code (Dtc) P0461 Fuel Level Sensor Circuit Range/Performance

    6E1–270 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P0461 FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE D06RX057 Circuit Description Action Taken When the DTC Sets f The PCM will not turn on the MIL. The Fuel Level sensor is an important input to the PCM for the Enhanced Evaporative System Diagnostic.
  • Page 898 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–271 DTC P0461 Fuel Level Sensor Circuit Range/Performance Step Action Value(s) Was the On–Board Diagnostic (OBD) System Check Go to performed? Powertrain OBD System — Go to Step 2 Check 1. Install the Tech 2.

  • Page 899: Diagnostic Trouble Code (Dtc) P0462 Fuel Level Sensor Circuit Low Input

    6E1–272 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P0462 FUEL LEVEL SENSOR CIRCUIT LOW INPUT D06RX057 Circuit Description Action Taken When the DTC Sets f The PCM will not turn on the MIL. The Fuel Level Sensor is an important input to the PCM for the Enhanced Evaporative System Diagnostic.
  • Page 900 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–273 DTC P0462 Fuel Level Sensor Circuit Low Input Step Action Value(s) Was the On–Board Diagnostic (OBD) System Check Go to performed? Powertrain OBD System — Go to Step 2 Check 1. Install the Tech 2.

  • Page 901: Diagnostic Trouble Code (Dtc) P0463 Fuel Level Sensor Circuit High Input

    6E1–274 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P0463 FUEL LEVEL SENSOR CIRCUIT HIGH INPUT D06RX057 Circuit Description Action Taken When the DTC Sets f The PCM will not turn on the MIL. The Fuel Level sensor is an important input to the PCM for the Enhanced Evaporative System Diagnostic.
  • Page 902 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–275 DTC P0463 Fuel Level Sensor Circuit High Input Step Action Value(s) Was the On–Board Diagnostic (OBD) System Check Go to performed? Powertrain OBD System — Go to Step 2 Check 1. Install the Tech 2.

  • Page 903: Diagnostic Trouble Code (Dtc) P0480 Cooling Fan 1 Control Circuit Malfunction

    6E1–276 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P0480 COOLING FAN 1 CONTROL CIRCUIT MALFUNCTION D06RX058 Circuit Description Action Taken When the DTC Sets f The PCM will not turn on the Malfunction Indicator The Powertrain Control Module (PCM) controls the engagement of the cooling fan Low speed through the Lamp.
  • Page 904 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–277 DTC P0480 Cooling Fan 1 Control Circuit Malfunction Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to OBD performed? System — Go to Step 2 Check 1. Ignition ON, Engine OFF.
  • Page 905 6E1–278 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0480 Cooling Fan 1 Control Circuit Malfunction (Cont'd) Step Action Value(s) Replace the Low Fan Relay. Is the action complete? — Verify repair — Replace the PCM. IMPORTANT: The replacement PCM must be programmed.

  • Page 906: Diagnostic Trouble Code (Dtc) P0481 Cooling Fan 2 Control Circuit Malfunction

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–279 DIAGNOSTIC TROUBLE CODE (DTC) P0481 COOLING FAN 2 CONTROL CIRCUIT MALFUNCTION D06RX058 Circuit Description Action Taken When the DTC Sets f The PCM will not turn on the Malfunction Indicator The Powertrain Control Module (PCM) controls the engagement of the cooling fan Low speed through the Lamp.
  • Page 907 6E1–280 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0481 Cooling Fan 2 Control Circuit Malfunction Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to OBD performed? System — Go to Step 2 Check 1. Ignition ON, Engine OFF.
  • Page 908 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–281 DTC P0481 Cooling Fan 2 Control Circuit Malfunction (Cont'd) Step Action Value(s) Replace the High Fan Relay. Is the action complete? — Verify repair — Replace the PCM. IMPORTANT: The replacement PCM must be programmed.

  • Page 909: Diagnostic Trouble Code (Dtc) P0502 Vehicle Speed Sensor (Vss) Circuit Low Input

    6E1–282 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P0502 VEHICLE SPEED SENSOR (VSS) CIRCUIT LOW INPUT D06RX059 Circuit Description The Decel Test will pass if vehicle speed is greater than 24 km/h (15mph). The vehicle speed sensor has a magnet rotated by the Power Test transmission output shaft.
  • Page 910 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–283 f Diagnostic Trouble Code P0502 can be cleared by locks, improperly formed or damaged terminals, and using the Scan Tool’s ”Clear Info” function. poor terminal to wire connection. f Damaged harness: Inspect the wiring harness to the...

  • Page 911: Diagnostic Trouble Code (Dtc) P0506 Idle Control System Rpm Lower Than Expected

    6E1–284 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P0506 IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED D06RX041 f MAP is less than 60 kPa. Circuit Description f Ignition voltage is between 9.5 volts and 16 volts.
  • Page 912 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–285 f Damaged harness – Inspect the wiring harness for f Large vacuum leak – Check for a condition that causes damage; shorts to ground, shorts to battery positive, a large vacuum leak, such as an incorrectly installed or and open circuits.
  • Page 913 6E1–286 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0506 – Idle Control System RPM Lower Than Expected (Cont'd) Step Action Value(s) 1. Check for a poor connection at the IAC harness connector. 2. If a problem is found, replace faulty terminals as necessary.

  • Page 914: Diagnostic Trouble Code (Dtc) P0507 Idle Control System Rpm Higher Than Expected

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–287 DIAGNOSTIC TROUBLE CODE (DTC) P0507 IDLE CONTROL SYSTEM RPM HIGHER THAN EXPECTED D06RX041 f The throttle is closed. Circuit Description f All conditions are met for 10 seconds. The powertrain control module (PCM) controls engine f MAP is less than 60 kPa.
  • Page 915 6E1–288 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION f Throttle body – Check for sticking throttle plate. Also improper mating, broken locks, improperly formed or damaged terminals, and poor terminal–to–wire inspect the IAC passage for deposits or objects which connection.
  • Page 916 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–289 DTC P0507 – Idle Control System RPM Higher Than Expected (Cont'd) Step Action Value(s) 1. Check for a poor connection at the IAC harness connector. 2. If a problem is found, replace faulty terminals as necessary.

  • Page 917: Diagnostic Trouble Code (Dtc) P0532 A/C Refrigerant Pressure Sensor Circuit Low Input

    6E1–290 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P0532 A/C REFRIGERANT PRESSURE SENSOR CIRCUIT LOW INPUT D06RX060 f The PCM will store the conditions that were present Circuit Description when the DTC was set as Freeze Frame and in Failure The Powertrain Control Module (PCM) monitors the A/C Records.
  • Page 918 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–291 DTC P0532 A/C Refigerant Pressure Sensor Circuit Low Input Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to OBD performed? System — Go to Step 2 Check 1. Ignition ON, Engine OFF.
  • Page 919 6E1–292 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0532 A/C Refigerant Pressure Sensor Circuit Low Input (Cont'd) Step Action Value(s) 1. Ignition OFF. 2. Place a fused jumper between the A/C refrigerant pressure sensor and the 5 volt signal circuit, both at the wiring harnesses A/C refrigerant pressure sensor connector.

  • Page 920: Diagnostic Trouble Code (Dtc) P0533 A/C Refrigerant Pressure Sensor Circuit High Input

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–293 DIAGNOSTIC TROUBLE CODE (DTC) P0533 A/C REFRIGERANT PRESSURE SENSOR CIRCUIT HIGH INPUT D06RX060 f The PCM will store the conditions that were present Circuit Description when the DTC was set as Freeze Frame and in Failure The Powertrain Control Module (PCM) monitors the A/C Records.
  • Page 921 6E1–294 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P0533 A/C Refigerant Pressure Sensor Circuit High Input Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to OBD performed? System — Go to Step 2 Check 1. Ignition ON, Engine OFF.
  • Page 922 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–295 DTC P0533 A/C Refigerant Pressure Sensor Circuit High Input (Cont'd) Step Action Value(s) 1. Ignition OFF. 2. Place a fused jumper between the A/C refrigerant pressure sensor and the 5 volt signal circuit, both at the wiring harnesses A/C refrigerant pressure sensor connector.

  • Page 923: Diagnostic Trouble Code (Dtc) P0562 System Voltage Low

    6E1–296 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P0562 SYSTEM VOLTAGE LOW D06RX061 Circuit Description Diagnostic Aids f If the Diagnostic Trouble Code sets when an accessory The powertrain control module (PCM) monitors the system voltage on the ignition feed terminal to the PCM. A is operated, check for a poor connection or excessive current draw.
  • Page 924 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–297 DTC P0562 System Voltage Low Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to OBD performed? System — Go to Step 2 Check Using a Digital Voltmeter (DVM), measure the battery Charge voltage at the battery.

  • Page 925: Diagnostic Trouble Code (Dtc) P0563 System Voltage High

    6E1–298 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P0563 SYSTEM VOLTAGE HIGH D06RX061 Circuit Description Conditions for Clearing the MIL/DTC f A history Diagnostic Trouble Code P0563 will clear The powertrain control module (PCM) monitors the system voltage on the ignition feed terminals to the PCM.
  • Page 926 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–299 DTC P0563 System Voltage High Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to OBD performed? System — Go to Step 2 Check 1. Ignition OFF, engine OFF. 2. Using a Digital Voltmeter (DVM), measure the battery voltage at the battery.

  • Page 927: Diagnostic Trouble Code (Dtc) P0601 Internal Control Module Memory Check Sum Error

    6E1–300 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P0601 INTERNAL CONTROL MODULE MEMORY CHECK SUM ERROR 014RX002 f The PCM will store conditions which were present Circuit Description when the Diagnostic Trouble Code was set in the The powertrain control module (PCM) used in this vehicle Failure Records data only.
  • Page 928 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–301 DTC P0601 Internal Control Module Memory Check Sum Error Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to OBD performed? System — Go to Step 2 Check Reprogram PCM with most recent calibrations. Refer to Service Bulletins and PCM Reprogramming.

  • Page 929: Diagnostic Trouble Code (Dtc) P1106 Manifold Absolute Pressure (Map) Sensor Circuit Intermittent High Voltage

    6E1–302 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P1106 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE D06RX042 f Throttle angle is below 2.7% if engine speed is below Circuit Description 1000 RPM. The manifold absolute pressure (MAP) sensor responds f Throttle angle is below 10% if engine speed is above to changes in intake manifold pressure.
  • Page 930 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–303 formed damaged terminals, poor the harness appears to be OK, observe the MAP terminal–to–wire connection. display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the f The MAP sensor shares a 5 Volt Reference with the TP display will indicate the location of the fault.

  • Page 931: Diagnostic Trouble Code (Dtc) P1107 Manifold Absolute Pressure (Map) Sensor Circuit Intermittent Low Voltage

    6E1–304 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P1107 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE D06RX042 f Throttle angle is below 0% if engine speed is less than Circuit Description 1300 RPM. The manifold absolute pressure (MAP) sensor responds f Throttle angle is below 5% if engine speed is above to changes in intake manifold pressure.
  • Page 932 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–305 locks, improperly formed or damaged terminals, and and open circuits. If the harness appears to be OK, poor terminal–to–wire connection. observe the MAP display on the Tech 2 while moving connectors and wiring harnesses related to the sensor.

  • Page 933: Diagnostic Trouble Code (Dtc) P1111

    6E1–306 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P1111 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE D06RX043 f The PCM will store conditions which were present Circuit Description when the Diagnostic Trouble Code set as Failure The intake air temperature (IAT) sensor is a thermistor Records data only.

  • Page 934: Intake Air Temperature (Iat) Sensor

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–307 be set occurs. This may assist in diagnosing the condition. Intake Air Temperature Sensor °C °F Temperature vs. Resistance Values (approximate) 1188 1802 2796 4450 7280 –5 12300 –15 21450 –30 –22 52700 –40...
  • Page 935 6E1–308 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P1111 – IAT Sensor Circuit Intermittent High Voltage Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to OBD performed? System — Go to Step 2 Check Is DTC P0113 also set?

  • Page 936: Diagnostic Trouble Code (Dtc) P1112

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–309 DIAGNOSTIC TROUBLE CODE (DTC) P1112 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE D06RX043 Circuit Description Records data only. This information will not be stored as Freeze Frame data. The intake air temperature (IAT) sensor is a thermistor...
  • Page 937 6E1–310 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION be set occurs. This may assist in diagnosing the Intake Air Temperature Sensor condition. °C °F Test Description Temperature vs. Resistance Values (approximate) Number(s) below refer to the step number(s) on the Diagnostic Chart.

  • Page 938: Diagnostic Trouble Code (Dtc) P1114 Engine Coolant Temperature (Ect) Sensor Circuit Intermittent Low Voltage

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–311 DIAGNOSTIC TROUBLE CODE (DTC) P1114 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE D06RX044 Circuit Description Records data only. This information will not be stored as Freeze Frame data. The engine coolant temperature (ECT) sensor is a thermistor mounted in the engine coolant stream.
  • Page 939 6E1–312 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION Engine Coolant Temperature Sensor °C °F Temperature vs. Resistance Values (approximate) 1188 1802 2796 4450 7280 –5 12300 –15 21450 –30 –22 52700 –40 –40 100700 DTC P1114 – ECT Sensor Circuit Intermittent Low Voltage...

  • Page 940: Diagnostic Trouble Code (Dtc) P1115 Engine Coolant Temperature (Ect) Sensor Circuit Intermittent High Voltage

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–313 DIAGNOSTIC TROUBLE CODE (DTC) P1115 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE D06RX044 Circuit Description Records data only. This information will not be stored as Freeze Frame data. The engine coolant temperature (ECT) sensor is a thermistor mounted in the engine coolant stream.
  • Page 941 6E1–314 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION Engine Coolant Temperature Sensor °C °F Temperature vs. Resistance Values (approximate) 1188 1802 2796 4450 7280 –5 12300 –15 21450 –30 –22 52700 –40 –40 100700...
  • Page 942 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–315 DTC P1115 ECT Sensor Circuit Intermittent High Voltage Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to OBD performed? System — Go to Step 2 Check Is DTC P0118 also set? Go to DTC —...

  • Page 943: Diagnostic Trouble Code (Dtc) P1121 Throttle Position (Tp) Sensor Circuit Intermittent High Voltage

    6E1–316 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P1121 THROTTLE POSITION (TP) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE D06RX045 Circuit Description Conditions for Clearing the DTC f A history Diagnostic Trouble Code P1121 will clear The throttle position (TP) sensor circuit provides a voltage signal that changes relative to the throttle blade angle.
  • Page 944 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–317 If Diagnostic Trouble Code P1121 cannot be duplicated, the condition that caused the Diagnostic Trouble Code to reviewing the Failure Records vehicle mileage since the be set occurs. This may assist in diagnosing the diagnostic test last failed may help to determine how often condition.

  • Page 945: Diagnostic Trouble Code (Dtc) P1122 Throttle Position (Tp) Sensor Circuit Intermittent Low Voltage

    6E1–318 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P1122 THROTTLE POSITION (TP) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE D06RX045 Circuit Description Conditions for Clearing the DTC f A history Diagnostic Trouble Code P1122 will clear The throttle position (TP) sensor circuit provides a voltage signal that changes relative to the throttle blade angle.
  • Page 946 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–319 Reviewing the Failure Records vehicle mileage since the be set occurs. This may assist in diagnosing the diagnostic test last failed may help to determine how often condition. the condition that caused the Diagnostic Trouble Code to DTC P1122 –...

  • Page 947: Diagnostic Trouble Code (Dtc) P1133

    6E1–320 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P1133 O2 SENSOR INSUFFICIENT SWITCHING (BANK 1 SENSOR 1) D06RX046 Circuit Description Action Taken When the DTC Sets f The PCM will illuminate the malfunction indicator lamp The powertrain control module (PCM) monitors the...
  • Page 948 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–321 the condition that caused the Diagnostic Trouble Code to 5. This step checks for conditions which may cause be set occurs. This may assist in diagnosing the the heated oxygen sensor to appear faulty. Correct any of the described conditions if present.
  • Page 949 6E1–322 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P1133 – O2 Sensor Insufficient Switching (Bank 1 Sensor 1) (Cont'd) Step Action Value(s) 1. Ignition OFF. 2. Check for damage to PCM pins or terminals. Was a problem found? —...

  • Page 950: Diagnostic Trouble Code (Dtc) P1134

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–323 DIAGNOSTIC TROUBLE CODE (DTC) P1134 O2 SENSOR TRANSITION TIME RATIO (BANK 1 SENSOR 1) D06RX046 f 90 seconds after ”Closed Loop” has been enabled, Circuit Description Bank 1 HO2S 1 transition ratio between lean–to–rich The powertrain control module (PCM) monitors the and rich–to–lean is less than 0.4 or greater than 3.8.
  • Page 951 6E1–324 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION Diagnostic Trouble Code P1134 continues to set, replace 3. A condition that affects other heated oxygen the Bank 1 HO2S 1. sensors indicates probable contamination. To avoid damaging the replacement sensors, correct the...
  • Page 952 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–325 DTC P1134 – O2 Sensor Transition Time Ratio (Bank 1 Sensor 1) (Cont'd) Step Action Value(s) 1. With Bank 1 HO2S 1 disconnected, jumper the high and low (PCM side) signal circuits to ground.

  • Page 953: Diagnostic Trouble Code (Dtc) P1171 Fuel System Lean During Acceleration

    6E1–326 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P1171 FUEL SYSTEM LEAN DURING ACCELERATION D06RX048 Circuit Description Action Taken When the DTC Sets f The PCM will illuminate the malfunction indicator lamp The powertrain control module (PCM) internal circuitry can identify if the vehicle fuel system is capable of (MIL) the first time the fault is detected.
  • Page 954 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–327 Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart: 4. When the engine is idling or at steady cruise, the HO2S voltage should vary from between approximately 100 mV to 900 mV. During ”power enrichment”...
  • Page 955 6E1–328 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P1171 – Fuel System Lean During Acceleration Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to OBD performed? System — Go to Step 2 Check Are any component–related Diagnostic Trouble Codes...

  • Page 956: Diagnostic Trouble Code (Dtc) P1336 Crankshaft Position Sensor (Ckp) System Variation Not Learned

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–329 DIAGNOSTIC TROUBLE CODE (DTC) P1336 CRANKSHAFT POSITION SENSOR (CKP) SYSTEM VARIATION NOT LEARNED 014RX002 Circuit Description Action Taken When the DTC Sets f The Malfunction Indicator Lamp (MIL) will illuminate In order to detect engine misfire at higher engine speeds, the Powertrain Control Module (PCM) must know of any the first time the error is detected.
  • Page 957 6E1–330 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION cycle of the vehicle unless the crank sensor to crankshaft Test Description relationship is disturbed. Removing a part for inspection Number(s) below refer to the step number(s) on the and then reinstalling the same part is considered a Diagnostic Chart: disturbance.
  • Page 958 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–331 DTC P1336 CKP System Variation Not Learned Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to performed? Powertrain OBD System — Go to Step 2 Check Perform the Crankshaft Position Sensor Tooth Error...

  • Page 959: Diagnostic Trouble Code (Dtc) P1380 Abs Rough Road System Fault

    6E1–332 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P1380 ABS ROUGH ROAD SYSTEM FAULT 014RX002 Circuit Description detected misfire was true or due to operating the vehicle on a rough surface. A misfire can be a true misfire with or The PCM identifies an engine misfire by detecting the without setting this DTC.
  • Page 960 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–333 8. Repair any condition that remains and is causing a 9. Replacement PCMs must be reprogrammed. Refer misfire by following the table for any DTC that has to the latest Isuzu Technical Communication System set.

  • Page 961: Diagnostic Trouble Code (Dtc) P1381

    6E1–334 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P1381 ABS ROUGH ROAD CLASS 2 SERIAL DATA FAULT 014RX002 f A history DTC is stored. Circuit Description f The PCM will not illuminate the Malfunction Indicator The PCM identifies an engine misfire by detecting the Lamp (MIL).
  • Page 962 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–335 3. Refer to the ABS portion of the service manual for ABS DTCs and repairs. Performing the ABS Diagnostic System Check is the first step in diagnosing a serial data problem. 4. Be careful to clear only DTCs and not the captured information stored on the Tech 2.
  • Page 963 6E1–336 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P1381 ABS Rough Road Class 2 Serial Data Fault Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to performed? Powertrain OBD System — Go to Step 2 Check 1.

  • Page 964: Diagnostic Trouble Code (Dtc) 1404 Exhaust Gas Recirculation (Egr) Closed Valve

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–337 DIAGNOSTIC TROUBLE CODE (DTC) 1404 EXHAUST GAS RECIRCULATION (EGR) CLOSED VALVE D06RX055 f A history DTC P1404 will clear after 40 consecutive Circuit Description warm up cylcles without a fault. The powertrain control module (PCM) monitors the f DTC P1404 can be cleared by using the Scan Tool’s...
  • Page 965 6E1–338 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P1404 EGR Closed Valve Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check Go to OBD performed? System — Go to Step 2 Check 1. Turn the ignition switch ON, with the engine OFF.
  • Page 966 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–339 DTC P1404 EGR Closed Valve (Cont'd) Step Action Value(s) 1. Ignition ON, engine OFF. 2. Using a Digital Voltmeter (DVM), check for voltage on the 5 volt Reference signal circuit at the Linear Exhaust Gas Recirculation (EGR) Valve wiring harness connector.

  • Page 967: Diagnostic Trouble Code (Dtc) P1441 Evaporative Emission (Evap) System Flow During Non-Purge

    6E1–340 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P1441 EVAPORATIVE EMISSION (EVAP) SYSTEM FLOW DURING NON–PURGE D06RX056 f BARO reading is above 72.3 kPa. Circuit Description f Start–up intake air temperature (IAT) and start–up Canister purge is controlled by a solenoid valve that engine coolant temperature(ECT) are both between allows manifold vacuum to purge the canister.
  • Page 968 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–341 Diagnostic Aids the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition. Check for the following conditions: f Poor connection at PCM – Inspect harness connectors Test Description for backed–out terminals, improper mating, broken...
  • Page 969 6E1–342 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P1441 – EVAP System Flow During Non-Purge (Cont'd) Step Action Value(s) 1. Disconnect the EVAP pressure / purge cart J41413, and then plug the hose end. 2. Disconnect the rubber hose end of engine vacuum source side, (the hose connected between Purge Solenoid Valve and engine).

  • Page 970: Diagnostic Trouble Code (Dtc) P1546 A/C Compressor Clutch Output Circuit Malfunction

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–343 DIAGNOSTIC TROUBLE CODE (DTC) P1546 A/C COMPRESSOR CLUTCH OUTPUT CIRCUIT MALFUNCTION D06RX037 f PCM senses voltage is Low with the A/C Compressor Circuit Description Clutch Solenoid commanded OFF. The Powertrain Control Module (PCM) controls the A/C...
  • Page 971 6E1–344 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P1546 A/C Compressor Clutch Output Circuit Malfunction Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to OBD performed? System — Go to Step 2 Check 1. Ignition ON, Engine OFF.
  • Page 972 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–345 DTC P1546 A/C Compressor Clutch Output Circuit Malfunction (Cont'd) Step Action Value(s) Replace the A/C Compressor Clutch Relay. Is the action complete? — Verify repair — Replace the PCM. IMPORTANT: The replacement must programmed.

  • Page 973: Diagnostic Trouble Code (Dtc) P1625 Pcm Unexpected Reset

    6E1–346 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION Diagnostic Trouble Code (DTC) P1625 PCM Unexpected Reset 014RX002 f A history DTC P1625 will clear after 40 consecutive Circuit Description warm-up cycles have occurred without a fault. powertrain control module (PCM) monitors f DTC P1625 can be cleared by using the Tech 2 “Clear...
  • Page 974 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–347 DTC P1625–PCM Unexpected Reset Step Action Value(s) Was the “On-Board Diagnostic (OBD) System Check” Go to OBD performed? System — Go to Step 2 Check 1. Ignition is “On”. 2. Install the Tech 2.

  • Page 975: Diagnostic Trouble Code (Dtc) P1627

    6E1–348 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P1627 PCM A/D CONVERSION MALFUNCTION 014RX002 Circuit Description Conditions for Clearing the MIL/DTC f The PCM will turn OFF the MIL on the third consecutive The Powertrain Control Module (PCM) monitors the 5 volt reference signal when the Ignition is ON.
  • Page 976 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–349 DTC P1627 PCM A/D Conversion Malfunction Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to OBD performed? System — Go to Step 2 Check 1. Ignition ON, Engine OFF.

  • Page 977: Diagnostic Trouble Code (Dtc) P1635 5 Volt Reference Voltage Circuit Malfunction

    6E1–350 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P1635 5 VOLT REFERENCE VOLTAGE CIRCUIT MALFUNCTION D06RX062 Circuit Description Action Taken When the DTC Sets f The PCM will illuminate the Malfunction Indicator Lamp The Powertrain Control Module (PCM) monitors the 5 volt reference signal when the Ignition is ON.
  • Page 978 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–351 DTC P1635 5 Volt Reference Voltage Circuit Malfunction Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to OBD performed? System — Go to Step 2 Check 1. Ignition ON, Engine OFF.

  • Page 979: Diagnostic Trouble Code (Dtc) P1640 Odm Output Circuit Fault

    6E1–352 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIAGNOSTIC TROUBLE CODE (DTC) P1640 ODM OUTPUT CIRCUIT FAULT 014RX002 Circuit Description Conditions for Clearing the DTC f A history DTC P1640 will clear after 40 consecutive Output driver modules (ODMs) are used by the powertrain control module(PCM) to turn ON many of the warm up cycles occur without a fault.
  • Page 980 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–353 f A15 EVAP Canister Vent Solenoid 2. The Tech 2 Driver Module Status indicates the PCM f B16 EVAP Canister Parge Solenoid pin that is affected. f A1 2 Low Fuel 9. The Tech 2 may indicate “short circuit” even when f C10 Tacho Meter the problem is an open circuit.
  • Page 981 6E1–354 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DTC P1640 –Output Driver Module (ODM) “A” Fault (Cont'd) Step Action Value(s) Repair the short to ground between the affected component and its PCM driver terminal. Is the action complete? — Verify repair —...

  • Page 982: Symptom Diagnosis

    RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–355 SYMPTOM DIAGNOSIS when the malfunction occurs is a good indication that there is a fault in the circuit being monitored. Use a Tech 2 to help detect intermittent conditions. PRELIMINARY CHECKS The Scan Tools have several features that can be used to Before using this section, perform the ”On–Board...
  • Page 983 6E1–356 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION Step Action Value(s) Was the ”On–Board Diagnostic (OBD) System Check” Go to OBD performed? System Check — Go to Step 2 1. Perform a bulletin search. 2. If a bulletin that addresses the symptom is found, correct the condition as instructed in the bulletin.
  • Page 984 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–357 Step Action Value(s) 1. Remove the spark plugs and check for gas or oil fouling cracks, wear, improper gap, burned electrodes, heavy deposits, or improper heat range. 2. If spark plugs are fouled, the cause of fouling must be determined before replacing the spark plugs.
  • Page 985 6E1–358 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION SURGES AND/or CHUGGLES SYMPTOM DEFINITION: Engine power variation under steady throttle or cruise. Feels like the vehicle speeds up and slows down with no change in the accelerator pedal. Step Action Value(s) Was the On–Board Diagnostic (OBD) System Check...
  • Page 986 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–359 Step Action Value(s) Visually/Physically inspect the secondary ignition wires. Check for the following conditions. Verify that all ignition wire resistance are less than the specified value. Verify that ignition wires are correctly routed to eliminated cross–firing.
  • Page 987 6E1–360 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION LACK OF POWER, SLUGGISH OR SPONGY SYMPTOM DEFINITION: Engine delivers less than expected power. Little or no increase in speed when accelerator pedal is pushed down part–way. Step Action Value(s) Was the On–Board Diagnostic (OBD) System Check...
  • Page 988 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–361 Step Action Value(s) Check the exhaust system for a possible restriction: Damaged or collapsed pipes Internal muffler failure Refer to Restricted Exhaust System Check to measure backpressure and determine if the catalytic converter is plugged.
  • Page 989 6E1–362 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DETONATION/SPARK KNOCK SYMPTOM DEFINITION: A mild to severe ping, usually worse under acceleration. The engine makes sharp metallic knocks that change with throttle opening. Step Action Value(s) Was the On–Board Diagnostic (OBD) System Check...
  • Page 990 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–363 Step Action Value(s) Check for an engine mechanical problem. Perform a cylinder compression check. Refer to Engine Mechanical. Go to Step 11 Was a problem found? — Verify repair 1. Review all diagnostic procedures within this table.
  • Page 991 6E1–364 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING SYMPTOM DEFINITION: Engine runs unevenly at idle. If severe, the engine or vehicle may shake. Engine idle speed may vary in RPM. Either condition may be severe enough to stall the engine.
  • Page 992 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–365 Step Action Value(s) Check for a loose ignition control module ground. Refer to Electrical Ignition System. Go to Step 11 Was a problem found? — Verify repair Monitor ”Long Term Fuel Trim” on the Tech 2.
  • Page 993 6E1–366 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION POOR FUEL ECONOMY SYMPTOM DEFINITION: Fuel economy, as measured by an actual road test, is noticeably lower than expected. Also, economy is noticeably lower than it was on this vehicle at one time, as previously shown by an actual road test.
  • Page 994 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–367 Step Action Value(s) Check for excessive exhaust system back–pressure. Refer to Restricted Exhaust System Check. Possible problems could be: Damaged or collapsed pipes. Internal muffler failure. Plugged catalytic converter. Go to Step 13 Was a problem found? —...
  • Page 995 6E1–368 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION EXCESSIVE EXHAUST EMISSIONS OR ODORS SYMPTOM DEFINITION: Vehicle fails an emission test. There is excessive ”rotten egg” smell. (Excessive odors do not necessarily indicate excessive emissions.) Step Action Value(s) Was the On–Board Diagnostic (OBD) System Check...
  • Page 996 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–369 Step Action Value(s) 1. Check items that can cause the engine to run rich. Refer to Diagnostic Aids in DTC P0172 Diagnostic Support. Make any necessary repairs. 2. Perform the exhaust emission test.
  • Page 997 6E1–370 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION DIESELING, RUN–ON SYMPTOM DEFINITION: Engine continues to run after key is turned OFF, but runs very rough. If engine runs smoothly, check the ignition switch and adjustment. Step Action Value(s) Was the On–Board Diagnostic (OBD) System Check...
  • Page 998 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–371 BACKFIRE SYMPTOM DEFINITION: Fuel ignites in the intake manifold, or in the exhaust system, making a loud popping noise. Step Action Value(s) Was the On–Board Diagnostic (OBD) System Check Go to OBD...
  • Page 999 6E1–372 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION Step Action Value(s) Check the intake and exhaust manifold(s) for casting flash. Refer to Engine Mechanical. Go to Step 11 Was a problem found? — Verify repair 1. Review all the diagnostic procedures within this table.
  • Page 1000 RODEO X22SE 2.2L ENGINE DRIVEABILITY AND EMISSION 6E1–373 CUTS OUT, MISSES SYMPTOM DEFINITION: Steady pulsation or jerking that follows engine speed; usually more pronounced as engine load increases. Step Action Value(s) Was the On–Board Diagnostic (OBD) System Check Go to OBD...

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