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Ford RANGER WL3 2001 Workshop Repair Manual
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Ford RANGER WL3 2001 Workshop Repair Manual

Ford RANGER WL3 2001 Workshop Repair Manual

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Summary of Contents for Ford RANGER WL3 2001

  • Page 2 Ford Motor Company. PRINTED IN JAPAN, SEPTEMBER, 2001 F175-10-01I Revised 4/2002 (Ref. No. LF012/02)
  • Page 3 2001 RANGER Repair Manual Supplement (F175-10-01I) VEHICLE IDENTIFICATION NUMBERS (VIN) WF0 LMBE40:W 204506- WF0 LMBD20:W 204506- WF0 LMDD20:W 204506- WF0 LMDE40:W 204506- WF0 LMFE40:W 204506- WF0 BMBD20:W 204506- WF0 LMAD20:W 204506- WF0 BMDE40:W 204506- WF0 BMDD20:W 204506- RELATED MATERIALS RANGER Training Manual .
  • Page 4 GENERAL INFORMATION VIN CODE ....... . GI-2 VIN CODE ....... GI-2 ELECTRICAL SYSTEM .
  • Page 5 VIN CODE VIN CODE VIN CODE ZCF200800021W02 YBR2010W002 D Euro 3 and non Euro 3 regulation models are distinguished as follows: Euro 3 Regulation models (WL-3, WLT-3) are equipped with an EGR water cooler in the engine room. Non Euro 3 Regulation models are not equipped with an EGR water cooler in the engine room. GI-2...
  • Page 6 VIN CODE ZCF4016W200 GI-3...
  • Page 7 ELECTRICAL SYSTEM ELECTRICAL SYSTEM D Inspect the terminals of waterproof connectors from the connector side since they cannot be accessed from the wiring harness side. CONNECTORS ZCF201700006W02 Disconnecting Connectors Caution D When disconnecting connector, grasp the D To prevent damage to the terminal, wrap a connectors, not the wires.
  • Page 8 ELECTRICAL SYSTEM Sensors, Switches, and Relays D When replacing a pullout fuse, use the fuse puller. D Handle sensors, switches, and relays carefully. Do not drop them or strike them against other objects. WGIWXX0050E Direction of View for Connector WGIWXX0047E Part-side connector Wiring Harness Direction of view is from the terminal side.
  • Page 9 ELECTRICAL SYSTEM Other Vehicle harness-side connectors, such as the DLC2, have to be viewed from the terminal side. WGIWXX0102E GI-6...
  • Page 10 NEW STANDARDS NEW STANDARDS NEW STANDARDS TABLE ZCF202800020W01 D The following is a comparison of the previous standard and the new standard. New Standard Previous Standard Remark Abbrevi- Abbrevi- Name Name ation ation Accelerator Pedal Accelerator Pedal Air Cleaner Air Cleaner Air Conditioning Air Conditioning BARO...
  • Page 11 NEW STANDARDS New Standard Previous Standard Remark Remark Abbrevi- Abbrevi- Name Name ation ation Malfunction Indicator Lamp Malfunction Indicator Light Manifold Absolute Pressure Intake Air Pressure MAF sensor Mass Air Flow Sensor Airflow Sensor Multiport Fuel Injection Multiport Fuel Injection On Board Diagnostic Diagnosis/Self Diagnosis Open Loop...
  • Page 12 ABBREVIATIONS ABBREVIATIONS ABBREVIATIONS TABLE ZCF203000011W01 Air conditioner ABDC After bottom dead center Accessories ATDC After top dead center BBDC Before bottom dead center BTDC Before top dead center Exhaust Intake L.H.D. Left hand drive Switch off Switch on Positive crankcase ventilation R.H.D.
  • Page 13 D To ensure efficient operation of the engine and all systems related to emission control, the ignition and fuel systems must be serviced regularly. It is strongly recommended that all servicing related to these systems be done by an authorized Ford Dealer. D After the described period, continue to follow the described maintenance at the recommended intervals.
  • Page 14 SCHEDULED MAINTENANCE Maintenance Interval (Number of months or km (miles), wichever comes first) Months Maintenance Item Maintenance Item Maintenance Item Maintenance Item 1000 Km ( 1000 Miles) (18) (27) (36) (45) (54) (63) (72) (81) (90) (99) (108) Brake lines, hoses & connections Brake fluid Parking brake Power brake unit &...
  • Page 15 SCHEDULED MAINTENANCE Maintenance Interval (Number of months or km (miles), wichever comes first) Months Maintenance Item Maintenance Item Maintenance Item Maintenance Item 1000 Km ( 1000 Miles) (12) (18) (24) (30) (36) (42) (48) (54) (60) (66) (72) (79) (84) (90) (96) Clutch fluid...
  • Page 16 ENGINE (WL, WL Turbo, WL-3, WLT-3) FEATURES OUTLINE ....... . . B2-2 OUTLINE OF CONSTRUCTION .
  • Page 17 OUTLINE OUTLINE OUTLINE OF CONSTRUCTION ZCF230201001W01 D The Euro 3 Regulation, WL-3 and WLT-3 models have been adopted . D The construction and operation of the WL-3 and WLT-3 engines are the same as that of the previous RANGER (UN) WL,WL Turbo engine models, except for the following features. (See RANGER TRAINING MANUAL F326-10-99A.) FEATURES ZCF230201001W02...
  • Page 18 ENGINE MECHANISM ENGINE MECHANISM CRANKSHAFT PULLEY DESCRIPSION ZCF232439000W01 Function/Structure (WL-3, WLT-3 models) D The shape of the crankshaft pulley has been modified to reduce noise and torsional vibration during high speed rotation of the crankshaft. ZCF2224W001 B2-3...
  • Page 19 ENGINE MECHANISM TIMING GEAR ZCF232439000W02 Injection Pump Gear (WL-3, WLT-3 models) D The gears are helical. Injection pump gear is combined with a scissors gear. D The scissors gear, through the force of the scissors gear spring, prevents the teeth of the injection pump gear from moving back and forth (backlash) between the teeth of the No.2 idler gear, with which the injection pump gear is meshed, and thus reduces gear noise.
  • Page 20 OUTLINE, VALVE CLEARANCE OUTLINE VALVE CLEARANCE SUPPLEMENTAL SERVICE INFORMATION VALVE CLEARANCE INSPECTION/ADJUSTMENT ZCF230201001W06 ZCF231112111W01 D The following changes have been made since the 1. Remove the EGR pipe (WL-3,WLT-3). (See publication of the RENGER REPAIR MANUAL F2-55 EGR SYSTEM (F161-10-99A). REMOVAL/INSTALLATION.) Valve clearance 2.
  • Page 21 VALVE CLEARANCE Tightening torque 16 20 N·m {1.6 2.1 kgf·m, 12 15 ft·lbf} ZCF2212W003 7. Install the cylinder head cover. 8. Install the EGR pipe (WL-3,WLT-3). (See F2-55 EGR SYSTEM REMOVAL/INSTALLATION.) B2-6...
  • Page 22 ROCKER ARM ROCKER ARM ROCKER ARM REMOVAL/INSTALLATION ZCF232112010W01 Caution D Removing the camshaft under load can break the camshaft. When removing the camshaft, be sure to prevent the camshaft from pressing down the rocker arm. (See B2-5 VALVE CLEARANCE INSPECTION/ADJUSTMENT.) 1.
  • Page 23 ROCKER ARM Camshaft pulley Removal Note Camshaft Installation Note D Hold the camshaft using a wrench cast hexagon. 1. Apply silicone sealant to the camshaft cap mounting surfaces as shown. Prevent sealant from getting onto the camshaft journal, oil seal surface, and camshaft thrust surface.
  • Page 24 2001 RANGER Repair Manual Supplement (F175-10-01I) ROCKER ARM, FRONT OIL SEAL Seal plate Installation Note FRONT OIL SEAL • Tighten the seal plate bolts in the order shown. FRONT OIL SEAL REPLACEMENT ZCF232010602W01 Caution • There are two types of crankshaft pulley lock bolts.
  • Page 25 FRONT OIL SEAL Caution Crankshaft pulley Installation Note (WL-3, WLT-3) D Hold the crankshaft using the SST D The TDC sensor plate is a very important part for engine operation control; any deformation of the plate may disable the operation control. When disassembling/assembling the crankshaft pulley, be very careful not to deform the plate by interference with other...
  • Page 26 COOLING SYSTEM FEATURES OUTLINE ........OUTLINE OF CONSTRUCTION .
  • Page 27 OUTLINE OUTLINE OUTLINE OF CONSTRUCTION ZCF360201004W01 D The construction and operation of the cooling systems of the Euro 3 Regulation models is essentially carried over from that of the current RANGER (UN)/RANGER WL, WL Turbo models (non-Euro 3 regulation models). (See RANGER Training Manual F326-10-99A.) D Euro 3 and non Euro 3 regulation models are distinguished as follows: Euro 3 Regulation models are equipped with an EGR water cooler in the coolant flow diagram.
  • Page 28 OUTLINE COOLANT FLOW DIAGRAM ZCF360201004W03 F2, G6 ZBE3602W001 WL, WL TURBO ZBE3602W003 Coolant reservoir Cylinder block Radiator Cylinder head Thermostat Heater Water pump Turbocharger Oil cooler...
  • Page 29 OUTLINE WL-3, WLT-3 ZBE3602W002 Coolant reservoir Cylinder block Radiator Cylinder head Thermostat Heater Water pump Turbocharger Oil cooler EGR water cooler...
  • Page 30 FUEL AND EMISSION CONTROL SYSTEMS FEATURES CLUTCH SWITCH DESCRIPTION ..F2-36 NEUTRAL SWITCH DESCRIPTION ..F2-36 OUTLINE ....... . . F2-3 FUEL INJECTION AMOUNT CONTROL .
  • Page 31 OUTLINE TIMER POSITION SENSOR INSPECTION F2-69 NO.5 CRANKS NORMALLY BUT WILL INJECTION PUMP EPROM INSPECTION F2-69 NOT START ......F2-140 TDC SENSOR REMOVAL/INSTALLATION F2-70...
  • Page 32 OUTLINE OUTLINE OUTLINE OF CONSTRUCTION ZCF400202000W01 D To match the Euro 3 Regulation, WL-3 and WLT-3 models have been adopted which have electronic control type injection pump. D The construction and operation of the fuel and emission control systems of the Euro 3 Regulation models is essentially carried over from that of the current RANGER (UN)/RANGER WL, WL Turbo models (non Euro 3 regulation models.) (See RANGER TRAINING MANUAL F326-10-99A.) except for the following features.
  • Page 33 OUTLINE SPECIFICATIONS ZCF400202000W03 Euro 3 Regulation models Non Euro 3 Regulation models Item Item WL 3 WLT 3 WL Turbo Air cleaner element Type Non woven fabric (dry) Turbocharger with Supercharger type Type Turbocharger with charge air cooler charge air cooler Glow plug Type Ceramic type...
  • Page 34 OUTLINE Fuel filter CS sensor Fuel warmer (if equipped) Electronic govenor Injection pump Injection pump EPROM Injection nozzle FSO solenoid Wastegate dumper Oxidation catalytic converter Timer position sensor EGR valve Pump speed sensor EGR valve position sensor Accelerator position sensor EGR solenoid valve (vent) Idle switch EGR solenoid valve (vacuum)
  • Page 35 OUTLINE CONTROL SYSTEM WIRING DIAGRAM ZCF400202000W05 Euro 3 Regulation Models ZCF4002W002 F2-6...
  • Page 36 OUTLINE ZCF4002W003 EGR solenoid valve (vent) Intake shutter solenoid valve Neutral switch WLT-3 engine only Clutch switch Immobilizer unit EGR solenoid valve (vacuum) Engine switch F2-7...
  • Page 37 OUTLINE Battery TDC sensor Starter Timer position sensor Generator Injection pump EPROM Instrument cluster PCM control relay Generator warning light EGR control solenoid valve Sedimentor switch Idle switch Oil pressure switch MAF/IAT sensor Heat gauge unit ECT sensor Vehicle speedometer sensor IAT sensor No.2 Glow plug relay Glow indicator light...
  • Page 38 INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM OUTLINE ZCF401001005W01 Euro 3 Regulation Models D The construction and operation of the intake-air system of the Euro 3 Regulation models is essentially carried over from that of the current RANGER (UN)/RANGER WL, WL Turbo models, except for following. (See RANGER TRAINING MANUAL F326-10-99A.) A small size turbocharger comparable to the one on the previous WL Turbo model has been adopted on the WL-3 models to improve response and engine torque at low/middle speeds.
  • Page 39 INTAKE-AIR SYSTEM GLOW PLUG DESCRIPTION ZCF401018601W01 Euro 3 Regulation Models Function D Glow plug improves ignitability and combustibility of intake air by generating heat. Structure/Operation D Ceramic material is used on the glow area end for self control of heat. ZCF4010W011 Glow plug Glow area end...
  • Page 40 FUEL SYSTEM FUEL SYSTEM OUTLINE ZCF401201006W01 Euro 3 Regulation Models D The construction and operation of the fuel system of the Euro 3 Regulation models is essentially carried over from that of the current RANGER (UN)/RANGER WL, WL Turbo models, except for following. (See RANGER TRAINING MANUAL F326-10-99A.) An electronic control type injection pump has been adopted to improve the emission performance.
  • Page 41 FUEL SYSTEM SYSTEM DIAGRAM ZCF401201006W03 Euro 3 Regulation Models ZCF4012W011 Fuel tank FSO solenoid Fuel filter Overflow valve Injection pump Fuel warmer (if equipped) Injection nozzle Sedimentor switch Electronic governor Fuel flow INJECTION PUMP DESCRIPTION ZCF401213800W01 Euro 3 Regulation Models Outline D Due to the adoption of the electronic control type injection pump, the PCM electrically controls the adjustment of the fuel injection amount and timing, which has been controlled mechanically in non Euro 3 regulation...
  • Page 42 FUEL SYSTEM Structure D The electronic control type injection pump consists of a pump mechanism, which has the same construction as the conventional mechanical injection pump, and electronic control parts such as an electronic governor and a timer control valve. ZCF4012W013 Injection pump cross sectional view Pump mechanism...
  • Page 43 FUEL SYSTEM Injection Timing Adjustment D As with the conventional mechanical injection pump, the fuel injection timing is determined by moving the timer piston to change the relative position of the roller holder that contacts the cam plate. D In the electronic control type injection pump, the fuel pressure that actuates the timer piston is controlled by the timer control valve.
  • Page 44 FUEL SYSTEM ELECTRONIC GOVERNOR DESCRIPTION ZCF401213800W03 Euro 3 Regulation Models Structure D The electronic governor is installed on the upper part of the injection pump and consists of a coil, rotor, shaft, and control sleeve (CS) sensor. ZCF4012W018 Electronic governor cross sectional view Shaft Coil Control sleeve...
  • Page 45 FUEL SYSTEM ZCF4012W019 Magnetized Shaft Core Ball pin Rotor Control sleeve Coil Fuel decrease Electricity passes Fuel increase TIMER CONTROL VALVE DESCRIPTION ZCF401213800W04 Euro 3 Regulation Models Function D The TCV is mounted to the bottom of the injection pump. The TCV is a solenoid valve that controls the position of the timer piston that modifies the fuel injection timing.
  • Page 46 EMISSION SYSTEM EMISSION SYSTEM OUTLINE ZCF401601007W01 Euro 3 Regulation Models D The construction and operation of the emission system of the Euro 3 Regulation models is essentially carried over from that of the current RANGER (UN)/RANGER WL, WL Turbo models, except for following. (See RANGER TRAINING MANUAL F326-10-99A.) The EGR system has been strengthened to comform to the Euro 3 Regulation.
  • Page 47 EMISSION SYSTEM SYSTEM DIAGRAM ZCF401601007W03 Euro 3 Regulation Models ZCF4016W014 EGR valve WLT 3 EGR solenoid valve (vent) Intake shutter solenoid valve EGR solenoid valve (vacuum) Intake shutter valve actuator EGR control solenoid valve Intake shutter valve EGR water cooler Oxidation catalytic converter Vacuum pump To PCM...
  • Page 48 EMISSION SYSTEM System diagram ZCF4016W015 EGR valve Intake shutter solenoid valve EGR solenoid valve (vent) Intake shutter valve actuator EGR solenoid valve (vacuum) Intake shutter valve EGR control solenoid valve WLT 3 EGR water cooler To PCM Vacuum pump EGR SORENOID VALVE (VACUUM, VENT) DESCRIPTION ZCF401618741W01 Euro 3 Regulation Models Function...
  • Page 49 EMISSION SYSTEM EGR CONTROL SOLENOID VALVE DESCRIPTION ZCF401618741W04 Euro 3 Regulation Models Function D EGR valve changes the pressure on the diaphragm of the EGR valve from vacuum to atmospheric pressure. Structure/Operation D EGR control solenoid valve consists of coil, spring, and plunger. D When EGR valve is not energized, the passage between the diaphragm and atmospheric air side is open.
  • Page 50 EMISSION SYSTEM INTAKE SHUTTER VALVE DESCRIPTION ZCF401620100W01 Euro 3 Regulation Models (WLT 3) Function D When the exhaust gas recirculation system is operated, the intake shutter valve closes, vacuum is generated in the intake manifold, and EGR gas is efficiently transported to the combustion chamber. As a result, NOx is reduced.
  • Page 51 CONTROL SYSTEM CONTROL SYSTEM OUTLINE ZCF404001070W01 Euro 3 Regulation Models D The construction and operation of the control system of the Euro 3 Regulation models is essentially carried over from that of the current RANGER (UN)/RANGER WL, WL Turbo models, except for following. (See RANGER TRAINING MANUAL F326-10-99A.) Fuel injection amount control has been adopted to improve emission performance.
  • Page 52 CONTROL SYSTEM PCM (integrated with barometric pressure sensor) Timer position sensor MAF/IAT sensor Control sleeve (CS) sensor IAT sensor No.2 EGR position sensor Boost sensor Glow plug relay ECT sensor PCM control relay TDC sensor A/C relay Accelerator position sensor Idle switch Battery Clutch switch...
  • Page 53 CONTROL SYSTEM BLOCK DIAGRAM ZCF404001070W03 Euro 3 Regulation Models ZCF4040W100 Fuel injection amount control FSO solenoid Fuel injection timing control Electronic governor Idle speed control CS sensor Glow control A/C cut-off control EGR control Immobilizer system F2-24...
  • Page 54 CONTROL SYSTEM MAF/IAT sensor Battery ECT sensor Accelerator position sensor Starter (starter signal) Idle switch Barometric pressure sensor (integrated in PCM) IAT sensor No.2 Timer position sensor Pump speed sensor EGR valve position sensor Fuel temperature sensor Timer control valve Injection pump EPROM EGR solenoid valve (vacuum) TDC sensor...
  • Page 55 CONTROL SYSTEM CONTROL SYSTEM DEVICE AND CONTROL RELATIONSHIP CHART ZCF404001070W04 Euro 3 Regulation Models ZCF4040W046 F2-26...
  • Page 56 CONTROL SYSTEM PCM DESCRIPTION ZCF404018880W01 Euro 3 Regulation Models Function D Based on the signal from each input sensor, the PCM outputs a drive (operation) signal to the drive parts (solenoid, etc.), which require an optimum control amount according to the engine condition (engine speed, engine coolant temperature, etc.).
  • Page 57 CONTROL SYSTEM Operation D The hot-wire (heat resistor) type MAF sensor detects the mass intake airflow that corresponds to the output current. D The output current is controlled by the control circuit in the MAF sensor and heats the hot wire (heat resistor) so that the temperature difference between the heat resistor and the intake air is constant.
  • Page 58 CONTROL SYSTEM FUEL TEMPERATURE SENSOR DESCRIPTION ZCF404013809W01 Euro 3 Regulation Models Function D The fuel temperature sensor is built into the electronic governor at the top of the injection pump. The fuel temperature sensor detects the fuel temperature required for correction of the fuel injection amount according to the change in the thermistor's resistance value and sends it to the PCM.
  • Page 59 CONTROL SYSTEM CONTROL SLEEVE (CS) SENSOR DESCRIPTION ZCF404013805W01 Euro 3 Regulation Models Function D The CS sensor detects the control sleeve position and is used as a fuel injection amount feedback signal in the PCM. Structure/Operation D The CS sensor is mounted to the top of the electronic governor. D The CS sensor consists of a sleeve position detection part and a temperature correction part.
  • Page 60 CONTROL SYSTEM TIMER POSITION SENSOR DESCRIPTION ZCF404013807W01 Euro 3 Regulation Models Function D The timer position sensor detects the timer piston position and is used as a fuel injection timing feedback signal in the PCM Structure/Operation D The timer position sensor is mounted to the low pressure chamber side and consists of a core rod, a coil, and a bobbin D The core rod is mounted to the timer piston.
  • Page 61 CONTROL SYSTEM TDC SENSOR DESCRIPTION ZCF404018230W01 Euro 3 Regulation Models Function D TDC sensor detects crankshaft speed signal. Structure/Operation D TDC sensor is installed near crankshaft pulley. D TDC sensor is a hall-element type and it detects hall voltage generated by the change in magnetic flux of the magnet inside the sensor and hall element as the crankshaft speed signal.
  • Page 62 CONTROL SYSTEM BOOST SENSOR DESCRIPTION ZCF404018660W01 Euro 3 Regulation Models Function D The boost sensor detects the intake air pressure as an absolute pressure, and sends it to the PCM as an intake air pressure signal. D The boost sensor is installed in the air pipe between the charge air cooler and the intake manifold. Operation D The boost sensor is filled with crystal (silicon) and it is the semi-conductor pressure sensor which utilizes the characteristic of the electrical resistance that changes when the crystal is pressurized.
  • Page 63 CONTROL SYSTEM ACCELERATOR POSITION SENSOR DESCRIPTION ZCF404041602W01 Euro 3 Regulation Models Function D The accelerator position sensor is installed on the accelerator pedal, and detects how much the accelerator pedal is being depressed from the change in the resistance value (variable resistance). ZCF4040W031 Accelerator position sensor Accelerator position signal (monitor)
  • Page 64 CONTROL SYSTEM IDLE SWITCH DESCRIPTION ZCF404066470W01 Euro 3 Regulation Models Function D The idle switch is mounted to the accelerator pedal and inputs to the PCM whether the accelerator pedal is depressed or released. The PCM detects the idle switch signal as an idle signal. D The idle signal inputted to the PCM is compared with the accelerator opening signal detected from the accelerator position sensor, and on-board diagnostic of the idle switch and the accelerator position sensor is performed.
  • Page 65 CONTROL SYSTEM CLUTCH SWITCH DESCRIPTION ZCF404017640W01 Euro 3 Regulation Models Function D The clutch switch detects the clutch connection condition. D The clutch switch is connected parallel to the neutral switch, and both the switches are connected to the PCM. D The clutch and neutral switch is a switch that detects whether the engine is under a loaded condition (engine output is transmitted to the road surface) or under an unloaded condition (engine output is not transmitted to the road surface).
  • Page 66 CONTROL SYSTEM FUEL INJECTION AMOUNT CONTROL ZCF404001070W06 Euro 3 Regulation Models Outline D Fuel injection amount control optimally controls the amount of fuel injected according to the engine operating condition. The PCM determines the engine operating condition based on the signals of the input sensors in the figure below and drives the governor with the control signal of the fuel injection amount calculated from this.
  • Page 67 CONTROL SYSTEM A/C switch Fuel injection amount at engine start Boost sensor Maximum fuel injection amount Neutral switch Idle speed feedback correction Clutch switch Basic fuel injection amount at idle IAT sensor No.2 Correction Accelerator position sensor Cylinder and differential learning Idle switch Idle load learning ECT sensor...
  • Page 68 CONTROL SYSTEM Maximum fuel injection amount D Maximum fuel injection amount is the maximum value for the basic fuel injection amount at idle and the basic fuel injection amount at normal operation, and is determined by intake air temperature, atmospheric pressure, and engine speed.
  • Page 69 CONTROL SYSTEM Timer position sensor Accelerator position sensor Pump speed sensor ECT sensor TDC sensor Starter Neutral switch Engine switch Clutch switch Timer control valve Barometric pressure sensor (integrated in PCM) Control outline D The PCM controls fuel injection timing by driving the timer control valve mounted to the injection pump by modifying the hydraulic pressure applied to the timer piston and by moving the position of the timer piston.
  • Page 70 CONTROL SYSTEM Block diagram ZCF4040W055 EGR solenoid valve (vent) MAF/IAT sensor Accelerator position sensor ECT sensor Idle switch Pump speed sensor TDC sensor Barometric pressure sensor (integrated in PCM) Neutral switch Starter Clutch switch EGR control solenoid valve EGR solenoid valve (vacuum) Intake shutter solenoid valve (WLT 3) Operation D To improve emission performance, target EGR valve position has been decided based on intake air flow,...
  • Page 71 ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC OUTLINE ZCF407018881W01 Euro 3 Regulation Models D DTCs for added parts, monitoring PIDs and simulation PIDs have been added to improve serviceability. ZCF407018881W02 Euro 3 Regulation Models D To match regulation the DTCs of Euro 3 Regulation model have been changed from 2 digits to 4 digits. D Due to the electric controlled injection pump has been added, the DTCs for their sensors and actuators have been added to improve the serviceability.
  • Page 72 ON-BOARD DIAGNOSTIC Diagnosed Memory circuit/ Detection condition Fail - safe function system D PCM monitors difference voltage between target D Turns FSO solenoid off. Injection injection amount and actual injection amount D Turns electronic governor amount while engine running. If difference voltage is off.
  • Page 73 ON-BOARD DIAGNOSTIC Diagnosed Memory circuit/ Detection condition Fail - safe function system D PCM monitors input voltage from timer position D Sets TCV position specified Timer sensor. If input voltage from timer position sensor value. position P1318 is above 4.50 Vor above 4.90 V, PCM sensor determines that timer position sensor circuit is malfunctioning.
  • Page 74 ON-BOARD DIAGNOSTIC Monitor item Monitoring item Condition/unit PCM terminal (Display on NGS tester) Glow plug control ON/OFF Glow indicator light ON/OFF IASV Intake shutter valve ON/OFF Intake air temperature (IAT sensor No.2) °C/°F Intake air temperature signal voltage (IAT sensor No.2) IATDC Intake air temperature (IAT sensor No.1) °C/°F...
  • Page 75 OUTLINE OUTLINE Injection pump EPROM D Inspection procedure has been added. TDC sensor SUPPLEMENTAL SERVICE INFORMATION D Removal/installation procedure has been ZCF400202000W06 modified. D The following changes and/or additions have been D Inspection procedure has been added. made since publication of the RANGER REPAIR EGR valve position sensor MANUAL (F161-10-99A).
  • Page 76 ENGINE TUNE-UP ENGINE TUNE-UP ENGINE TUNE UP ZCF400802000W01 Euro 3 Regulation Models Engine tune up 1. Prepare for the engine tune up. (1) Warm up the engine to normal operating temperature. (2) Shift the transmission into neutral (MT) or P range (AT).
  • Page 77 INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM VACUUM TUBE ROUTING DIAGRAM ZCF401020030W01 Euro 3 Regulation Models ZCF4010W004 TURBOCHARGER INSPECTION Note ZCF401013700W02 D To make work accurate, use a penlight to Euro 3 Regulation Models (WL 3) inspect. Compressor wheels inspection 1. Remove the air hose. 2.
  • Page 78 INTAKE-AIR SYSTEM 4. Inspect all fins of compressor wheel while rotating the compressor wheel by hand. D If the compressor wheel is interfering with the housing, it is likely that more than two fins are damaged, cracked or bent. Replace the turbocharger.
  • Page 79 INTAKE-AIR SYSTEM Glow plug cleaning before installation note R.H.D. Caution D Carbon on the glow plug can damage the glow plug and engine. Remove carbon on the glow plug and fitting holes before installing the glow plug. 1. Wrap tape on both a 5.5 mm and a 5.7 mm drills, starting from the tip to a point 50 mm from the tip.
  • Page 80 INTAKE-AIR SYSTEM Pedal component installation note D Carry out the BRAKE PEDAL HEIGHT INSPECTION" procedure after installing the pedal component. (See Section P) D Carry out the CLUTCH PEDAL INSPECTION" procedure after installing the pedal component. (See Section H) ACCELERATOR PEDAL COMPONENT DISASSEMBLY/ASSEMBLY ZCF401041600W03 Euro 3 Regulation Models...
  • Page 81 FUEL SYSTEM FUEL SYSTEM INJECTION PUMP INSPECTION ZCF401213800W05 Euro 3 Regulation Models Injection pump inner parts inspection Caution D Injection pump is sealed to maintain proper function. Special tools and testers are required when disassembling the injection ZCF4012W007 pump. Disassembling the injection pump without special tools and testers will cause Terminal Part name...
  • Page 82 FUEL SYSTEM D If as specified, but the engine does not start, perform the following off-vehicle inspection. ZCF4012W005 Terminal Part name ZCF4012W009 Pump speed sensor (+) Specification Pump speed sensor ( ) FSO temperature (°C {°F}) Resistance (ohm) 13 33 {55.4 91.4} 7.5 9.7 Off-vehicle inspection Operation inspection...
  • Page 83 FUEL SYSTEM ELECTRONIC GOVERNOR INSPECTION D If no continuity is detected, perform resistance ZCF401213800W07 inspection. Euro 3 Regulation models Resistance inspection Note D Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Disconnect the injection pump connector A. 3.
  • Page 84 EMISSION SYSTEM EMISSION SYSTEM EGR SYSTEM REMOVAL/INSTALLATION ZCF401601075W02 Euro 3 Regulation Models 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. ZCF4016W009 EGR pipe EGR valve EGR water cooler Intake shutter valve (WLT 3) EGR system installation note...
  • Page 85 EMISSION SYSTEM EGR VALVE INSPECTION Open circuit ZCF401620300W01 D Power circuit (EGR solenoid valve (vacuum) Euro 3 Regulation models connector terminal A and PCM control relay 1. Inspect for airflow between 1 and 2 when vacuum connector terminal D) is applied using a vacuum pump as shown in the D GND circuit (EGR solenoid valve (vacuum) figure.
  • Page 86 EMISSION SYSTEM EGR CONTROL SOLENOID VALVE INSPECTION Specification ZCF401618741W05 Euro 3 Regulation Models Vacuum Rod movement 1. Inspect airflow between the ports under the kPa {mmHg, inHg} following conditions. Below 5.3 { 40, 1.57} Starts to move D If not as specified, replace the EGR control Above 26.6 { 200, 7.9} Fully pulled solenoid valve.
  • Page 87 EMISSION SYSTEM Circuit Open/Short Inspection 1. Inspect for an open or short circuit in the following wiring harnesses. D If there is an open or short circuit, repair or replace wiring harnesses. Open circuit D Power circuit (intake shutter solenoid valve connector terminal A and PCM control relay connector terminal D) D GND circuit (intake shutter solenoid valve...
  • Page 88 CONTROL SYSTEM CONTROL SYSTEM CONTROL SYSTEM COMPONENT ZCF404001070W05 Euro 3 Regulation Models ZCF4040W045 MAF/IAT sensor Timer position sensor IAT sensor No.2 Control sleeve (CS) sensor Boost sensor EGR valve position sensor ECT sensor Glow plug relay TDC sensor PCM control relay Accelerator position sensor A/C relay Idle switch...
  • Page 89 CONTROL SYSTEM Glow indicator light Neutral switch PCM REMOVAL/INSTALLATION ZCF404018880W02 Euro 3 Regulation Models 1. Disconnect the battery negative cable. 2. Remove the passenger's side front side trim. 3. Remove in the order indicated in the table. ZCF4040W050 Set bolt (with immobilizer) PCM connector (See F2-61 Set bolt removal note) (See F2-61 Set bolt installation note)
  • Page 90 CONTROL SYSTEM Set bolt removal note Set bolt installation note 1. Using a chisel and a hammer, cut a groove on the 1. Install new set bolt and tighten it until the neck of head of the set bolt so that a screwdriver can be the bolt is cut.
  • Page 91 CONTROL SYSTEM Monitor item Unit/ Condition/Specification Action (Definition) Condition terminal ECT is 20°C {68°F}: 20°C {68°F} Inspect ECT sensor. °C °F ECT (Engine ECT is 85°C {185°F}: 85°C {185°F} (See F2-66 ENGINE COOLANT coolant coolant TEMPERATURE (ECT) SENSOR TEMPERATURE (ECT) SENSOR ECT is 20°C {68°F}: 3.0 3.2 V temperature) INSPECTION)
  • Page 92 CONTROL SYSTEM Monitor item Unit/ Condition/Specification Action (Definition) Condition terminal IAT is 20°C {68°F}: 20°C {68°F} Inspect MAF/IAT sensor. °C °F IAT is 30°C {86°F}: 30°C {86°F} (See F2-65 MASS AIR FLOW IATDC (MAF)/INTAKE AIR (MAF)/INTAKE AIR (IAT sensor No.1) IAT is 20°C {68°F}: 2.3 2.5 V TEMPERATURE (IAT) SENSOR IAT is 30°C {86°F}: 1.8 2.0 V...
  • Page 93 CONTROL SYSTEM Not using SSTs (WDS or equivalent) at constant Verify there is no continuity between the voltage terminal inspection accelerator position sensor connector 1. Turn the engine switch to ON. (vehicle side) terminal A and battery 2. Measure the voltage between the accelerator positive harness using an ohmmeter.
  • Page 94 CONTROL SYSTEM Not using SSTs (WDS or equivalent) at serial D GND circuit (MAF/IAT sensor connector terminal B communication terminal inspection and PCM connector terminal 4A) 1. Turn the engine switch to OFF. 2. Disconnect the PCM connectors. 3. Verify there is continuity between the PCM connector terminal 2B and DLC KLN terminal.
  • Page 95 CONTROL SYSTEM ZCF4040W010 CIrcuit open/short inspection 1. Inspect for an open or short circuit in the following wiring harnesses. D If there is an open or short circuit, repair or replace wiring harnesses. Open circuit D Signal circuit (MAF/IAT sensor connector terminal D and PCM connector terminal 3D) D GND circuit (MAF/IAT sensor connector terminal E and PCM connector terminal 1B)
  • Page 96 CONTROL SYSTEM 1. Place the sensor in water with a thermometer, and Circuit open/short inspection heat the water gradually. 1. Inspect for an open or short circuit in the following wiring harnesses. D If there is an open or short circuit, repair or replace wiring harness.
  • Page 97 CONTROL SYSTEM Circuit open/short inspection Circuit open/short inspection 1. Inspect for an open or short circuit in the following 1. Inspect for an open or short circuit in the following wiring harnesses. wiring harnesses. D If there is an open or short circuit, repair or Open circuit replace wiring harnesses.
  • Page 98 CONTROL SYSTEM CS sensor circuit open/short inspection Specification 1. Inspect for an open or short circuit in the following Atmospheric Terminal Resistance (ohm) wiring harnesses. temperature °C {°F} D if there is an open or short circuit, repair or 76.3 87.7 15 35 {59 95} replace wiring harnesses.
  • Page 99 CONTROL SYSTEM TDC SENSOR INSPECTION ZCF404018230W03 Euro 3 Regulation Models Wave profile Inspection 1. Set oscilloscope. Measuring terminals PCM terminal: 1H(+)⇔1B( ) 2. Verify that output voltage when ON and OF and output pattern are within the specification. ZCF4040W005 Circuit open/short inspection Open circuit D Power Circuit (Injection pump connector B terminal D and PCM connector terminal 1A)
  • Page 100 CONTROL SYSTEM EGRVP PID Open circuit approx. 0.6 V D Boost circuit (Boost sensor connector terminal B and PCM connector terminal 1P) 3. Start the engine and warm up the engine D Constant voltage circuit (Boost sensor connector completely. terminal A and PCM connector terminal 1A) 4.
  • Page 101 CONTROL SYSTEM 4. Verify that the voltage between the PCM terminals (1) Verify that the voltage between the PCM 1R (accelerator position detection signal) and 1B terminals 1A (power circuit) and 1B (ground is as shown below according to the accelerator circuit) is 4.75 5.25 V.
  • Page 102 CONTROL SYSTEM IDLE SWITCH INSPECTION Open circuit ZCF404066470W02 D Signal circuit (Idle switch connector terminal A and Euro3 Regulation models PCM connector terminal 3O) D GND circuit (Idle switch connector terminal B and body GND) Note D Power circuit (Accelerator position sensor D Perform the following test only when directed.
  • Page 103 CONTROL SYSTEM CLUTCH SWITCH INSPECTION ZCF404017640W02 Euro 3 Regulation Models Inspection of Continuity Note D Perform the following test only when directed. 1. Inspect continuity between the clutch switch terminals using an ohmmeter. D If not as specified, replace the clutch switch. D If clutch switch is okay, but PID value is out of specification, perform the Circuit open/short inspection."...
  • Page 104 CONTROL SYSTEM NEUTRAL SWITCH INSPECTION ZCF404017640W04 Euro 3 Regulation Models Note D Perform the following inspection only when directed. Continuity inspection 1. Inspect for continuity between the neutral switch terminals using an ohmmeter. ZCF4040W018 D If the neutral switch is okay, but the PNP PID is out of specification, carry out of the Circuit open/short inspection."...
  • Page 105 ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC FOREWORD ZCF407018881W05 Euro 3 Regulation Models D When the customer reports a vehicle malfunction, check the warning light indication and diagnostic trouble code (DTC), then diagnose the malfunction according to following flowchart. If a DTC exists, diagnose the applicable DTC inspection. (See F2-77 DTC TABLE.) If no DTC exists and the warning light does not illuminate or flash, diagnose the applicable symptom troubleshooting.
  • Page 106 ON-BOARD DIAGNOSTIC ON BOARD DIAGNOSTIC TEST PID/DATA monitor and record procedure ZCF407018881W08 1. Perform the necessary vehicle preparation and Euro 3 Regulation Models visual inspection. DTCs retrieving procedure 2. Connect WDS or equivalent to the vehicle DLC 1. Perform the necessary vehicle preparation and located the engine room.
  • Page 107 ON-BOARD DIAGNOSTIC Output pattern Possible cause Page (See F2-99 P0400 EGR system malfunction P0400) WALTPX0400 (See Vehicle speed sensor (VSS) F2-101 P0500 circuit malfunction P0500) WALTPX0500 (See F2-103 P0510 Idle switch malfunction P0510) WALTPX0510 (See F2-104 P0606 PCM malfunction P0606) WALTPX0606 (See F2-105...
  • Page 108 ON-BOARD DIAGNOSTIC Output pattern Possible cause Page (See P1621 Code word does not match after F2-123 engine cranking P1621) WALTPX1621 (See P1622 F2-124 Key ID number does not match P1622) WALTPX1622 (See P1623 Code word or key ID number F2-124 read/write error in PCM P1623) WALTPX1623...
  • Page 109 ON-BOARD DIAGNOSTIC DTC P0100 MAF circuit malfunction HIGH INPUT ZCF4070W002 ZCF4070W003 Diagnostic procedure STEP INSPECTION ACTION VERIFY RELATED SERVICE INFORMATION Perform repair or diagnosis according to available Service AVAILABILITY Information. D Check for related Service Information D If vehicle is not repaired, go to next step. availability availability.
  • Page 110 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION CHECK POWER SUPPLY CIRCUIT FOR OPEN Go to next step. CIRCUIT CIRCUIT Inspect for open circuit in wiring harness between D Turn engine switch to ON (Engine OFF). MAF/IAT sensor terminal A (harness-side) and PCM D Check voltage at MAF/IAT sensor terminal A control relay terminal D (harness-side).
  • Page 111 ON-BOARD DIAGNOSTIC DTC P0105 ZCF407018881W11 DTC P0105 Boost sensor circuit malfunction D PCM monitors input voltage from boost sensor when engine switch is turned ON. If PCM detects either DETECTION of following conditions, PCM determines that boost sensor circuit has a malfunction. Input voltage at PCM terminal 1P is below 0.19 V.
  • Page 112 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION VERIFY RELATED SERVICE INFORMATION Perform repair or diagnosis according to available Service AVAILABILITY Information. D Check for related Service Information D If vehicle is not repaired, go to next step. availability availability. Go to next step. D Is any related Service Information available? VERIFY CURRENT INPUT SIGNAL STATUS Go to Step 11.
  • Page 113 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT PCM CONNECTOR FOR POOR Repair terminal, then go to next step. CONNECTION D Turn engine switch to OFF. D Disconnect PCM connector D Disconnect PCM connector. Inspect boost sensor, then go to next step. D Check for poor connection at terminals 1A, (See F2-71 BOOST SENSOR INSPECTION) 1B and 1P (damaged, pulled-out terminals,...
  • Page 114 ON-BOARD DIAGNOSTIC DTC P0110 IAT No. 1 circuit malfunction HIGH INPUT ZCF4070W053 ZCF4070W060 Diagnostic procedure STEP INSPECTION ACTION VERIFY RELATED SERVICE INFORMATION Perform repair or diagnosis according to available Service AVAILABILITY Information. D Check for related Service Information D If vehicle is not repaired, go to next step. availability availability.
  • Page 115 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION CLASSIFY IF IAT SENSOR No. 1 Go to next step. MALFUNCTION OR HARNESS MALFUNCTION D Turn engine switch to ON (Engine OFF) D Turn engine switch to ON (Engine OFF). Go to Step 10. D Access IATDC PID using WDS or equivalent. D Is IATDC PID below 0.13 V? INSPECT IAT SENSOR No.
  • Page 116 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P1110 Replace PCM, then go to next step. COMPLETED D Make sure to reconnect all disconnected connectors connectors. Go to next step. D Clear DTC from PCM memory. D Start engine. D Is same DTC present? VERIFY AFTER REPAIR PROCEDURE Go to applicable DTC inspection.
  • Page 117 ON-BOARD DIAGNOSTIC DTC P0115 ECT circuit malfunction HIGH INPUT ZCF4070W007 ZCF4070W017 Diagnostic procedure STEP INSPECTION ACTION VERIFY RELATED REPAIR INFORMATION Perform repair or diagnosis according to available Service AVAILABILITY information. D Check for related Service Information D If vehicle is not repaired, go to next step. availability availability.
  • Page 118 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT ECT SENSOR CONNECTOR FOR Repair or replace terminal, then go to Step 13. POOR CONNECTION D Turn engine switch to OFF. D Disconnect ECT sensor connector D Disconnect ECT sensor connector. Go to next step. D Check for poor connection (damaged, pulled-out terminals, corrosion, etc.).
  • Page 119 ON-BOARD DIAGNOSTIC DTC P0120 ZCF407018881W14 DTC P0120 Accelerator position sensor circuit malfunction D PCM monitors accelerator position sensor signal at PCM terminal 1R. If PCM detects either of following conditions, PCM determines that accelerator position sensor circuit has a malfunction. Input voltage at PCM terminal 1R is below 0.29 V.
  • Page 120 ON-BOARD DIAGNOSTIC DTC P0120 Accelerator position sensor circuit malfunction ZCF4070W18 Diagnostic procedure STEP INSPECTION ACTION VERIFY RELATED SERVICE INFORMATION Perform repair or diagnosis according to available Service AVAILABILITY Information. D Check for related Service Information D If vehicle is not repaired, go to next step. availability availability.
  • Page 121 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION CLASSIFY IF INTERMITTENT CONCERN OR Go to next step. CONTINUOUS CONCERN D Turn engine switch ON (engine OFF) D Turn engine switch ON (engine OFF). Intermittent concern exists. Go to INTERMITTENT D Connect the WDS or equivalent. CONCERN TROUBLESHOOTING procedure.
  • Page 122 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT ACCELERATOR POSITION SENSOR Go to next step. D Make sure to reconnect all disconnected connectors. D Inspect accelerator position sensor D Inspect accelerator position sensor. Replace accelerator position sensor, then go to Step 11. (See F2-71 ACCELERATOR POSITION SENSOR INSPECTION) D Is it okay?
  • Page 123 ON-BOARD DIAGNOSTIC DTC P0180 Fuel temperature sensor malfunction HIGH INPUT ZCF4070W009 ZCF4070W019 Diagnostic procedure STEP INSPECTION ACTION VERIFY RELATED SERVICE INFORMATION Perform repair or diagnosis according to available Service AVAILABILITY Information. D Check for related Service Information D If vehicle is not repaired, go to next step. availability availability.
  • Page 124 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT FUEL TEMPERATURE SENSOR Repair or replace shorted harness, then go to Step 15. SIGNAL CIRCUIT FOR SHORT TO GND D Turn engine switch to OFF. D Disconnect PCM connector. D Check for continuity between fuel Go to next step.
  • Page 125 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P0180 Replace PCM, then go to next step. COMPLETED D Make sure to reconnect all disconnected connectors. D Turn engine switch to ON (engine OFF) D Turn engine switch to ON (engine OFF). Go to next step.
  • Page 126 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY CURRENT INPUT SIGNAL STATUS-IS Go to next step. CONCERN INTERMITTENT OR CONSTANT? D Turn engine switch to ON (Engine OFF). Intermittent concern exists. Go to INTERMITTENT D Clear DTC from PCM memory using WDS or CONCERN TROUBLESHOOTING Procedure.
  • Page 127 ON-BOARD DIAGNOSTIC DTC P0335 ZCF407018881W17 DTC P0335 TDC sensor circuit malfunction DETECTION D If PCM does not receive input signal from TDC sensor when engine is running, PCM determines that CONDITION TDC sensor circuit has a malfunction. D TDC sensor malfunction D Poor connection at TDC sensor or PCM connector D PCM malfunction POSSIBLE...
  • Page 128 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT PCM CONNECTOR FOR POOR Repair or replace terminal, then go to Step 9. CONNECTION D Turn engine switch to OFF. D Disconnect PCM connector. D Check for poor connection at terminals 1B Go to next step. and 1H (damaged, pulled-out terminals, corrosion, etc.).
  • Page 129 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION VERIFY RELATED REPAIR INFORMATION Perform repair or diagnosis according to available repair AVAILABILITY information. D Check for related Service Bulletins and/or D If vehicle is not repaired, go to next step. on line repair information availability on-line repair information availability.
  • Page 130 ON-BOARD DIAGNOSTIC DTC P0500 ZCF407018881W19 DTC P0500 Vehicle speed sensor (VSS) circuit malfunction D PCM detects after following conditions, PCM determines that VSS sensor circuit has a malfunction: DETECTION Gear is in position other than neutral. Engine speed is avobe 4,000 rpm. CONDITION Vehicle speed is below 3.76 km/h {2.33 mph}.
  • Page 131 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION CHECK SPEEDOMETER Go to next step. D Check speedometer. Inspect speedometer, then go to next step. D Does vehicle speedometer needle move? (See Section T.) CLASSIFY INTERMITTENT CONCERN OR Go to next step. CONTINUOUS CONCERN D Turn engine switch ON (engine OFF) D Turn engine switch ON (engine OFF).
  • Page 132 ON-BOARD DIAGNOSTIC DTC P0510 ZCF407018881W20 DTC P0510 Idle switch malfunction D PCM detects after following conditions, PCM determines that idle switch has a malfunction: DETECTION Output voltage from accelerator position sensor is avobe 1.35 V with idle switch ON. CONDITION Output voltage from accelerator position sensor is below 0.86 V with idle switch OFF.
  • Page 133 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT IDLE SWITCH SIGNAL CIRCUIT FOR Repair or replace shorted harness, then go to Step 9. SHORT TO GND D Turn engine switch to OFF. D Disconnect PCM connector D Disconnect PCM connector. Go to next step. D Check for continuity between idle switch terminal A (harness-side) and body GND.
  • Page 134 ON-BOARD DIAGNOSTIC DTC P1110 ZCF407018881W22 DTC P1110 IAT sensor No.2 circuit malfunction DETECTION D PCM monitors IAT sensor No.2 signal at PCM terminal 1J. If voltage at PCM terminal 1J is below 0.14 V CONDITION or above 4.90 V, PCM determines that IAT sensor No.2 circuit has a malfunction. D IAT sensor No.2 malfunction D Short to GND circuit between IAT sensor No.2 terminal A and PCM terminal 1J D IAT No.2 signal and IAT GND circuit are shorted each other...
  • Page 135 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION CLASSIFY IF INTERMITTENT CONCERN OR Go to next step. CONTINUOUS CONCERN D Turn engine switch ON (engine OFF) D Turn engine switch ON (engine OFF). Intermittent concern exists. Go to INTERMITTENT D Connect the WDS or equivalent. CONCERN TROUBLESHOOTING procedure.
  • Page 136 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT PCM CONNECTOR FOR POOR Repair or replace terminal, then go to Step 15. CONNECTION D Turn engine switch to OFF. D Disconnect PCM connector D Disconnect PCM connector. Go to next step. D Inspect PCM terminals 1J and 1B (damaged, pulled out pins, corrosion, etc.).
  • Page 137 ON-BOARD DIAGNOSTIC DTC P1182 ZCF407018881W23 DTC P1182 Fuel shut off (FSO) solenoid malfunction D When the engine switch is turned off while the engine is running, if the decrease in engine speed is 200 DETECTION rpm or less 2 seconds after the engine switch is turned off, PCM determines that FSO solenoid has CONDITION malfunction.
  • Page 138 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P0110 Replace PCM, then go to next step. COMPLETED D Make sure to reconnect all disconnected connectors connectors. Go to next step. D Clear DTC from PCM memory. D Start engine. D Is same DTC present? VERIFY AFTER REPAIR PROCEDURE Go to applicable DTC inspection.
  • Page 139 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY PUMP SPEED SENSOR VOLTAGE Go to Step 4. D Disconnect pump speed sensor connector. D Connect voltmeter pump speed sensor terminals A and B (part side) terminals A and B (part-side). Go to next step. D Check voltage in AC range while cranking engine.
  • Page 140 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION VERIFY RELATED SERVICE INFORMATION Perform repair or diagnosis according to Service AVAILABILITY Information. D Check for related Service Information D If vehicle is not repaired, go to next step. availability availability. Go to next step. D Is any related Service Information available? VERIFY DTC P1195 DETECTED AGAIN Replace PCM, then go to next step.
  • Page 141 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION VERIFY RELATED SERVICE INFORMATION Perform repair or diagnosis according to Service AVAILABILITY Information. D Check for related Service Information D If vehicle is not repaired, go to next step. availability availability. Go to next step. D Is any related Service Information available? VERIFY DTC P1226 DETECTED AGAIN Go to next step.
  • Page 142 ON-BOARD DIAGNOSTIC DTC P1312 ZCF407018881W27 DTC P1312 Timer control valve circuit malfunction D PCM monitors difference voltage between target injection timing and actual injection timing while ECT is DETECTION above 80°C {176°F} and engine running. If difference voltage is above threshold for 5 s, PCM CONDITION determines that injection timing control system is malfunctioning.
  • Page 143 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT INJECTION PUMP CONNECTOR Repair or replace terminal, then go to Step 9. POOR CONNECTION D Turn engine switch to OFF. D Disconnect injection pump connector A D Disconnect injection pump connector A. Go to next step. D Check for poor connection (damaged, pulled-out pins, corrosion, etc.).
  • Page 144 ON-BOARD DIAGNOSTIC DTC P1318 ZCF407018881W28 DTC P1318 Timer position sensor circuit malfunction DETECTION D PCM monitors input voltage from timer position sensor. If input voltage from timer position sensor is CONDITION below 0.25 V or above 4.90 V, PCM determines that timer position sensor circuit is malfunctioning. D Timer position sensor malfunction D PCM malfunction D Connector or terminal malfunction...
  • Page 145 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT PCM CONNECTOR FOR POOR Repair or replace terminal, then go to Step 8. CONNECTION D Turn engine switch to OFF. D Disconnect PCM connector D Disconnect PCM connector. Go to next step. D Check for poor connection (damaged, pulled-out pins, corrosion, etc.).
  • Page 146 ON-BOARD DIAGNOSTIC DTC P1402 ZCF407018881W29 DTC P1402 EGR valve position sensor circuit malfunction DETECTION D If PCM detects EGR valve position sensor voltage at PCM terminal 1F below 0.10 V or above 4.90 V CONDITION after engine start, PCM determines that EGR valve position circuit has a malfunction. D EGR valve position sensor malfunction D Connector or terminal malfunction D Open circuit between EGR valve position sensor terminal C and PCM terminal 1F.
  • Page 147 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT EGR VALVE POSITION SENSOR Repair terminal, then go to Step 18. CONNECTOR D Turn engine switch to OFF. D Disconnect EGR valve position sensor connector. Go to next step. D Check for poor connection (damaged, pulled-out pins, corrosion, etc.).
  • Page 148 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT EGR VALVE POSITION SENSOR Repair or replace shorted harness, then go to Step 18. SIGNAL AND GROUND CIRCUIT FOR SHORT EACH OTHER D Check continuity between EGR valve position D Check continuity between EGR valve position Go to next step.
  • Page 149 ON-BOARD DIAGNOSTIC DTC P1602 ZCF407018881W30 DTC P1602 Immobilizer unit-PCM communication error DETECTION D Command transmission from the PCM to the immobilizer unit exceeds limit. CONDITION D No response from immobilizer unit D Immobilizer unit malfunction D Coil (immobilizer system) malfunction D Key (transponder) malfunction D PCM malfunction POSSIBLE...
  • Page 150 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT GROUND CIRCUIT OF IMMOBILIZER Go to next step. UNIT FOR OPEN CIRCUIT D Measure resistance between immobilizer unit D Measure resistance between immobilizer unit Repair or replace harness for open, then go to Step 19. terminal C (harness-side) and body ground.
  • Page 151 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT IMMOBILIZER UNIT CONNECTOR Repair or replace harness, then go to next step. FOR POOR CONNECTION D Turn ignition key to OFF. D Disconnect immobilizer unit connector D Disconnect immobilizer unit connector. Go to next step. D Check for poor connection (damaged, pulled-out terminals, corrosion, etc.).
  • Page 152 ON-BOARD DIAGNOSTIC DTC P1604 ZCF407018881W32 DTC P1604 Key ID numbers are not registered in PCM DETECTION D Key ID numbers are not registered in PCM. CONDITION POSSIBLE D Immobilizer system reprogram procedure (key IDs) was not performed after replacing PCM. CAUSE Diagnostic procedure STEP...
  • Page 153 ON-BOARD DIAGNOSTIC DTC P1622 ZCF407018881W34 DTC P1622 Key ID number does not match DETECTION D ID number stored in immobilizer unit (IU) and PCM does not match. This DTC is indicated only after CONDITION immobilizer unit is replaced and reprogramming system. POSSIBLE D Transformation of key ID number stored in PCM.
  • Page 154 ON-BOARD DIAGNOSTIC DTC P1624 ZCF407018881W36 DTC P1624 Immobilizer system communication counter = 0 DETECTION D PCM detected immobilizer system communication malfunction three times or more CONDITION POSSIBLE D Attempted to start engine three times or more under malfunction. CAUSE D Code word mismatch Diagnostic procedure STEP INSPECTION...
  • Page 155 ON-BOARD DIAGNOSTIC DTC P1649 Injection pump EPROM circuit malfunction ZCF4070W204 Diagnostic procedure STEP INSPECTION ACTION VERIFY RELATED SERVICE INFORMATION Perform repair or diagnosis according to Service AVAILABILITY Information. D Check for related Service Information D If vehicle is not repaired, go to next step. availability availability.
  • Page 156 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT PCM CONNECTOR FOR POOR Repair or replace terminal, then go to Step 9. CONNECTION D Turn engine switch to OFF. D Disconnect PCM connector D Disconnect PCM connector. Go to next step. D Check for poor connection (damaged, pulled-out pins, corrosion, etc.).
  • Page 157 TROUBLESHOOTING TROUBLESHOOTING FORWORD ZCF408018881W01 D Before proceeding with the following troubleshooting: See Section GI to understand the basic troubleshooting procedure. Perform the DTC inspection. If a DTC is displayed, proceed with inspection steps for the code. Y3U103WN3 When the engine can be started, perform "ENGINE TUNE-UP."...
  • Page 158 TROUBLESHOOTING 4. Vibrate the actuator or relay with your finger for 3 When testing a vehicle with a water s after SIMULATION TEST is activated. leakage problem, special caution must be D If variable click sound is heard, check for poor used.
  • Page 159 TROUBLESHOOTING TROUBLESHOOTING ITEM DESCRIPTION Poor fuel economy Fuel economy is unsatisfactory. High oil consumption/leakage Oil consumption is excessive. Cooling system concerns Overheating Engine runs at higher than normal temperature/overheats. Cooling system concerns Runs cold Engine does not reach normal operating temperature. Excessive black smoke Excessive black smoke is observed in exhaust gas.
  • Page 160 TROUBLESHOOTING QUICK DIAGNOSIS CHART ZCF408018881W04 Y6E4080W002 F2-131...
  • Page 161 TROUBLESHOOTING ZCF4080W001 F2-132...
  • Page 162 TROUBLESHOOTING ZCF4080W002 F2-133...
  • Page 163 TROUBLESHOOTING NO.1 MELTING OF MAIN OR OTHER FUSES ZCF408018881W05 Melting of main or other fuses [TROUBLESHOOTING HINTS] Inspect condition of fuse. Y6E4080W001 Damaged fuse Related wiring harness MAIN (80 A) MAIN fuse D Generator D Engine switch ENG fuse D Blower relay Blower fan motor D A/C relay...
  • Page 164 TROUBLESHOOTING STEP INSPECTION ACTION D Is clicking sound heard from starter when Go to next step. it h i t d t START? engine switch is turned to START? Go to Step 6. D Do any other electrical accessories work? Go to next step.
  • Page 165 TROUBLESHOOTING STEP INSPECTION ACTION D Does engine start normally after warm-up? Inspect glow plug and glow plug relay. (SeeF2-50 GLOW PLUG INSPECTION) (See Section F2) Replace any malfunctioning part as necessary. If glow system is okay, go to next step. Go to next step.
  • Page 166 TROUBLESHOOTING Diagnostic procedure STEP INSPECTION ACTION Note Both conditions appear: D Following test should be performed on D Go to Step 4. vehicles with immobilizer system. D Go to Step 12 for vehicles without immobilizer system. Either or other condition appear: D Connect WDS or equivalent to DLC.
  • Page 167 TROUBLESHOOTING STEP INSPECTION ACTION D Inspect for following: Go to next step. Fuel quality including water contamination Fuel line restriction Fuel line restriction Service as necessary. Loose bands on intake-air system Repeat Step 12. Cracks on intake-air system parts Intake-air system restriction D Are all items okay? D Is engine overheating? Go to symptom troubleshooting NO.13 COOLING...
  • Page 168 TROUBLESHOOTING STEP INSPECTION ACTION D Depress accelerator pedal slightly. Inspect and adjust idle speed. D Crank engine. (See F2-47 ENGINE TUNE-UP) D Does engine start now? If symptom still appears, go to next step. Go to next step. D Perform FSO solenoid inspection. Go to next step.
  • Page 169 TROUBLESHOOTING NO.5 CRANKS NORMALLY BUT WILL NOT START ZCF408018881W09 Cranks normally but will not start D Starter cranks engine at normal speed but engine will not run. D Refer to No.4 ENGINE STALLS" if this symptom appears after engine stall. DESCRIPTION D Fuel is in tank.
  • Page 170 TROUBLESHOOTING STEP INSPECTION ACTION D Disconnect accelerator position sensor Go to next step. connector connector. Access PCM connector. D Inspect for continuity between GND Inspect for continuity between PCM connector 4A/4B terminal at accelerator position sensor terminals and body GND. vehicle harness connector and body GND.
  • Page 171 TROUBLESHOOTING STEP INSPECTION ACTION D Inspect timing belt for following Inspector for following: Chipping of gear teeth D Burnt valve Low tension D Worn piston, piston ring or cylinder Breakage, damage or cracks D Damaged cylinder head gasket D Is timing belt okay? D Damaged valve seat D Worn valve system or valve guide Repair or replace as necessary.
  • Page 172 TROUBLESHOOTING STEP INSPECTION ACTION D Inspect for air leakage from intake-air Repair or replace as necessary. system components while racing engine to higher speed. Go to next step. D Is there any air leakage? D Remove thermostat and inspect operation. Inspect and adjust idle speed.
  • Page 173 TROUBLESHOOTING STEP INSPECTION ACTION Note Go to next step. D The following test should be performed on the vehicles with A/C system. If the on the vehicles with A/C system. If the following test cannot be performed due A/C is always on: to engine stalls, go to next step.
  • Page 174 TROUBLESHOOTING NO.8 RUNS ON ZCF408018881W12 Runs on DESCRIPTION D Engine runs after engine switch is turned to OFF. POSSIBLE D FSO solenoid malfunction. CAUSE Diagnostic procedure STEP INSPECTION ACTION D Run engine at idle speed. Inspect for following: D Disconnect FSO solenoid connector. D Short to power line between engine switch and FSO D Make sure engine stops.
  • Page 175 TROUBLESHOOTING STEP INSPECTION ACTION D Does symptom disappear after warm-up? Go to next step. Go to Step 6. D Inspect glow plug and glow plug relay. Go to next step. (See F2 50 GLOW PLUG INSPECTION) (See F2-50 GLOW PLUG INSPECTION) Repair or replace any malfunctioning part according to (See Section F2) glow system operation results.
  • Page 176 TROUBLESHOOTING STEP INSPECTION ACTION D Inspect timing belt for following: Inspect for following: Chipping of gear teeth D Burnt valve Low tension D Worn piston, piston ring or cylinder Breakage damage or cracks D Damaged cylinder head gasket D Is timing belt okay? D Damaged valve seat D Worn valve stem and valve guide Repair or replace as necessary.
  • Page 177 TROUBLESHOOTING STEP INSPECTION ACTION D Inspect A/C cut-off operation. Go to next step. D Does A/C cut-off work properly? Inspect A/C cut-off system components. D Inspect air cleaner and/or intake-air Go to next step. system for clogging or restriction. D Are air cleaner and intake-air system Clean or replace as necessary.
  • Page 178 TROUBLESHOOTING STEP INSPECTION ACTION D Is there any restriction in exhaust system? Repair or replace as necessary. Go to next step. D Remove injection nozzle. Go to next step. D Inspect injection nozzle for following: Clogged nozzle Seized needle valve Seized needle valve Repair or replace injection nozzle.
  • Page 179 TROUBLESHOOTING STEP INSPECTION ACTION D Connect WDS or equivalent to DLC. DTC is displayed: D Turn engine switch to ON. Go to appropriate DTC test. D Retrieve any DTC. No DTC is displayed: D Is DTC displayed? Go to next step. D Access ECT PID.
  • Page 180 TROUBLESHOOTING NO.12 HIGH OIL CONSUMPTION/LEAKAGE ZCF408018881W16 High oil consumption/leakage DESCRIPTION D Oil consumption is excessive. D Improper engine oil level D Improper dipstick POSSIBLE D Improper engine oil viscosity CAUSE D Engine internal parts malfunction D Oil leakage D Turbocharger malfunction Diagnostic procedure STEP INSPECTION...
  • Page 181 TROUBLESHOOTING STEP INSPECTION ACTION D Measure engine compression. Inspect oil leakage from outside of engine. D Is compression okay? Inspect for following: D Damaged valve seat D Worn valve stem and valve guide D Worn or stuck piston ring D Worn piston, piston ring or cylinder Service as necessary.
  • Page 182 TROUBLESHOOTING STEP INSPECTION ACTION D Is drive belt okay? Go to next step. Replace drive belt. D Is there any leakage around heater unit in Inspect and service heater for leakage. passenger compartment? Go to next step. D Is there any leakage at coolant hoses Replace malfunctioning parts.
  • Page 183 TROUBLESHOOTING Diagnostic procedure STEP INSPECTION ACTION D Connect WDS or equivalent to DTC. DTC is displayed: D Turn engine switch to ON. D Go to appropriate DTC test. D Retrieve any DTC. No DTC is displayed: D Is DTC displayed? D Go to next step.
  • Page 184 TROUBLESHOOTING STEP INSPECTION ACTION D Is rumble or grind sound present? Inspect drive belt. Go to next step. D Is rattle sound present? Inspect location of rattle for loose parts. Go to next step. D Is hiss sound present? Inspect for vacuum leakage. Go to next step.
  • Page 185 TROUBLESHOOTING STEP INSPECTION ACTION D Is any engine oil found inside turbocharger Wipe oil out of vehicle. compressor housing? Then, go to next step. Go to next step. D Is any exhaust gas leakage found around Remove turbocharger. location where turbocharger is attached to Inspect for cracks on centre housing inlet surface.
  • Page 186 TROUBLESHOOTING Diagnostic procedure STEP INSPECTION ACTION D Connect WDS or equivalent to DLC. DTC is displayed: D Turn engine switch to ON. D Go to appropriate DTC test. D Retrieve any DTC. No DTC is displayed: D Is DTC displayed? D Go to next step.
  • Page 187 TROUBLESHOOTING Diagnostic procedure STEP INSPECTION ACTION D Connect WDS or equivalent to DLC. DTC is displayed: D Turn engine switch to ON. D Go to appropriate DTC test. D Retrieve any DTC. No DTC is displayed: D Is DTC displayed? D Go to next step.
  • Page 188 TROUBLESHOOTING STEP INSPECTION ACTION D Accurately spray water on suspect Fault occurred while spraying on component: component wire, component or vacuum D Replace part and verify repair. line related to possible fault area. Fault occurred while spraying wiring: D Are any PID values out of range, or D Inspect each wire for corrosion, bent or loose suddenly change and go back into range, terminals and poor wire terminal crimps.
  • Page 189 TROUBLESHOOTING STEP INSPECTION ACTION D Turn engine switch to OFF. Replace MAF/IAT sensor. D Leave accelerator position sensor disconnected. D Disconnect MAF/IAT sensor connector. D Turn engine switch to ON. D Measure voltage between following D Measure voltage between following Go to next step.
  • Page 190 MANUAL TRANSMISSION (R15M-D, R15MX-D) FEATURES OUTLINE ....... . . J2-2 OUTLINE OF CONSTRUCTION .
  • Page 191 OUTLINE OUTLINE OUTLINE OF CONSTRUCTION ZCF520201029W01 D The construction and operation of the manual transmission is essentially carried over from that of the current RANGER, except for the following specifications. (See RANGER Training Manual F326 1* 99A.) FEATURES ZCF520201029W02 Improved Emission Performance D The neutral switch has been added to the transmission of WL-3 and WLT-3 engine models.
  • Page 192 OUTLINE, MANUAL TRANSMISSION OUTLINE SUPPLEMENTAL SERVICE INFORMATION ZCF520201029W03 D The following changes and/or additions have been made since publication of the RANGER Repair Manual (F161 1* 99A). Manual transmission D Removal/installation procedure has been modified. MANUAL TRANSMISSION MANUAL TRANSMISSION REMOVAL/INSTALLATION ZCF521001029W01 4x2 (R15M-D) 1.
  • Page 193 MANUAL TRANSMISSION ZCF5210W001 Shift lever knob Vehicle speedometer sensor connector Console Back-up light switch connector Dust boot Neutral switch connector Change boot upper plate Front pipe bracket Boot Clutch release cylinder Dust boot Crossmember See J2-5 Crossmember removal note Gasket Transmission lower mount Wave washer Transmission...
  • Page 194 MANUAL TRANSMISSION Crossmember removal note D Securely support the transmission on a transmission jack, then remove the crossmember. Transmission removal note Warning D Do not allow the transmission to fall from the transmission jack. D Maintain the stability of the transmission while removing it.
  • Page 195 MANUAL TRANSMISSION 4x4 (R15MX-D) 1. Disconnect the negative battery cable. 2. Drain the transmission and transfer oil into a container. 3. Remove the front and rear propeller shaft. 4. Remove the starter. 5. Remove in the order indicated in the table. 6.
  • Page 196 MANUAL TRANSMISSION Neutral switch connector Front pipe bracket Clutch release cylinder Crossmember Transmission lower mount Transmission and transfer See J2-7 Transmission and transfer removal note See J2-7 Transmission and transfer installation note Transmission and transfer removal note Warning D Do not allow the transmission to fall from the transmission jack.
  • Page 197 FRONT AND REAR AXLES FEATURES OUTLINE ........OUTLINE OF CONSTRUCTION .
  • Page 198 OUTLINE OUTLINE OUTLINE OF CONSTRUCTION ZCF630201018W01 D The construction and operation of the front and rear axles for the WL 3 engine model is essentially carried over from that of the current RANGER WL engine model, except the following features. (See RANGER Training Manual F326 10 99A.) D The construction and operation of the front and rear axles for the WLT 3 engine model is the same as that of the current RANGER WL Turbo engine model.
  • Page 199 OUTLINE Specification New Ranger (UN) Current Ranger (UN) Item Item Item Item WL 3 WLT 3 ← Reduction gear Hypoid gear Straight bevel ← Differential gear gear ← Ring gear size (mm {in}) 184 {7.25} 4.444 ( WL Final gear ratio 4.444 Turbo, G6), 4.777 (WL)
  • Page 200 BODY ELECTRICAL SYSTEM FEATURES OUTLINE ........OUTLINE OF CONSTRUCTION .
  • Page 201 OUTLINE, IMMOBILIZER SYSTEM OUTLINE OUTLINE OF CONSTRUCTION ZCF810201088W01 D The construction and operation of the body electrical system is essentially carried over from that of the current RANGER model, except the following features. (See RANGER Training Manual F326-10-99A.) FEATURES ZCF810201088W02 Improved Security D The immobilizer system has been modified.
  • Page 202 IMMOBILIZER SYSTEM STRUCTURAL VIEW ZCF812267000W02 ZCF8122W108 Security light Immobilizer unit Key (transponder) Coil Starter relay...
  • Page 203 IMMOBILIZER SYSTEM SYSTEM WIRING DIAGRAM ZCF812267000W05 YLE8122W002 Security light Engine switch (Start position) Key reminder switch Starter relay Coil Starter Immobilizer unit ROOM 10 A fuse ENGINE 15 A fuse...
  • Page 204 OUTLINE SUPPLEMENTAL SERVICE INFORMATION ZCF810201088W03 D The additions and modifications have been made since publication of the below manuals, as follows. Ford RANGER Repair Manual (F161-10-99A) Relay D Inspection procedure has been added. Immobilizer unit D Inspection procedure has been modified.
  • Page 205 POWER SYSTEM RELAY INSPECTION D If not as specified, replace the relay. ZCF811066191W02 Relay Type Terminal type Parts name Type A Starter relay Four terminal Four-terminal Type B PCM control relay Note Y5A8110W151 D The inspection of theft-deterrent relay has not been changed.
  • Page 206 IMMOBILIZER SYSTEM IMMOBILIZER SYSTEM IMMOBILIZER UNIT INSPECTION ZCF812267003W01 1. Measure the voltage at the immobilizer unit terminals as indicated below. 2. Disconnect the immobilizer unit connector before inspecting for continuity at terminal C. D If not as specified, inspect the parts listed under Action." D If the parts and wiring harnesses are okay but the system still does not work properly, replace the immobilizer unit.
  • Page 207 IMMOBILIZER SYSTEM IMMOBILIZER SYSTEM REPROGRAM PROCEDURE ZCF812267000W03 Note D When an error occurs during the reprogram procedures, except when both the immobilizer unit and PCM are replaced, repeat the procedure from Step 1. If you still cannot reprogram, confirm how many keys can start the engine.
  • Page 208 IMMOBILIZER SYSTEM When the customer has only one or no valid key (code word is required) Y5A8122W103 Note D If no specific time interval is given, each step should be performed within 30 seconds of the previous step. 1. Cut new transponder-equipped key(s). 2.
  • Page 209 IMMOBILIZER SYSTEM 5. Insert key 3 into the new steering lock and hold for 1 second or more. 6. Remove and insert key 3 five times at no more than 1-second intervals. (1) After the final key insertion, verify that the security light illuminates.
  • Page 210 IMMOBILIZER SYSTEM (2) After verifying that the security light goes off, turn the key to the LOCK position and remove from the steering lock. 5. Insert key 3 into the steering lock and turn the key to the ON position. (1) Verify that the security light illuminates for 1 2 seconds.
  • Page 211 IMMOBILIZER SYSTEM PCM Replacement When the customer does not have valid key D Immobilizer unit needs to be replaced with PCM. Perform Both Immobilizer Unit and PCM Replacement" of the IMMOBILIZER SYSTEM REPROGRAM PROCEDURE. (See T-13 Both Immobilizer Unit and PCM Replacement.) When the customer has two or more valid keys Y5A8122W107...
  • Page 212 IMMOBILIZER SYSTEM 4. After verifying that the security light goes off, turn key 1 to the LOCK position. (1) Remove the key from the steering lock and wait for 2 seconds or more. 5. Insert key 2 into the steering lock and wait for 1 second or more. 6.
  • Page 213 IMMOBILIZER SYSTEM CODE WORD INPUT PROCEDURE ZCF812267000W04 Note D A code word is composed of eight digits from 1 9 and is part of the immobilizer unit from the manufacturer. Each unit has its own code word. To obtain the code word, you need to have the immobilizer serial number, then ask the distributor.
  • Page 214 IMMOBILIZER SYSTEM D The engine switch is turned to ON position and LOCK position while the security light is off. ZCF8122W104 D The engine switch is turned to LOCK position and ON position while the security light is on. ZCF8122W105 D The engine switch is turned to LOCK position and ON position while the security light is off.
  • Page 215 ON-BOARD DIAGNOSTIC [IMMOBILIZER SYSTEM] ON-BOARD DIAGNOSTIC [IMMOBILIZER SYSTEM] FOREWORD ZCF817067000W01 Caution D When the engine does not start or stalls and the following DTCs are not indicated, go to engine symptom troubleshooting. Note D If engine condition is normal but light stays on, inspect for short circuit between security light and immobilizer unit connector terminal M.
  • Page 216 ON-BOARD DIAGNOSTIC [IMMOBILIZER SYSTEM] DTC 01 ZCF817067000W03 ID number unregistered in immobilizer unit is input after engine switch is turned to ON position or DTC 01 engine cranking. POSSIBLE D ID number is unregistered in immobilizer unit. CAUSE Diagnostic procedure STEP INSPECTION ACTION...
  • Page 217 ON-BOARD DIAGNOSTIC [IMMOBILIZER SYSTEM] DTC 11 ZCF817067000W06 DTC 11 Coil or wiring harness between immobilizer unit and coil is open circuit. D Open circuit in coil POSSIBLE D Poor connection of coil connector D Poor connection of immobilizer unit CAUSE D Defective wiring harness between immobilizer unit and coil ZCF8170W101 Diagnostic procedure...
  • Page 218 ON-BOARD DIAGNOSTIC [IMMOBILIZER SYSTEM] DTC 21 ZCF817067000W07 DTC 21 Code word/ID number stored in immobilizer unit EEPROM cannot be read. POSSIBLE D Defective immobilizer unit CAUSE Diagnostic procedure STEP INSPECTION ACTION INSPECT IMMOBILIZER UNIT Replace immobilizer unit and reprogram immobilizer D Turn engine switch from LOCK position to system.
  • Page 219 ON-BOARD DIAGNOSTIC [IMMOBILIZER SYSTEM] STEP INSPECTION ACTION INSPECT COMMUNICATION CIRCUIT Replace immobilizer unit and reprogram immobilizer D Connect PCM connector. system. D Turn engine switch to ON position. (See T-11 Immobilizer Unit Replacement) D Measure voltage at immobilizer unit connector terminal A. Note D Is voltage more than 10 V? D Confirm that voltage at immobilizer unit connector...
  • Page 220 TECHNICAL DATA TECHNICAL DATA ......TD-2 ENGINE ....... . . TD-2 FUEL AND EMISSION CONTROL SYSTEMS TD-2 TD-1...
  • Page 221 TECHNICAL DATA TECHNICAL DATA ENGINE ZCF931001001W01 Engine Item Item WL, WL Turbo, WL 3, WLT 3 0.05 0.15 {0.0020 0.0059} (0.10 ± 0.05 {0.0039 ± 0.0020}) 0.15 {0.0059} [Engine hot (Reference)] Valve clearance [Engine cold] Valve clearance [Engine cold] (mm {in}) (mm {in}) 0.15 0.25 {0.0060 0.0098} (0.20 ±...
  • Page 222 SPECIAL TOOLS SPECIAL TOOLS ......ST-2 ENGINE ....... . . ST-2 FUEL AND EMISSION CONTROL SYSTEMS ST-2 ST-1...
  • Page 223 SPECIAL TOOLS SPECIAL TOOLS ENGINE ZCF941001001W01 49 S010 001 49 S011 102A 49 S010 301 Oil seal Crankshaft lock Oil seal installer tool installer TB014001X TS011102A TS010301X FUEL AND EMISSION CONTROL SYSTEMS ZCF941001087W01 TWDS00000 ST-2...
  • Page 224 Numbers (VIN), shown on the following Suspension page. Body Body Electrical System Heater and Air Conditioner Systems Technical Data Special Tools There are explanations given only for the sections marked with shadow ( © 2003 Ford Motor Company PRINTED IN , JANUARY 2003 F183–10–03A...
  • Page 225 VEHICLE IDENTIFICATION NUMBERS (VIN) MNB BS4D40?W 100001 — MNB LS4D40?W 100001 — MNB BS4D70?W 100001 — MNB LS4D70?W 100001 — MNB BSYD40?W 100001 — MNB LSYD40?W 100001 — MNC BS4D40?W 100001 — MNC LS4D40?W 100001 — MNC BS4D70?W 100001 — MNC LS4D70?W 100001 —...
  • Page 226 G ENERAL INFORMATION HOW TO USE THIS MANUAL ......GI-2 RANGE OF TOPICS .......... GI-2 VIN CODE............. GI-2 VIN CODE............GI-2 NEW STANDARDS ..........GI-3 NEW STANDARDS TABLE ....... GI-3 ABBREVIATIONS ..........GI-5 ABBREVIATIONS ..........GI-5 SCHEDULED MAINTENANCE ......GI-6 SCHEDULED MAINTENANCE TABLE .....
  • Page 227 4= New wagon Product source S= Japan Air bag B= Without air bag L= With air bag (Driver & Passenger) World manufacturer indication MNB= FORD (General (R.H.D.), Thailand) MNC= FORD (General (L.H.D.)) MND= FORD (Gulf) AVF2008W001 End Of Sie GI–2...
  • Page 228 NEW STANDARDS NEW STANDARDS NEW STANDARDS TABLE AVF202800020W01 • The following is a comparison of the previous standard and the new standard. New Standard Previous Standard Remark Abbrevi- Abbrevi- Name Name ation ation Accelerator Pedal — Accelerator Pedal Air Cleaner —...
  • Page 229 NEW STANDARDS New Standard Previous Standard Remark Abbrevi- Abbrevi- Name Name ation ation Open Loop — Open Loop — Output Speed Sensor — Vehicle Speed Sensor 1 Oxidation Catalytic Converter — Catalytic Converter Oxygen Sensor — Oxygen Sensor Park/Neutral Position —...
  • Page 230 ABBREVIATIONS ABBREVIATIONS ABBREVIATIONS AVF203000011W01 Antilock brake system Electric load Emergency locking retractor Electronic spark advance High Left hand L.H.D. Left hand drive Limited slip differential LSPV Load sensing proportioning valve Motor Powertrain control module Parameter identification Pressure regulator control Power steering Remote freewheel R.H.D.
  • Page 231 SCHEDULED MAINTENANCE SCHEDULED MAINTENANCE SCHEDULED MAINTENANCE TABLE AVF203400013W01 For General (L.H.D. R.H.D.) Maintenance Interval (Number of months or kilometers (miles), whichever comes first) Months Maintenance Item × × × × 1000 km 90 100 110 120 130 140 150 160 ×...
  • Page 232 • To ensure efficient operation of the engine and all systems related to emission control, the ignition and fuel systems must be serviced regularly. It is strongly recommended that all servicing related to these systems be done by an authorized Ford Dealer.
  • Page 233 • To ensure efficient operation of the engine and all systems related to emission control, the ignition and fuel systems must be serviced regularly. It is strongly recommended that all servicing related to these systems be done by an authorized Ford Dealer.
  • Page 234 F UEL AND EMISSION CONTROL SYSTEMS (G6) NO.10 ENGINE STALLS/QUITS, FEATURES ENGINE RUNS ROUGH, MISSES, BUCK/JERK, HESITATION/STUMBLE, OUTLINE .............. F1-2 SURGES ............F1-35 OUTLINE OF CONSTRUCTION ....... F1-2 NO.11 LACK/LOSS OF FEATURES ............F1-2 POWER-ACCELERATION/CRUISE..... F1-37 SPECIFICATIONS ..........F1-2 NO.12 KNOCKING/ CONTROL SYSTEM WIRING DIAGRAM..
  • Page 235 OUTLINE OUTLINE OUTLINE OF CONSTRUCTION AVF390218881W01 • The fuel and emission control system is essentially carried over those of the current RANGER G6 engine models except for the following features. (See RANGER Training Manual F326-10-99A.) End Of Sie FEATURES AVF390218881W02 Improved Serviceability •...
  • Page 236 OUTLINE CONTROL SYSTEM WIRING DIAGRAM AVF390218881W04 With Immobilizer System CMP SENSOR IMMOBILIZER UNIT FUEL INJECTOR NO. 3 FUEL INJECTOR NO. 1 SENSOR FUEL INJECTOR SENSOR NO. 4 FUEL INJECTOR NO. 2 ECT SENSOR IGNITER IAT SENSOR TP SENSOR RELAY TO INSTRUMENT CLUSTER IAC VALVE A/C SWITCH...
  • Page 237 OUTLINE Without Immobilizer System CMP SENSOR FUEL INJECTOR NO. 3 FUEL INJECTOR NO. 1 FUEL INJECTOR NO. 4 SENSOR FUEL INJECTOR NO. 2 SENSOR ECT SENSOR IGNITER IAT SENSOR RELAY TP SENSOR TO INSTRUMENT CLUSTER IAC VALVE P C M PURGE A/C SWITCH SOLENOID...
  • Page 238 OUTLINE CONTROL SYSTEM DIAGRAM AVF390218881W05 FUEL FILTER (HIGH–PRESSURE) PULSATION DAMPER PURGE SOLENOID VALVE EVAPORATIVE GAS CHECK VALVE (TWO–WAY) CHARCOAL CANISTER PRESSURE REGULATOR ROLLOVER VALVE PRC SOLENOID VALVE FUEL PUMP TP SENSOR, IAT SENSOR CTP SWITCH FUEL FILTER (LOW–PRESSURE) AIR VALVE AIR CLEANER FUEL INJECTOR MAF SENSOR...
  • Page 239 FUEL SYSTEM FUEL SYSTEM FUEL SYSTEM OUTLINE AVF391201006W01 • The fuel system is essentially carried over from that of the current RANGER G6 engine models. (See RANGER Training Manual F161-10-99A.) — The shape of the fuel tank has been changed, accordingly the number of rollover valves has been reduced from 2 to 1.
  • Page 240 CONTROL SYSTEM CONTROL SYSTEM CONTROL SYSTEM OUTLINE AVF394018881W01 • The construction and operation of the EVEREST is essentially carried over from that of the current RANGER, except for the following. — The idle-up speed has been changed. — A PCM compliant with the immobilizer system has been added. End Of Sie CONTROL DEVICES AND CONTROL RELATIONSHIP CHART AVF394018881W02...
  • Page 241 CONTROL SYSTEM End Of Sie BLOCK DIAGRAM AVF394018881W03 MAF SENSOR IAT SENSOR TP SENSOR CMP SENSOR IAC VALVE (IN DISTRIBUTOR) IMMOBILIZER SYSTEM ECT SENSOR ESA CONTROL PURGE SOLENOID VALVE CTP SWITCH FUEL INJECTION CONTROL FUEL INJECTOR NEUTRAL SWITCH FUEL PUMP CONTROL FUEL PUMP RELAY CLUTCH SWITCH PSP SWITCH...
  • Page 242 • The construction and operation of the on-board diagnostic system is essentially carried over from that of the current RANGER G6 engine models, except for the following. (See Ford RANGER Training Manual F326-10- 99A.) (See Ford RANGER Repair Manual F161-10-99A.) —...
  • Page 243 ON-BOARD DIAGNOSTIC PID/DATA MONITOR AND RECORD AVF397018881W03 • The PID/DATA monitoring items for the fuel and emission control system is as shown in the table below. Monitor item table —: Not applicable PID item Definition Unit/Condition PCM terminal ACCS A/C relay ON/OFF ACSW A/C switch...
  • Page 244 OUTLINE, ENGINE TUNE-UP OUTLINE SUPPLEMENTAL SERVICE INFORMATION AVF390218881W06 • The following changes and/or additions have been made since publication of the Ford RANGER Repair Manual (F161-10-99A). Idle-up speed • Inspection procedure has been modified. Fuel tank • Removal/installation procedure has been modified.
  • Page 245 ENGINE TUNE-UP, FUEL SYSTEM Not Using the SSTs (WDS or equivalent) 1. Turn off the electrical loads. 2. Warm up the engine as follows. (1) Start the engine. (2) Maintain the engine speed at approx. 3,000 rpm until the cooling fan starts to operate. (3) Release the accelerator pedal.
  • Page 246 FUEL SYSTEM 7. Complete the “AFTER REPAIR PROCEDURE”. 1.1—2.1 N·m {11—22 kgf·cm, 10—19 in·lbf} 1.1—2.1 N·m {11—22 kgf·cm, 10—19 in·lbf} SEAL RUBBER 7.9—10.7 N·m {80—110 kgf·cm, 70—94 in·lbf} 2.5—4.6 N·m {25—47 kgf·cm, 22—40 in·lbf} 11.8—16.6 N·m {120—170 kgf·cm, 105—147 in·lbf} 2.5—3.5 N·m {25—36 kgf·cm, 22—26 in·lbf}...
  • Page 247 FUEL SYSTEM Evaporative Gas Check valve (Two-way) Installation Note 1. Install the arrow mark of the evaporative gas check valve (two-way) facing the charcoal canister. CHARCOAL FUEL TANK CANISTER SIDE SIDE AVF3912W001 Evaporative Hose, Breather Hose Installation Note 1. Fit the breather hose onto the respective fittings, and install clamps as shown.
  • Page 248 CONTROL SYSTEM CONTROL SYSTEM PCM INSPECTION AVF394018880W01 Caution • • • • The PCM terminal voltages vary with change in measuring conditions and vehicle conditions. Always carry out a total inspection of the input systems, output systems, and PCM determine the cause of trouble.
  • Page 249 CONTROL SYSTEM Monitor item Unit/ Condition/Specification Inspection item(s) (definition) Condition (Reference) terminal Inspect the following monitor items: Ignition switch ON: OFF — RPM FP (Fuel pump relay) ON/OFF Idle: ON — CMP sensor Cranking: ON Fuel pump relay Ignition switch on: OFF Inspect the following monitor items: FPRC ON/OFF...
  • Page 250 CONTROL SYSTEM Using Voltmeter (Not Using SSTs (WDS or equivalent)) 1. Remove the PCM. 2. Reconnect the PCM connector and battery negative terminal. Note • With the PCM connector connected, GND the voltmeter negative (–) lead and measure voltage at each PCM terminal by inserting the voltmeter positive (+) lead.
  • Page 251 CONTROL SYSTEM Voltage Terminal Signal Connected to Test condition Inspection item(s) Below 1.0 Vehicle stopped Approx. • VSS Vehicle speed • Related harness Approx. Vehicle running Accelerator pedal Ignition switch • CTP switch depressed CTP switch • Related harness Accelerator Below 1.0 pedal released Brake pedal depressed...
  • Page 252 CONTROL SYSTEM Voltage Terminal Signal Connected to Test condition Inspection item(s) Ignition switch ON 0.55 Engine cold 0.0—1.0 Idle • O2S 0.0—1.0 • Related harness Acceleration After warm up 0.5—1.0 Deceleration 0.0—0.5 Ignition switch ON 1.45 Idle (after warm up) 2.15 •...
  • Page 253 ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC DTC TABLE AVF397018881W05 DTC No. Condition Page P0100 MAF circuit malfunction – P0115 ECT circuit malfunction – P0120 TP sensor circuit malfunction – P0134 HO2S circuit no activity detected – P0340 CMP sensor circuit malfunction – P0443 Evaporative emission solenoid system purge control valve circuit malfunction –...
  • Page 254 ON-BOARD DIAGNOSTIC DTC P1602 AVF397001083W01 DTC P1602 Immobilizer unit-PCM communication error DETECTION • Command transmission from the PCM to the immobilizer unit exceed the limit. CONDITION • No response from the immobilizer unit • Immobilizer unit malfunction • Coil (immobilizer system) malfunction •...
  • Page 255 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT GND CIRCUIT OF IMMOBILIZER UNIT Yes Go to the next step. FOR OPEN CIRCUIT Repair or replace the wiring harness, then go to Step 19. • Measure the resistance between the immobilizer unit terminal B (wiring harness- side) and body GND.
  • Page 256 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT IMMOBILIZER UNIT CONNECTOR Yes Repair or replace the wiring harness, then go to the next step. FOR POOR CONNECTION • Turn the ignition switch to the OFF position. Go to the next step. • Disconnect the immobilizer unit connector. •...
  • Page 257 ON-BOARD DIAGNOSTIC End Of Sie DTC P1604 AVF397001083W03 DTC P1604 Code word unregistered in PCM DETECTION • The code word unregistered in PCM. CONDITION POSSIBLE • The immobilizer system reprogram procedure (code word) was not performed after replacing the PCM. CAUSE Diagnostic procedure STEP...
  • Page 258 ON-BOARD DIAGNOSTIC DTC P1622 AVF397001083W05 DTC P1622 Key ID number mismatch DETECTION • The ID numbers stored in the immobilizer unit (IU) and the PCM do not match. This DTC is indicated only CONDITION after the immobilizer unit is replaced and the system is reprogrammed. POSSIBLE •...
  • Page 259 ON-BOARD DIAGNOSTIC DTC P1624 AVF397001083W07 DTC P1624 Immobilizer system communication counter = 0 DETECTION • The PCM detected immobilizer system communication malfunction more than three times CONDITION POSSIBLE • Try to start the engine more than three times under the malfunction condition. CAUSE •...
  • Page 260 TROUBLESHOOTING TROUBLESHOOTING SYMPTOM QUICK DIAGNOSIS CHART AVF398018881W01 X : Applicable Posslble factor Troubleshooting item Melting of main or other fuses Will not crank Hard to start/long crank/erratic start/erratic crank After start/at idle Engine stalls. Cranks normally but will not start Slow return to idle Engine runs rough/rolling idle Fast idle/runs on...
  • Page 261 TROUBLESHOOTING NO.4 ENGINE STALLS-AFTER START/AT IDLE AVF398018881W02 ENGINE STALLS-AFTER START/AT IDLE DESCRIPTION • Engine stops unexpectedly at idle and/or after start. • A/C system operation is improper • Air leakage from intake-air system parts • Purge solenoid valve malfunction • Improper operation of IAC valve •...
  • Page 262 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Connect WDS or equivalent to DLC and retrieve Go to appropriate DTC test. DTC. Go to next step. Is any of following DTC displayed? • DTC: P1602, P1603, P1604, P1621, P1622, P1624 Disconnect throttle position sensor connector. Go to next step.
  • Page 263 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Is strong blue spark visible at each disconnected Go to next step. high-tension lead while cranking engine? If symptom occurs with A/C ON, go to Step 25. Inspect for following: • Open or short circuit in ignition coil •...
  • Page 264 TROUBLESHOOTING NO.5 CRANDS NORMALLY BUT WILL NOT START AVF398018881W03 CRANKS NORMALLY BUT WILL NOT START • Starter cranks engine at normal speed but engine will not run. • Refer to “Engine stalls” if this symptom appears after engine stall. DESCRIPTION •...
  • Page 265 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Turn ignition switch to OFF. Reconnect immobilizer unit connector. Disconnect immobilizer unit connector. Go to next step. Connect jumper wire between immobilizer unit Inspect for open circuit between immobilizer unit connector terminal M and GND. connector terminal M and instrument cluster.
  • Page 266 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Connect WDS or equivalent to DLC Go to next step. Access RPM PID. Inspect for following: Is RPM PID indicating engine speed when • Open or short circuit in CMP sensor cranking engine? • Open or short circuit between CMP sensor and PCM terminal 2E •...
  • Page 267 TROUBLESHOOTING End Of Sie NO.9 LOW IDLE/STALLS DURING DECELERATION AVF398018881W04 LOW IDLE/STALLS DURING DECELERATION DESCRIPTION • Engine stops unexpectedly at beginning of deceleration or recovery from deceleration. • Vacuum leakage • IAC valve malfunction • Air leakage from intake-air system POSSIBLE CAUSE •...
  • Page 268 TROUBLESHOOTING NO.10 ENGINE STALLS/QUITS, ENGINE RUNS ROUGH, MISSES, BUCK/JERK, HESITATION/STUMBLE, SURGES AVF398018881W05 ENGINE STALLS/QUITS-ACCELERATION/CRUISE ENGINE RUNS ROUGH-ACCELERATION/CRUISE MISSES-ACCELERATION/CRUISE BUCK/JERK-ACCELERATION/CRUISE/DECELERATION HESITATION/STUMBLE-ACCELERATION SURGES-ACCELERATION/CRUISE • Engine stops unexpectedly at beginning of acceleration or during acceleration. • Engine stops unexpectedly while cruising. • Engine speed fluctuates during acceleration or cruising. DESCRIPTION •...
  • Page 269 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Connect WDS or equivalent WDS or equivalent No DTC displayed: to DLC. Go to next step. Turn ignition switch ON. DTC displayed: Retrieve any DTC. Go to appropriate DTC test. Is DTC displayed? • Proper routing and no damage of vacuum lines •...
  • Page 270 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Install vacuum gauge to intake manifold. Go to next step. Start engine. Connect vacuum hose to pressure regulator. Does fuel pressure gauge reading increase as Start engine. vacuum gauge reading decreases and/or does Verify that fuel pressure gauge reading changes as fuel pressure gauge reading decrease as vacuum changes.
  • Page 271 TROUBLESHOOTING Diagnostic procedure STEP INSPECTION RESULTS ACTION Verify following: Go to next step. • Vacuum connection Service if necessary. • Air cleaner element Repeat Step 1. • No air leakage from intake-air system • No restriction of intake-air system • Proper sealing of intake manifold and components attached to intake manifold (e.g.
  • Page 272 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Note Go to next step. • Following test is for engine stalling with A/ If A/C is always ON, go to symptom troubleshooting C ON concern. If other symptoms exist, "No.23 A/C is always ON or A/C compressor runs go to next step.
  • Page 273 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Install fuel pressure gauge between fuel main Go to next step. pipe and fuel distributor. Zero or low: Start engine and run it at idle. Inspect fuel pump circuit. Measure fuel line pressure at idle. Inspect for open fuel pump relief valve.
  • Page 274 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Is strong blue spark visible at each disconnected Inspect for following: high-tension lead while cranking engine? • Spark plugs malfunction Repair or replace malfunctioning parts. If okay, go to next step. Inspect following: • High-tension leads •...
  • Page 275 TROUBLESHOOTING Diagnostic procedure STEP INSPECTION RESULTS ACTION Inspect for following: Go to next step. • Vacuum lines for leakage or blockage Service if necessary. • Electrical connections Repeat Step 1. • Proper maintenance schedule followed • Intake-air system and air cleaner element concerns: obstructions, leakage or dirtiness Are all items okay? Connect WDS or equivalent to DLC.
  • Page 276 TROUBLESHOOTING NO.15 HIGH OIL CONSUMPTION/LEAKAGE AVF398018881W10 HIGH OIL CONSUMPTION/LEAKAGE DESCRIPTION Oil consumption is excessive. • PCV valve malfunction • Improper dipstick POSSIBLE CAUSE • Improper engine oil viscosity • Engine internal parts malfunction Diagnostic procedure STEP INSPECTION RESULTS ACTION Remove and shake PCV valve. Go to next step.
  • Page 277 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Connect WDS or equivalent to DLC. Go to next step. Access ACSW PID ON WDS or equivalent. Inspect following: Start engine and run it at idle speed. • Refrigerant pressure switch operation Turn A/C switch ON. •...
  • Page 278 TROUBLESHOOTING NO.18 EXHAUST SMOKE AVF398018881W13 EXHAUST SMOKE DESCRIPTION Blue, black, or white smoke from exhaust system Blue smoke (Burning oil): • PCV valve malfunction • Engine internal oil leakage White smoke (Water in combustion): • Cooling system (coolant loss) malfunction •...
  • Page 279 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Install fuel pressure gauge between fuel main Go to next step. pipe and fuel distributor. Zero or low: Start engine and run it at idle. • Inspect fuel pump circuit. Measure fuel line pressure at idle. •...
  • Page 280 TROUBLESHOOTING NO.20 ENGINE NOISE AVF398018881W15 ENGINE NOISE DESCRIPTION Engine noise from under hood Squeal, click or chirp noise: • Improper engine oil level • Improper drive belt tension Rattle sound noise: • Loose parts Hiss sound noise: • Vacuum leakage POSSIBLE CAUSE •...
  • Page 281 TROUBLESHOOTING NO.22 A/C DOES NOT WORK SUFFICIENTLY AVF398018881W17 A/C DOES NOT WORK SUFFICIENTLY. DESCRIPTION A/C compressor magnetic clutch does not engage when A/C switch is turned ON. • Improper refrigerant charging amount • Open A/C magnetic clutch • Open circuit between A/C relay and A/C magnetic clutch •...
  • Page 282 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Start engine and run it at idle. Inspect for following: Turn A/C switch ON. • A/C relay is stuck closed. Remove A/C relay. • Short to GND circuit between A/C relay and PCM Does A/C magnetic clutch disengage? terminal 1J If both items are okay, go to next step.
  • Page 283 TROUBLESHOOTING NO.25 EXHAUST SULPHUR SMELL AVF398018881W20 EXHAUST SULPHUR SMELL DESCRIPTION Rotten egg smell (sulphur) from exhaust • Electrical connectors are disconnected or connected poorly • Charcoal canister malfunction • Vacuum lines are disconnected or connected improperly. • Improper fuel pressure Warning The following troubleshooting flow chart contains fuel system diagnosis and repair POSSIBLE CAUSE...
  • Page 284 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Connect WDS or equivalent to DLC. Inspect each wire for corrosion, bent or loose terminal If input is switch-type component, turn ON crimps. manually. Go to next step. Turn ignition switch ON. Access PIDs for suspect component. Lightly tap on suspect component, wiggle and pull each wire/connector at suspect component or PCM.
  • Page 285 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Turn ignition switch to OFF. Go to next step. Disconnect TP sensor and variable resistor Repair open circuit between PCM terminal 1B and connector disconnected main relay. Disconnect PCM connector. Turn ignition switch to ON. Measure voltage between PCM connector terminals 1B and 2B.
  • Page 286 TROUBLESHOOTING DIAGNOSTIC INSPECTION AVF398018881W23 Spark Plug Condition Inspection Purpose 1. Inspecting spark plugs condition can determine whether problem is related to a specific cylinder or to all cylinders. Procedure 1. Remove the spark plug. 2. Inspect spark plug condition. 3. Go to appropriate troubleshooting chart for further information. Spark plug condition Troubleshooting chart Specific plug is wet or covered with carbon.
  • Page 287 TROUBLESHOOTING NO.2 GRAYISH WHITE WHTH SPECIFIC PLUG AVF398018881W25 Grayish white with specific plug • Air /fuel mixture—Insufficient fuel injection volume POSSIBLE CAUSE • Faulty spark plug Diagnostic procedure STEP INSPECTION RESULTS ACTION Inspect spark plug for following: Go to next step. •...
  • Page 288 TROUBLESHOOTING NO.4 GRAYISH WHITE WITH ALL PLUGS AVF398018881W27 Grayish white with all plugs • Air/fuel mixture—Too lean Warning The following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system services: POSSIBLE CAUSE •...
  • Page 290 F UEL AND EMISSION CONTROL SYSTEMS (WL) NO.13 COOLING SYSTEM FEATURES CONCERNS - OVERHEATING ....F2-31 NO.14 COOLING SYSTEM OUTLINE .............. F2-2 CONCERNS - RUNS COLD ......F2-31 OUTLINE OF CONSTRUCTION ....... F2-2 NO.15 EXCESSIVE BLACK SMOKE....F2-32 FEATURES ............F2-2 NO.16 ENGINE NOISE........
  • Page 291 OUTLINE OUTLINE OUTLINE OF CONSTRUCTION AVF400218881W01 • The fuel and emission control system is essentially carried over those of the current RANGER WL Turbo models, except for the following features. (See RANGER Training Manual F326-10-99A, RANGER Repair Manual Supplement F172-10-00J, RANGER Repair Manual Supplement F176-10-01H.) End Of Sie FEATURES AVF400218881W02...
  • Page 292 INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM OUTLINE AVF401001005W01 • The construction and operation of the intake-air system of the EVEREST models is essentially carried over from that of the current RANGER WL Turbo models, except for following. (See RANGER Training Manual F326- 10-99A.) —...
  • Page 293 INTAKE-AIR SYSTEM, FUEL SYSTEM FRESH-AIR DUCT AVF401001005W03 Function • A resonance chamber has been adopted to reduce air intake noise at low engine speeds. FRESH-AIR DUCT RESONANCE CHAMBER AVF4010W005 End Of Sie FUEL SYSTEM OUTLINE AVF401201006W01 • The fuel system is essentially carried over from that of the current RANGER WL Turbo models, except for following.
  • Page 294 EXHAUST SYSTEM EXHAUST SYSTEM OUTLINE AVF401440000W01 • The exhaust system is essentially carried over from that of the current RANGER WL Turbo models, except for following. (See RANGER Training Manual F326-10-99A, RANGER Repair Manual Supplement F172-10-00J.) — An after silencer has been adopted to reduce noise. End Of Sie STRUCTURAL VIEW AVF401440000W02...
  • Page 295 OUTLINE, ENGINE TUNE-UP OUTLINE SUPPLEMENTAL SERVICE INFORMATION AVF400218881W04 • The following changes and/or additions have been made since publication of the RANGER Repair Manual (F161-10-99A), RANGER Repair Manual Supplement (F172-10-00J), and RANGER Repair Manual Supplement (F176-10-01H). Idle-up speed • Adjustment procedure has been modified. Intake-air system •...
  • Page 296 INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM REMOVAL/INSTALLATION AVF401013000W01 Warning • • • • Hot engines and intake-air system can cause severe burns. Turn off the engine and wait until it and the intake-air system have cooled before removing or installing the intake-air system. 1.
  • Page 297 INTAKE-AIR SYSTEM Step 2 19—25 {1.9—2.6, 14—18} 7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf} 19—25 {1.9—2.6, 14—18} 19—25 {1.9—2.6, 14—18} 19—25 {1.9—2.6, 14—18} N·m {kgf·m, ft·lbf} AVF4010W003 FICD solenoid valve No.1 FICD solenoid valve bracket FICD solenoid valve No.2 Air intake pipe EGR solenoid valve Intake manifold End Of Sie...
  • Page 298 FUEL SYSTEM FUEL SYSTEM FUEL TANK REMOVAL/INSTALLATION AVF401242110W01 Warning • • • • Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it. 1.
  • Page 299 FUEL SYSTEM Evaporative Hose, Breather Hose Installation Note 1. Fit the breather hose onto the respective fittings, and install clamps as shown. 10 mm {0.39 in} 10 mm {0.39 in} BREATHER HOSE EVAPORATIVE HOSE AVF3912W002 Joint Hose Installation Note 1. Fit the joint hose onto the respective fittings, and 20 mm install clamps as shown.
  • Page 300 EXHAUST SYSTEM EXHAUST SYSTEM EXHAUST SYSTEM REMOVAL/INSTALLATION AVF401440000W03 Warning • • • • When the engine and exhaust system are hot, they can badly burn. Turn off the engine and wait until they are cool before removing the exhaust system. 1.
  • Page 301 EXHAUST SYSTEM Turbocharger Removal Note Caution • • • • Do not drop the turbocharger. • • • • Do not bend the wastegate actuator mounting or rod. 1. Cover the intake, exhaust, and oil passages to prevent dirt other objects from entering. Oil Pipe Installation Note 1.
  • Page 302 TROUBLESHOOTING TROUBLESHOOTING FOREWORD AVF408018881W01 Before processing with the following troubleshooting, refer to Section GI to understand the basic troubleshooting procedure. End Of Sie SYMPTOM TROUBLESHOOTING AVF408018881W02 • Confirm trouble symptom using the following diagnostic index, then go to appropriate troubleshooting chart. •...
  • Page 303 TROUBLESHOOTING SYMPTOM QUICK DIAGNOSIS CHART AVF408018881W03 X : Applicable Posslble factor Troubleshooting item Melting of main or other fuses Will not crank Hard to start/long crank/erratic start/erratic crank Engine stalls. After start/at idle Cranks normally but will not start Slow return to idle Engine runs rough/rolling idle Runs on Engine stalls/quits.
  • Page 304 TROUBLESHOOTING X : Applicable Possible factor Troubleshooting item Melting of main or other fuses Will not crank Hard to start/long crank/erratic start/erratic crank After start/at idle Engine stalls. Cranks normally but will not start Slow return to idle Engine runs rough/rolling idle Runs on Engine stalls/quits.
  • Page 305 TROUBLESHOOTING X : Applicable Possible factor Troubleshooting item Melting of main or other fuses Will not crank Hard to start/long crank/erratic start/erratic crank After start/at idle Engine stalls. Cranks normally but will not start Slow return to idle Engine runs rough/rolling idle Runs on Engine stalls/quits.
  • Page 306 TROUBLESHOOTING NO.1 MELTS MAIN OR OTHER FUSE AVF408018881W04 MELTS MAIN OR OTHER FUSE [TROUBLESHOOTING HINTS] Inspect condition of fuse. Damaged Fuse Related Wiring Harness MAIN Main fuse • Engine switch • Generator • PCM Blower relay • Blower fan motor A/C relay •...
  • Page 307 TROUBLESHOOTING NO.2 WILL NOT CRANK AVF408018881W05 WILL NOT CRANK DESCRIPTION • Starter does not work. • Open starter circuit between battery and starter through engine switch POSSIBLE CAUSE • Starter malfunction • Seized/hydrolocked engine, flywheel Diagnostic procedure STEP INSPECTION ACTION Verify the following: Go to next step.
  • Page 308 TROUBLESHOOTING NO.3 HARD START/LONG CRANK/ERRATIC START/ERRATIC CRANK AVF408018881W06 HARD START/LONG CRANK/ERRATIC START/ERRATIC CRANK • Starter cranks engine at normal speed but engine requires excessive cranking. DESCRIPTION • Battery is in normal condition. • Poor fuel quality • Starting system malfunction •...
  • Page 309 TROUBLESHOOTING NO.4 ENGINE STALLS - AFTER START/AT IDLE AVF408018881W07 ENGINE STALLS - AFTER START/AT IDLE DESCRIPTION • Engine stops unexpectedly at idle and/or after start. • Poor fuel quality • Starting system malfunction • Air cleaner restriction • Incorrect idle speed •...
  • Page 310 TROUBLESHOOTING STEP INSPECTION ACTION Depress accelerator pedal slightly. Inspect and adjust idle speed. Crank the engine. If symptom still appears, go to next step. Does engine start now? Go to next step. Inspect fuel leakage from fuel pipe. Repair or replace if necessary. Is any fuel leakage found on fuel pipe? Go to next step.
  • Page 311 TROUBLESHOOTING NO.5 CRANKS NORMALLY BUT WILL NOT START AVF408018881W08 CRANKS NORMALLY BUT WILL NOT START • Starter cranks engine at normal speed but engine will not run • Refer to “ENGINE STALLS” if this symptom appears after engine stall DESCRIPTION •...
  • Page 312 TROUBLESHOOTING End Of Sie NO.6 SLOW RETURN TO IDLE/FAST IDLE AVF408018881W09 SLOW RETURN TO IDLE/FAST IDLE • Engine takes more time than normal to return to idle speed DESCRIPTION • Engine speed continues at fast idle after warm-up • Malfunction of ECT sensor •...
  • Page 313 TROUBLESHOOTING STEP INSPECTION ACTION Does engine run normally after warm-up? Go to next step. Go to Step 5. Inspect glow system operation. Go to Step 6. Is glow system operation normal? Repair or replace any defective part according to glow system operation results.
  • Page 314 TROUBLESHOOTING NO.8 RUNS ON AVF408018881W11 RUNS ON DESCRIPTION • Engine runs after engine switch is turned off POSSIBLE CAUSE • Fuel cut valve (FCV) malfunction Diagnostic procedure STEP INSPECTION ACTION Run the engine at idle speed. Inspect for the following: Disconnect the FCV connector.
  • Page 315 TROUBLESHOOTING STEP INSPECTION ACTION Inspect air cleaner for clogging. Go to next step. Is air cleaner okay? Clean or replace air cleaner element. Note Retighten the hose band. If the concern is resolved, complete the inspection. • The following test should be performed on If the concern still exits, go to next step.
  • Page 316 TROUBLESHOOTING NO.10 LACK/LOSS OF POWER - ACCELERATION/CRUISE AVF408018881W13 LACK/LOSS OF POWER - ACCELERATION/CRUISE DESCRIPTION • Performance is poor under load (i.e. power down when climbing hills) • Poor fuel quality • Starting system malfunction • Air leaks from intake-air system •...
  • Page 317 TROUBLESHOOTING STEP INSPECTION ACTION Inspect if the turbocharger turbine wheel is Replace the turbocharger. damaged, cracked, or interfering with the Go to next step. housing on the vehicles. Note • Inspect all fins on each turbine wheel. Is there any problem? Is any engine oil found inside the turbocharger If an excessive engine oil is found on the vehicle, turbine housing?
  • Page 318 TROUBLESHOOTING NO.11 POOR FUEL ECONOMY AVF408018881W14 POOR FUEL ECONOMY DESCRIPTION • Fuel economy is unsatisfactory • Idle speed or idle-up speed incorrect adjustment • Accelerator cable free play incorrect adjustment • Air cleaner restriction • Engine cooling system malfunction • Improper transmission fluid level •...
  • Page 319 TROUBLESHOOTING STEP INSPECTION ACTION Inspect timing belt for the following: Inspect for the following: • Chipping of gear teeth • Burnt valve • Low tension • Worn piston, piston ring, or cylinder • Breakage, damage, or cracks • Damaged cylinder head gasket Is timing belt okay? •...
  • Page 320 TROUBLESHOOTING STEP INSPECTION ACTION Is any engine oil found around oil pipes attached If the oil leaked from the damaged pipe, replace the oil on the turbocharger center housing? pipe. Then, go to next step. Go to next step. Is any engine oil found inside the air intake pipes Wipe the engine oil out.
  • Page 321 TROUBLESHOOTING NO.15 EXCESSIVE BLACK SMOKE AVF408018881W18 EXCESSIVE BLACK SMOKE DESCRIPTION • Excessive black smoke is observed in exhaust gas • Air cleaner element restriction • Incorrect fuel injection timing • Injection nozzle malfunction POSSIBLE CAUSE • Injection pump malfunction • Low engine compression •...
  • Page 322 TROUBLESHOOTING Diagnostic procedure STEP INSPECTION ACTION Note Replace the turbocharger. • The following test should be performed on Go to next step. turbocharger equipped model. For other models, go to Step 9. Remove the parts necessary to inspect the turbocharger. Do not remove the turbocharger. Inspect if the turbocharger primary compressor wheel is bent, damaged, or interfering with the housing on the vehicle.
  • Page 323 TROUBLESHOOTING STEP INSPECTION ACTION Note Go to next step. • The following test should be performed on Repair or replace if necessary. vehicles with EGR system. Go to next step for vehicles without EGR system. Carry out the EGR system inspection. Is EGR system okay? Remove injection nozzle.
  • Page 324 TROUBLESHOOTING Diagnostic procedure STEP INSPECTION ACTION Turn engine switch on. Go to next step. Set the fan switch to 1st, 2nd, 3rd, or 4th Inspect for the following: position. • Poor ground of fan switch Verify the blower motor is operating. •...
  • Page 325 TROUBLESHOOTING NO.19 A/C ALWAYS ON / A/C COMPRESSOR RUNS CONTINUOUSLY AVF408018881W22 A/C ALWAYS ON / A/C COMPRESSOR RUNS CONTINUOUSLY DESCRIPTION • A/C compressor magnetic clutch does not disengage • Improper magnetic clutch clearance • Short to ground circuit between PCM and thermostat •...
  • Page 326 TROUBLESHOOTING STEP INSPECTION ACTION Accurately spray water on suspect Fault area is identified. component wire, component, or vacuum line If fault occurred while spraying on component: related to possible fault area. Replace part and verify repair. Is any voltage out of range, or suddenly If fault occurred while spraying water: change and go back into range, or was there Inspect each wire for corrosion,...
  • Page 328 P ROPELLER SHAFT FEATURES OUTLINE ..............L-2 OUTLINE OF CONSTRUCTION......L-2 SPECIFICATIONS ..........L-2 SERVICE OUTLINE ..............L-2 SUPPLEMENTAL SERVICE INFORMATION ..L-2 PROPELLER SHAFT ..........L-3 PROPELLER SHAFT (4X2) REMOVAL/INSTALLATION ......L-3 REAR PROPELLER SHAFT (4X4) REMOVAL/INSTALLATION ......L-4 L–1...
  • Page 329 OUTLINE OUTLINE OUTLINE OF CONSTRUCTION AVF610225002W01 • With the adoption of a dynamic damper for WL (4x2), WL (4x4), G6 (4x2) and G6 (4x4) models, vibration and noise have been reduced. • The construction and service procedures are essentially carried over from the current RANGER model (See RANGER Repair Manual F161-10-99A, RANGER Training Manual F326-10-99A.), but some specifications are revised.
  • Page 330 PROPELLER SHAFT PROPELLER SHAFT PROPELLER SHAFT (4X2) REMOVAL/INSTALLATION AVF611025002W05 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. Bolt, nut 50—58 (See L–4 Nut Installation Note) {5.0—6.0, 37—43} Propeller shaft (See L–3 Propeller Shaft Removal Note) (See L–3 Propeller Shaft Installation Note) Dynamic damper 37—52 {3.7—5.4, 27—39}...
  • Page 331 PROPELLER SHAFT Nut Installation Note 1. Tighten the center bearing installation nuts with the vehicle *unloaded. *unloaded: • Fuel tank is full. • Engine coolant and engine oil are at specified levels. • Jack and tools are in designated position. End Of Sie REAR PROPELLER SHAFT (4X4) REMOVAL/INSTALLATION AVF611025002W06...
  • Page 332 F RONT AND REAR AXLES FEATURES OUTLINE ............... M-2 OUTLINE OF CONSTRUCTION......M-2 FEATURES ............M-2 SPECIFICATIONS ..........M-2 CROSS SECTIONAL VIEW........ M-3 SERVICE OUTLINE ............... M-4 SUPPLEMENTAL SERVICE INFORMATION ..M-4 FRONT AXLE ............M-4 WHEEL HUB, STEERING KNUCKLE (4×2) PRE-INSPECTION...........
  • Page 333 OUTLINE OUTLINE OUTLINE OF CONSTRUCTION AVF630201018W01 • The construction and operation of the front and rear axles is essentially carried over from that of the current RANGER, except for the following features. (See RANGER Training Manual.) (See RANGER Repair Manual Supplement F165-10-99J.) (See RANGER Repair Manual Supplement F166-10-00G.) (See RANGER Repair Manual Supplement F172-10-00J.) (See RANGER Training Manual F326-10-99A.) (See RANGER Repair Manual Supplement F179-10-02D.) (See RANGER Repair Manual Supplement F182-10-02I.)
  • Page 334 OUTLINE Specification Item EVEREST Current RANGER Freewheel type — — Reduction gear Hypoid gear Hypoid gear Straight bevel Straight bevel Differential gear gear gear Ring gear size (mm {in}) 184 {7.25} 184 {7.25} Final gear ratio 4.444 4.444 Grade API service GL-5 API service GL-5 Front —...
  • Page 335 OUTLINE, FRONT AXLE OUTLINE SUPPLEMENTAL SERVICE INFORMATION AVF630201018W05 • The following changes and/or additions have been made since publication of the below manuals. — RANGER Repair Manual — RANGER Repair Manual (F161-10-99A) — RANGER Repair Manual Supplement (F179-10-02D) — RANGER Repair Manual Supplement (F182-10-02I) Wheel hub, steering knuckle (4x2) •...
  • Page 336 FRONT AXLE 24.5—36.2 {2.5—3.6, 18.1—26.6} 19—25 {1.9—2.6, 14—18} 108—127 {11.1—12.9, 79.7—93.6} 29.4—51 {3.0—5.2, 22—50} 19—25 {1.9—2.6, 14—18} 235—314 {24.0—32.0, 54.9—80.4 174—231} {5.60—8.19, 40.5—59.3} 45—58 {4.5—6.0, 117.6—156.8 33—43} 54.9—67.6 {12.00—15.98, {5.6—6.8, 40.5—49.8} 86.74—115.6} 88.2—117.6 {9.00—11.99, 65.06—86.73} WHEEL BEARING SIDE N·m {kgf·m, ft·lbf} AVF6312W011 ABS wheel-speed sensor Wheel hub, steering knuckle, dust cover...
  • Page 337 FRONT AXLE Locknut Removal Note Note • Remove the locknut with the vehicle on level ground. 1. Knock the crimped portion of the locknut outward using a small chisel and a hammer. AVF6312W051 2. Remove the locknut. AVF6312W052 Brake Caliper Component Removal Note 1.
  • Page 338 FRONT AXLE Wheel Hub Component Removal Note 1. Remove the wheel hub component using the SSTs and a press. 49 G033 102 49 F026 103 AVF6312W004 2. If the bearing inner race remains on the front wheel hub component, grind a section of the bearing inner race until approx.
  • Page 339 FRONT AXLE 2. Remove the dust cover using a chisel. ABR6312W009 Hub Bolt Removal Note Note • The hub bolts do not need to be removed unless they are being replaced. 1. Remove the hub bolts using a press. AVF6312W006 Hub Bolt Installation Note 1.
  • Page 340 FRONT AXLE 3. Install the new dust cover using the SSTs and a press. 49 S011 103 49 D026 102 ABR6312W011 Wheel Bearing Installation Note 1. Install the new wheel bearing using the SSTs and a press. 49 S033 107 49 G030 797 49 D026 102 ABR6312W012...
  • Page 341 FRONT AXLE WHEEL HUB BOLT (4× × × × 2) REPLACEMENT AVF631233060W01 1. Remove the hub bolt using the SSTs. 2. Install the hub bolt into the wheel hub and install a washer and hub nut on the hub bolt. 49 T028 305 49 T028 303 AVF6312W010...
  • Page 342 B RAKING SYSTEM FEATURES OUTLINE ..............P-2 OUTLINE OF CONSTRUCTION......P-2 FEATURES ............P-2 SPECIFICATIONS ..........P-2 SERVICE OUTLINE ..............P-3 SUPPLEMENTAL SERVICE INFORMATION ..P-3 CONVENTIONAL BRAKE SYSTEM ...... P-4 POWER BRAKE UNIT INSPECTION ....P-4 LOAD SENSING PROPORTIONING VALVE (LSPV) INSPECTION (4×2)....
  • Page 343 OUTLINE OUTLINE OUTLINE OF CONSTRUCTION AVF690201020W01 • The construction and operation of the braking system is essentially carried over from that of the current RANGER, except for the following features. (See RANGER Training Manual F326-10-99A.) (See RANGER Repair Manual Supplement F179-10-02D.) (See RANGER Repair Manual Supplement F182-10-02I.) End Of Sie FEATURES AVF690201020W02...
  • Page 344 OUTLINE Specification Item EVEREST Current RANGER Vacuum multiplier Thailand specs. without ABS: Type Tandem diaphragm Tandem diaphragm Single diaphragm Tandem diaphragm Except above: Tandem diaphragm Power G6 engine except L.H.D. with G6 brake unit Thailand specs. Philippine: 213.4 engine: 213.4 without ABS:239.0 {8.402} + 240.2 {8.402} + 240.2...
  • Page 345 CONVENTIONAL BRAKE SYSTEM CONVENTIONAL BRAKE SYSTEM POWER BRAKE UNIT INSPECTION AVF691243800W01 Power Brake Unit Function Inspection (Inspection using gauges) 1. Connect the SST gauges, a vacuum gauge, and 49 U043 004A 49 U043 005 a pedal depression gauge as shown in the figure. 2.
  • Page 346 CONVENTIONAL BRAKE SYSTEM LOAD SENSING PROPORTIONING VALVE (LSPV) INSPECTION (4× × × × 2) AVF691243901W01 1. Place the vehicle on level ground. 2. Check the tire inflations and set them to the recommended pressure if necessary. • If not as specified, replace or adjust. 3.
  • Page 347 CONVENTIONAL BRAKE SYSTEM LOAD SENSING PROPORTIONING VALVE (LSPV) ADJUSTMENT (4× × × × 2) AVF691243901W02 1. Place the unloaded vehicle on level ground. Unloaded: Fuel tank is full. Engine coolant and tire, jack and tools are in designated position. Note •...
  • Page 348 CONVENTIONAL BRAKE SYSTEM LOAD SENSING PROPORTIONING VALVE (LSPV) REMOVAL/INSTALLATION (4× × × × 2) AVF691243901W03 Caution • • • • Do not disassemble the LSPV. • • • • Do not move nut A. 1. Remove in the order indicated in the table. 2.
  • Page 349 CONVENTIONAL BRAKE SYSTEM FRONT BRAKE (DISC) INSPECTION (4× × × × 2) AVF691233980W01 Disc Pad Thickness Inspection 1. Jack up the front of the vehicle on level ground and support it with safety stands. 2. Remove the wheels. 3. Look through the caliper inspection hole and verify the remaining thickness of the pad. Thickness 2.0 mm {0.079 in} min.
  • Page 350 CONVENTIONAL BRAKE SYSTEM FRONT BRAKE (DISC) REMOVAL/INSTALLATION (4× × × × 2) AVF691233980W02 Caution • • • • Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while the vehicle is being serviced.
  • Page 351 CONVENTIONAL BRAKE SYSTEM Guide Plate Removal Note 1. Pull up and at a slant on the supporting part of the guide plate in the direction indicated by the arrow (1) and (2) as shown in the figure, to remove the guide plate from the mounting support.
  • Page 352 CONVENTIONAL BRAKE SYSTEM 3. Assemble the cover-shim to the grease-applied rubber coated shim. COVER-SHIM Caution • • • • Be careful not to get any grease on the pad lining surface. ACF6912W004 Disc Pad Installation Note 1. Push the piston fully inward using the SST. 2.
  • Page 353 CONVENTIONAL BRAKE SYSTEM CALIPER (FRONT) DISASSEMBLY/ASSEMBLY (4× × × × 2) AVF691233990W01 1. Disassemble in the order indicated in the table. 5.9—8.8 Dust seal {60—89, 53—77} Piston (See P–12 Piston Disassembly Note) Piston seal (See P–12 Piston Seal Disassembly Note) Bleeder cap Bleeder screw Caliper...
  • Page 354 CONVENTIONAL BRAKE SYSTEM REAR BRAKE (DRUM) INSPECTION (4× × × × 2) AVF691226250W01 Brake Lining Thickness Inspection 1. Remove the brake drum. 2. Inspect the remaining thickness of the lining. • Replace both left and right brake shoes if either is at or less than the minimum thickness. Thickness 1.0 mm {0.04 in} min.
  • Page 355 PARKING BRAKE SYSTEM PARKING BRAKE SYSTEM PARKING BRAKE CABLE (STICK TYPE) REMOVAL/INSTALLATION AVF691444150W01 1. Remove the brake drum. 2. Remove the under guard. 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. 5.
  • Page 356 PARKING BRAKE SYSTEM L.H.D. WL engine 15.7—22.5 {1.60—2.29, 11.6—16.5} 15.7—22.5 {1.60—2.29, 11.6—16.5} 15.7—22.5 {1.60—2.29, 11.6—16.5} 15.7—22.5 {1.60—2.29, 15.7—22.5 11.6—16.5} {1.60—2.29, 11.6—16.5} 15.7—22.5 {1.60—2.29, 11.6—16.5} 15.7—22.5 15.7—22.5 {1.60—2.29, {1.60—2.29, 11.6—16.5} 11.6—16.5} G6 engine 15.7—22.5 {1.60—2.29, 11.6—16.5} 15.7—22.5 {1.60—2.29, 11.6—16.5} 15.7—22.5 {1.60—2.29, 15.7—22.5 11.6—16.5} {1.60—2.29,...
  • Page 357 ANTILOCK BRAKE SYSTEM ANTILOCK BRAKE SYSTEM FRONT ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION (4× × × × 2) AVF691643720W01 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. VIEW FROM LEFT SIDE INSERT CLIP COMPLETELY 19—25 {1.9—2.6, 14—18} 19—25...
  • Page 358 ANTILOCK BRAKE SYSTEM REAR ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION (4× × × × 2) AVF691643710W01 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 18.6—25.5 {190—260, 165—225} CLIP 18.6—25.5 {190—260, 165—225} 7.8—10.8 {80—110, ABS SENSOR HARNESS IS 69.1—95.5} ROUTED ABOVE BRAKE PIPE...
  • Page 360 S USPENSION FEATURES OUTLINE ..............R-2 OUTLINE OF CONSTRUCTION......R-2 FEATURES ............R-2 SPECIFICATIONS ..........R-2 SERVICE OUTLINE ..............R-3 SUPPLEMENTAL SERVICE INFORMATION ..R-3 WHEEL ALIGNMENT..........R-3 FRONT WHEEL ALIGNMENT ......R-3 FRONT SUSPENSION ...........R-5 VEHICLE HEIGHT ADJUSTMENT ......R-5 REAR SUSPENSION ..........R-6 REAR SHOCK ABSORBER AND LEAF SPRING REMOVAL/INSTALLATION ......R-6 R–1...
  • Page 361 OUTLINE OUTLINE OUTLINE OF CONSTRUCTION AVF740201013W01 • The construction and operation of the suspension system is essentially carried over from that of the current RANGER, except for the following features. (See RANGER Training Manual F326-10-99A.) (See RANGER Repair Manual Supplement F179-10-02D.) (See RANGER Repair Manual Supplement F182-10-02I.) End Of Sie FEATURES AVF740201013W02...
  • Page 362 OUTLINE, WHEEL ALIGNMENT OUTLINE SUPPLEMENTAL SERVICE INFORMATION AVF740201013W04 • The following change has been made since publication of the RANGER Repair Manual F161-10-99A, RANGER Repair Manual, RANGER Repair Manual Supplement F166-10-00G, and RANGER Repair Manual Supplement F182-10-02I. Wheel alignment • Front wheel alignment has been modified. Vehicle height •...
  • Page 363 WHEEL ALIGNMENT Total Toe-in Adjustment 1. Loosen the tie-rod end locknuts. 2. Turn the tie rods by the same amount in the opposite direction. Note • The left and right tie rods are both right threaded, to increase the toe-in, turn the right tie rod toward the front of the vehicle and the left tie rod equally toward the rear.
  • Page 364 FRONT SUSPENSION End Of Sie FRONT SUSPENSION VEHICLE HEIGHT ADJUSTMENT AVF741401015W01 Caution • • • • If the vehicle height on a winch or towbar (bullbar or similar accessory) equipped vehicle is adjusted, it is possible that the vehicle height will drop below specification again or the tires will be subject to uneven wear.
  • Page 365 REAR SUSPENSION REAR SUSPENSION REAR SHOCK ABSORBER AND LEAF SPRING REMOVAL/INSTALLATION AVF741605910W01 Warning • • • • Use safety stands for support of the left and right axle casings, and while supporting the differential casing with a jack, raise or lower the jack as necessary. 1.
  • Page 366 REAR SUSPENSION Leaf Spring Bushing (Front Side) Removal Note 1. Remove the rubber bushing using the SSTs. 49 T034 002A 49 W038 002 49 G034 202 49 G034 205 49 S028 103 AVF7416W002 Leaf Spring Bushing (Rear Side) Removal Note 1.
  • Page 368 B ODY FUEL-FILLER LID OPENER SWITCH FEATURES REMOVAL/INSTALLATION ......S-18 FUEL-FILLER LID OPENER SWITCH OUTLINE ..............S-3 INSPECTION ..........S-18 OUTLINE OF CONSTRUCTION ......S-3 BUMPER............... S-18 FEATURES............S-3 REAR BUMPER POWER DOOR LOCK SYSTEM......S-4 REMOVAL/INSTALLATION ......S-18 OUTLINE ............. S-4 REAR BUMPER STRUCTURAL VIEW...........
  • Page 369 FLOOR COVERING ..........S-32 FLOOR COVERING REMOVAL/INSTALLATION ......S-32 SEAT BELT ............S-32 SECOND-ROW SEAT BELT REMOVAL/INSTALLATION ......S-32 THIRD-ROW SEAT BELT REMOVAL/INSTALLATION ......S-33 FRONT BUCKLE REMOVAL/INSTALLATION ......S-33 SECOND-ROW BUCKLE REMOVAL/INSTALLATION ......S-33 THIRD-ROW BUCKLE REMOVAL/INSTALLATION ......S-34 SEAT..............
  • Page 370 OUTLINE OUTLINE OUTLINE OF CONSTRUCTION AVF770201086W01 • The construction and operation of the body system is essentially carried over from that of the current RANGER model, except for the following features. (See RANGER Training Manual F326-10-99A.) End Of Sie FEATURES AVF770201086W02 Improved Marketability •...
  • Page 371 POWER DOOR LOCK SYSTEM POWER DOOR LOCK SYSTEM OUTLINE AVF771866000W01 • The function, structure and operation of the power door lock system is essentially carried over from that of the current RANGER, except for the following. — A back door lock actuator has been adopted. End Of Sie STRUCTURAL VIEW AVF771866000W02...
  • Page 372 FUEL-FILLER LID AND OPENER FUEL-FILLER LID AND OPENER OUTLINE AVF772466640W01 • A power fuel-filler lid opener has been adopted. End Of Sie STRUCTURAL VIEW AVF772466640W02 FUEL-FILLER LID OPENER SWITCH FUEL-FILLER LID FUEL-FILLER LID OPENER AVF7724T101 End Of Sie SYSTEM WIRING DIAGRAM AVF772466640W03 FUEL-FILLER LID OPENER SWITCH...
  • Page 373 EXTERIOR ATTACHMENT EXTERIOR ATTACHMENT OUTLINE AVF772801092W01 • A roof rail has been adopted on the roof. • A rear spoiler with a built in high-mount brake light has been adopted on the end of the roof rail. End Of Sie STRUCTURAL VIEW AVF772801092W02 ROOF RAIL...
  • Page 374 SEAT SEAT OUTLINE AVF775257000W01 • An armrest has been adopted on the front seat (bench type). • A foldable seat has been adopted on the second-row seat. • A third-row seat has been adopted. There are three type of third-row seats according to market. —...
  • Page 375 SEAT, OUTLINE 4. Lift the seat to upward and then remove from floor. REAR LOCK LOCK LEVER UNLOCK LEVER LOCK UNLOCK FRONT LOCK LEVER AVF7752T104 End Of Sie OUTLINE SUPPLEMENTAL SERVICE INFORMATION AVF770201086W03 • The following changes and/or additions have been made since publication of the RANGER Repair Manual (F161-10-99A).
  • Page 376 OUTLINE Back door garnish • Removal/Installation procedure has been added. Rear spoiler • Removal/Installation procedure has been added. Roof rail • Removal/Installation procedure has been added. Rear beltline molding • Removal/Installation procedure has been modified. Roof molding • Removal/Installation procedure has been modified. Side window glass •...
  • Page 377 LOCATION INDEX LOCATION INDEX EXTERIOR AVF770001086W01 AVF7700W101 Roof rail Fuel-filler lid opener (See S–21 ROOF RAIL REMOVAL/ (See S–17 FUEL-FILLER LID AND OPENER INSTALLATION) REMOVAL/INSTALLATION) (See S–17 FUEL-FILLER LID AND OPENER Rear spoiler INSPECTION) (See S–20 REAR SPOILER REMOVAL/ INSTALLATION) Fuel-filler lid (See S–17 FUEL-FILLER LID AND OPENER Rear window glass...
  • Page 378 LOCATION INDEX End Of Sie INTERIOR AVF770001086W02 Type A AVF7700W102 Rear door trim Third-row buckle (See S–29 REAR DOOR TRIM REMOVAL/ (See S–34 THIRD-ROW BUCKLE REMOVAL/ INSTALLATION) INSTALLATION) Headliner Floor covering (See S–31 HEADLINER REMOVAL/ (See S–32 FLOOR COVERING REMOVAL/ INSTALLATION) INSTALLATION) C-pillar trim...
  • Page 379 LOCATION INDEX, DOOR Type B AVF7700W103 Front seat (bench type) Third-row seat belt (See S–35 FRONT SEAT REMOVAL/ (See S–33 THIRD-ROW SEAT BELT REMOVAL/ INSTALLATION) INSTALLATION) (See S–36 FRONT SEAT DISASSEMBLY/ Front buckle ASSEMBLY) (See S–33 FRONT BUCKLE REMOVAL/ Third-row seat INSTALLATION) (See S–38 THIRD-ROW SEAT REMOVAL/ Cup holder...
  • Page 380 DOOR REAR DOOR DISASSEMBLY/ASSEMBLY AVF771472010W02 1. Disassemble in the order indicated in the table. 6.9—9.8 Inner handle {71—99, 62—86} Door screen Rear power window regulator Chan-center Rear door glass Glass run channel Rear door quarter glass Rear door lock knob 6.9—9.8 {71—99, 62—86} Rear door lock...
  • Page 381 DOOR 7. Raise or lower the rear door glass so that the part REAR connected to the rear door regulator is visible. DOOR GLASS 8. Detach the connecting part. 9. Insert your hand through the inside of the rear door and lift out the rear door glass. REAR 10.
  • Page 382 DOOR BACK DOOR DISASSEMBLY/ASSEMBLY AVF771462010W02 1. Remove the back door lower trim. 2. To remove the back door outer handle and back door key cylinder, remove the back door garnish. 3. Disassemble in the order indicated in the table. 6.9—9.8 N·m {71—99 kgf·cm, 62—86 in·lbf} SCREW...
  • Page 383 POWER DOOR LOCK SYSTEM POWER DOOR LOCK SYSTEM BACK DOOR LOCK ACTUATOR INSPECTION AVF771875911W01 1. Apply battery positive voltage to the back door WITHOUT THEFT-DETERRENT lock actuator terminals and inspect the operation UNLOCK LOCK SYSTEM of the back door lock actuator. •...
  • Page 384 FUEL-FILLER LID AND OPENER FUEL-FILLER LID AND OPENER FUEL-FILLER LID AND OPENER REMOVAL/INSTALLATION AVF772466640W04 1. Disconnect the negative battery cable. 2. Remove the rear side trim. 3. Remove in the order indicated in the table. Fuel-filler lid Lift spring Connector Fuel-filler lid opener 4.
  • Page 385 FUEL-FILLER LID AND OPENER, BUMPER FUEL-FILLER LID OPENER SWITCH REMOVAL/INSTALLATION AVF772466640W07 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. Fuel-filler lid opener switch Connector 3. Install in the reverse order of removal. AVF7724W104 End Of Sie FUEL-FILLER LID OPENER SWITCH INSPECTION AVF772466640W08...
  • Page 386 BUMPER Rear Bumper Removal Note 1. Pull the rear bumper rearward to detach it from the bumper slider. Caution • • • • If only one side of the rear bumper is detached from the bumper slider and the bumper falls, it could be damaged.
  • Page 387 EXTERIOR ATTACHMENT EXTERIOR ATTACHMENT EXTRACTOR CHAMBER REMOVAL/INSTALLATION AVF772851908W01 1. Remove the rear bumper. (See S–18 REAR BUMPER REMOVAL/INSTALLATION.) 2. Remove the screws, then remove the extractor chamber. 3. Install in the reverse order of removal. SCREW EXTRACTOR CHAMBER AVF7728W101 End Of Sie OVER FENDER REMOVAL/INSTALLATION AVF772851908W02 1.
  • Page 388 EXTERIOR ATTACHMENT, MOLDING ROOF RAIL REMOVAL/INSTALLATION AVF772851720W01 1. Remove the headliner. 2. Remove the rear spoiler. (vehicles with rear spoiler) 3. Remove the nuts. 4. Pull the roof rail upward, then remove the roof rail ROOF RAIL from the body. 5.
  • Page 389 WINDOW GLASS WINDOW GLASS SIDE WINDOW GLASS REMOVAL AVF773862580W01 1. Remove the C-pillar trim. 2. Apply protective tape along the edge of the body to protect it from damage. 3. Avoiding pins and spacers, make a hole through SPACER the sealant from the inside of the vehicle using an awl.
  • Page 390 WINDOW GLASS SIDE WINDOW GLASS INSTALLATION AVF773862580W02 Caution • • • • Proper installation of the side window glass may be difficult if sealant is cracked or the glass is pushed out by air pressure when a door is opened/closed with all the windows closed. Leave all the windows open until the side window glass is installed completely.
  • Page 391 WINDOW GLASS 6. Apply sealant to the areas of the glass surface as shown in the figure. SEC. A—A {0.55} {0.19} SEC. D—D SEC. B—B SEC. C—C 12.5 {0.19} {0.49} {0.67} {0.19} 12.5 {0.49} {0.19} {0.19} mm {in} AVF7738W105 7. Set the side window glass in place and insert the pins into the body.
  • Page 392 WINDOW GLASS 6. Working with another person, saw through the sealant around the edge of the glass. 7. Remove the rear window glass. 8. Remove the spacers and pins from the glass. 49 0305 870A A6E7738W021 End Of Sie REAR WINDOW GLASS INSTALLATION AVF773863931W02 Caution •...
  • Page 393 WINDOW GLASS 5. Use only glass primer on the glass, and body CENTER primer on the body. Allow it to dry for approx. 30 8.0 {0.31} R START min. {0.37} 13.0 {0.51} R START SEC. A—A 9.0 {0.35} 9.0 {0.35} R START 25.0 {0.98} 8.0 {0.31}...
  • Page 394 DASHBOARD AND CONSOLE DASHBOARD AND CONSOLE REAR CONSOLE REMOVAL/INSTALLATION AVF774264271W01 1. Remove the screws. REAR ASHTRAY REAR CONSOLE COVER SCREW CUP HOLDER AVF7742W103 2. Remove the screws. REAR CONSOLE 3. Remove the rear console. 4. Install in the reverse order of removal. SCREW SCREW CUP HOLDER...
  • Page 395 TRIM TRIM REAR SCUFF PLATE REMOVAL/INSTALLATION AVF774468730W01 1. Remove the screw. REAR SCUFF PLATE 2. Pull the rear scuff plate upward, then detach clips CLIP A SCREW A and pins B from the body. 3. Install in the reverse order of removal. PIN B AVF7744W101 End Of Sie...
  • Page 396 TRIM REAR DOOR TRIM REMOVAL/INSTALLATION AVF77446852YW01 1. Fully lower the rear door glass. 2. Disconnect the negative battery cable. 3. Open the cap using a small screwdriver, then INNER HANDLE REAR DOOR TRIM remove screws A. COVER SCREW B 4. Remove the inner handle cover. CLIP A 5.
  • Page 397 TRIM REAR END TRIM REMOVAL/INSTALLATION AVF774468890W01 1. Pull the rear end trim upward, then detach clips A and pins B from the body. REAR END TRIM 2. Remove the rear end trim. 3. Install in the reverse order of removal. PIN B CLIP A AVF7744W107...
  • Page 398 TRIM, HEADLINER 3. Remove screws A, then remove the handle. SCREW A 4. Remove screw B, then remove the inner handle cover. 5. Pull the back door lower trim outward, then BACK DOOR HANDLE detach clips A and pins B from the body. LOWER TRIM 6.
  • Page 399 FLOOR COVERING, SEAT BELT FLOOR COVERING FLOOR COVERING REMOVAL/INSTALLATION AVF774868670W01 1. Disconnect the negative battery cable. 2. Remove the front seats. 3. Remove the front buckles. (Bench seat type) 4. Remove the second-row seats. 5. Remove the third-row seat. 6. Remove the front scuff plates. 7.
  • Page 400 SEAT BELT THIRD-ROW SEAT BELT REMOVAL/INSTALLATION AVF775057830W01 Caution • • • • The ELR has a spring that will unwind if the retractor cover is removed. The spring cannot be rewound by hand. If this occurs, the ELR will not work properly. Therefore, do not disassemble the retractor.
  • Page 401 SEAT BELT THIRD-ROW BUCKLE REMOVAL/INSTALLATION AVF775057720W02 Fixed Seat Type, Detachable Seat Type 1. Remove the bolt. FIXED SEAT TYPE 38.2—78.4 BOLT {3.90—7.99, 28.2—57.8} DETACHABLE SEAT TYPE 38.2—78.4 BOLT {3.90—7.99, 28.2—57.8} N·m {kgf·m, ft·lbf} AVF7750W105 2. Remove the third-row buckle from the third-row seat.
  • Page 402 SEAT SEAT FRONT SEAT REMOVAL/INSTALLATION AVF775257100W01 Bench Type 1. Remove the bolts. 2. Remove the bench seat. 3. Install in the reverse order of removal. 35—63 {3.5—6.5, 26—47} BENCH SEAT 35—63 {3.5—6.5, 26—47} N·m {kgf·m, ft·lbf} AVF7752W101 End Of Sie S–35...
  • Page 403 SEAT FRONT SEAT DISASSEMBLY/ASSEMBLY AVF775257100W02 Bench Type 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. 36—54 {3.7—5.5, 27—39} 15.7—22.5 {16.1—16.5, 11.6—16.5} 15.7—22.5 {16.1—16.5, N·m {kgf·m, ft·lbf} 11.6—16.5} AVF7752W103 Headrest Cup holder Pole guide Latch Recliner lever...
  • Page 404 SEAT SECOND-ROW SEAT REMOVAL/INSTALLATION AVF77525720XW01 1. Move headrest to the lowest position. 2. Releasing Recliner lever, fold the seat back to forward. 3. Tumble second-row seat to forward. RECLINER LEVER AVF7752W104 4. Remove the bolts and remove the second-row seat. 5.
  • Page 405 SEAT THIRD-ROW SEAT REMOVAL/INSTALLATION AVF77525730XW01 Fixed Type 1. Remove the bolts, then tumble seat to forward. 36—54 N·m {3.7—5.5 kgf·m, 27—39 ft·lbf} AVF7752W108 2. Releasing front lock by operating the front lock lever. FRONT LOCK 3. Lift the third-row seat to upward and then remove LEVER from the floor.
  • Page 406 SEAT Inward Facing Type 1. Remove in the order indicated in the table. 15.7—22.5 BOLT Seat back {1.61—2.29, 11.6—16.5} Seat back frame Third-row buckle Seat cushion 2. Install in the reverse order of removal. BOLT 15.7—22.5 {1.61—2.29, 11.6—16.5} BOLT 38.2—78.4 {3.90—7.99, BOLT 28.2—57.8}...
  • Page 408 B ODY ELECTRICAL SYSTEM REAR WIPER ARM AND BLADE FEATURES ADJUSTMENT ..........T-18 REAR WIPER MOTOR OUTLINE ..............T-2 REMOVAL/INSTALLATION ......T-18 OUTLINE OF CONSTRUCTION ......T-2 REAR WIPER MOTOR INSPECTION ....T-19 FEATURES............T-2 REAR WASHER TANK EXTERIOR LIGHTING SYSTEM......T-2 REMOVAL/INSTALLATION ......
  • Page 409 OUTLINE, EXTERIOR LIGHTING SYSTEM OUTLINE OUTLINE OF CONSTRUCTION AVF810201088W01 • The construction and operation of the body electrical system is essentially carried over from that of the current RANGER model, except for the following features. (See RANGER Training Manual F326-10-99A.) End Of Sie FEATURES AVF810201088W02...
  • Page 410 EXTERIOR LIGHTING SYSTEM HIGH-MOUNT BRAKE LIGHT AVF811201052W02 Outline • A high-mount brake light has been adopted for the rear spoiler. Structural View HIGH-MOUNT BRAKE LIGHT AVF8112T102 End Of Sie REAR COMBINATION LIGHT AVF811201052W03 Outline • A rear combination light has been changed due to a change in the shape of the vehicle rear end. Structural View REAR TURN LIGHT BULB...
  • Page 411 INTERIOR LIGHTING SYSTEM INTERIOR LIGHTING SYSTEM OUTLINE AVF811401053W01 • An interior and map light has been adopted at the centre of the ceiling. • A cargo compartment light has been adopted at the rear of the ceiling. • A back door switch has been adopted. The function of the switch is the same as that of RANGER model. End Of Sie STRUCTURAL VIEW AVF811401053W03...
  • Page 412 INTERIOR LIGHTING SYSTEM SYSTEM WIRING DIAGRAM AVF811401053W02 INTERIOR AND MAP LIGHT INTERIOR LIGHT LIGHT LIGHT CARGO COMPARTMENT LIGHT DOOR DOOR BACK DOOR DOOR DOOR DOOR DOOR SWITCH SWITCH SWITCH SWITCH SWITCH AVF8114T101 End Of Sie T–5...
  • Page 413 WIPER AND WASHER WIPER AND WASHER STRUCTURAL VIEW AVF811601063W02 REAR WIPER ARM AND BLADE REAR WIPER AND WASHER SWITCH REAR WIPER MOTOR REAR WASHER HOSE REAR WASHER REAR WASHER REAR WASHER MOTOR NOZZLE TANK AVF8100W221 End Of Sie REAR WIPER AND WASHER SYSTEM AVF811601063W01 Outline •...
  • Page 414 WIPER AND WASHER System Operation Low speed operation • When the rear wiper switch is turned on, current flows to operate the rear wiper motor continuously. • When the rear wiper switch is turned off, the auto stop function activates and the rear wiper stops at the park position.
  • Page 415 WIPER AND WASHER, WARNING AND INDICATOR SYSTEM Washer operation • When the rear wiper and washer switch is pressed to ON2 while the rear wiper is operating, the rear washer switch turns on, allowing current to flow to the rear washer motor to spray washer fluid. When the rear wiper and washer switch is pressed to ON3 and the rear wiper motor is off, current flows to the rear washer motor to spray washer fluid.
  • Page 416 WARNING AND INDICATOR SYSTEM INSTRUMENT CLUSTER AVF811855430W01 Outline • A door ajar warning light that illuminates to notify the driver when the door is open has been adopted. Structural View Structural View DOOR AJAR WARNING LIGHT AVF8118T102 System Wiring Diagram INSTRUMENT CLUSTER DOOR AJAR MICROCOMPUTER...
  • Page 417 OUTLINE OUTLINE SUPPLEMENTAL SERVICE INFORMATION AVF810201088W03 • The following changes and/or additions have been made since publication of the RANGER Repair Manual (F161-10-99A). Rear combination light • Removal/Installation procedure has been modified. License plate light • Removal/Installation procedure has been modified. High-mount brake light •...
  • Page 418 LOCATION INDEX LOCATION INDEX LOCATION INDEX EXTERIOR LIGHTING SYSTEM AVF810001052W01 AVF8100W101 License plate light High-mount brake light (See T–13 LICENSE PLATE LIGHT REMOVAL/ (See T–13 HIGH-MOUNT BRAKE LIGHT INSTALLATION.) REMOVAL/INSTALLATION.) Back-up light Rear combination light (See T–14 BACK-UP LIGHT REMOVAL/ (See T–13 REAR COMBINATION LIGHT INSTALLATION.) REMOVAL/INSTALLATION.)
  • Page 419 LOCATION INDEX End Of Sie LOCATION INDEX WIPER AND WASHER SYSTEM AVF810001052W03 AVF8100W103 Rear washer tank Rear wiper arm and blade (See T–20 REAR WASHER TANK REMOVAL/ (See T–17 REAR WIPER ARM AND BLADE INSTALLATION.) REMOVAL/INSTALLATION.) (See T–18 REAR WIPER ARM AND BLADE Rear washer motor ADJUSTMENT.) (See T–20 REAR WASHER MOTOR REMOVAL/...
  • Page 420 EXTERIOR LIGHTING SYSTEM End Of Sie EXTERIOR LIGHTING SYSTEM REAR COMBINATION LIGHT REMOVAL/INSTALLATION AVF811251150W01 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. Screw Rear combination light Connector Socket Rear turn light bulb Brake light/taillight bulb 3.
  • Page 421 EXTERIOR LIGHTING SYSTEM High-Mount Brake Light Removal Note 1. Tie a string to the end of the connector of the high-mount brake light beforehand so that the REAR SPOILER connector can be passed easily through the rear spoiler during installation. HIGH-MOUNT BRAKE LIGHT HARNESS AVF8112W116...
  • Page 422 INTERIOR LIGHTING SYSTEM INTERIOR LIGHTING SYSTEM INTERIOR AND MAP LIGHT REMOVAL/INSTALLATION AVF811401058W01 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. Lens (See T–15 Lens Removal Note.) Interior light bulb Map light bulb Screw Interior and map light Connector 3.
  • Page 423 INTERIOR LIGHTING SYSTEM CARGO COMPARTMENT LIGHT REMOVAL/INSTALLATION AVF811451441W01 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. Lens (See T–16 Lens Removal Note.) Cargo compartment light bulb Screw Connector Cargo compartment light 3. Install in the reverse order of removal. AVF8114W104 Lens Removal Note 1.
  • Page 424 INTERIOR LIGHTING SYSTEM, WIPER AND WASHER BACK DOOR SWITCH INSPECTION AVF811466540W02 1. Remove the back door switch. 2. Inspect for continuity between back door switch terminal A and a body ground using an ohmmeter. • If not as indicated in the table, replace the back door switch.
  • Page 425 WIPER AND WASHER REAR WIPER ARM AND BLADE ADJUSTMENT AVF811667420W02 1. Operate the rear wiper motor to set the wiper in the park position. 2. Set the rear wiper arm onto the ceramics end line. CERAMICS END LINE 69mm {2.7in} CERAMICS END LINE AVF8116W102 End Of Sie...
  • Page 426 WIPER AND WASHER REAR WIPER MOTOR INSPECTION AVF811667450W02 1. Disconnect the negative battery cable. 2. Remove the back door lower trim. 3. Disconnect the rear wiper motor connector. 4. Connect battery positive voltage to the rear wiper motor terminal A and the ground to a bare metal part of the vehicle and the rear wiper motor terminal B.
  • Page 427 WIPER AND WASHER REAR WASHER TANK REMOVAL/INSTALLATION AVF811667480W01 1. Disconnect the negative battery cable. 2. Remove the back door lower trim. 3. Remove in the order indicated in the table. Bolt Connector Washer hose 4.9—6.9 Washer tank {50—70, 44—61} 4. Install in the reverse order of removal. 4.9—6.9 {50—70, N·m {kgf·m, ft·lbf}...
  • Page 428 WIPER AND WASHER REAR WASHER NOZZLE REMOVAL/INSTALLATION AVF811667511W01 1. Disconnect the negative battery cable. 2. Remove the back door lower trim. 3. Remove the rear wiper motor. 4. Remove the rear washer hose form the rear washer nozzle. 5. Squeeze the tabs of the rear washer nozzle. 6.
  • Page 429 WIPER AND WASHER REAR WIPER AND WASHER SWITCH REMOVAL/INSTALLATION AVF811666122W01 1. Disconnect the negative battery cable. 2. Remove the meter hood. 3. Remove in the order indicated in the table. Connector Wiper and washer switch 4. Install in the reverse order of removal. AVF8116W113 End Of Sie REAR WIPER AND WASHER SWITCH INSPECTION...
  • Page 430 WARNING AND INDICATOR SYSTEM WARNING AND INDICATOR SYSTEM FUEL GAUGE SENDER UNIT INSPECTION AVF811860960W01 1. Move the float to the topmost and bottommost 24.4 mm positions, and verify that the resistance between {0.96 in} TOPMOST terminals A and B of the unit and the position of 6—14 ohms POSITION the float are as indicated in the figure.
  • Page 432 H EATER AND AIR CONDITIONER SYSTEMS CLIMATE CONTROL UNIT FEATURES DISASSEMBLY/ASSEMBLY ......U-26 REAR FAN SWITCH OUTLINE ..............U-2 REMOVAL/INSTALLATION ......U-26 OUTLINE OF CONSTRUCTION ......U-2 REAR FAN SWITCH FEATURES............U-2 DISASSEMBLY/ASSEMBLY ......U-27 SPECIFICATIONS ..........U-2 REAR FAN SWITCH INSPECTION....U-27 BASIC SYSTEM .............U-4 TROUBLESHOOTING..........U-28 BASIC SYSTEM ..........U-4 FOREWORD............U-28 AIR FILTER............U-5 TROUBLESHOOTING INDEX ......U-28...
  • Page 433 OUTLINE OUTLINE OUTLINE OF CONSTRUCTION AVF850201038W01 • The construction and operation of the heater and air conditioner system is essentially carried over from that of the current RANGER model, except for the following features. (See RANGER Training Manual.) End Of Sie FEATURES AVF850201038W02 Improved comfort...
  • Page 434 OUTLINE Specification Item EVEREST Current RANGER Type Multiflow (sub-cooling type) Multiflow Radiated heat (kW {kcal/h}) 5.35 {4,600} 9.36 (8,050) Condenser Receiver/drier (ml {cc, fl oz}) 220 {220, 7.44} 250 {250, 8.45} capacity Desiccant XH-7 Synthetic zeolite Front Internal pressure equalizer Expansion valve Type Rear...
  • Page 435 BASIC SYSTEM BASIC SYSTEM BASIC SYSTEM AVF851601040W01 R.H.D. REAR COOLER DUCT REAR A/C UNIT HEATER UNIT HEATER HOSE A/C COMPRESSOR COOLING UNIT CONDENSER REFRIGERANT LINES BLOWER UNIT L.H.D. REAR COOLER DUCT COOLING UNIT REAR A/C UNIT BLOWER UNIT HEATER HOSE HEATER UNIT REFRIGERANT LINES CONDENSER...
  • Page 436 BASIC SYSTEM AIR FILTER AVF851613988W01 • An air filter that can be reused after cleaning has been adopted. • An air filter that can remove pollen and dust has been added. FRESH AIR TO COOLING UNIT AIR FILTER AVF8516W007 End Of Sie REAR A/C UNIT AVF851661130W01 •...
  • Page 437 CONTROL SYSTEM CONTROL SYSTEM CONTROL SYSTEM AVF854001042W01 FRONT R.H.D. MAGNETIC CLUTCH REFRIGERANT PRESSURE SWITCH CLIMATE CONTROL UNIT A/C RELAY EVAPORATOR TEMPERATURE SENSOR FRONT RESISTOR FRONT BLOWER MOTOR MAGNETIC CLUTCH A/C RELAY L.H.D. CONDENSER FAN RELAY (FOR COASTAL AREAS AND OTHER REFRIGERANT PRESSURE SWITCH PLACES WITH INTENSE HEAT) CONDENSER FAN...
  • Page 438 CONTROL SYSTEM REAR REAR BLOWER MOTOR REAR BLOWER RELAY REAR RESISTOR REAR FAN SWITCH AVF8500W001 End Of Sie CONDENSER FAN AVF854061190W01 For Coastal Areas And Other Places With Intense heat • The condenser fan cools the condenser to facilitate coolant liquefaction. CONDENSER FAN AVF8540W018 End Of Sie...
  • Page 439 CONTROL SYSTEM CLIMATE CONTROL UNIT AVF854061190W02 • A climate control unit with a built-in rear A/C switch has been adopted. (Type A) • A climate control unit with a built-in rear A/C main switch has been adopted. (Type B) • The micro switch has been eliminated, and the A/C is turned on by turning the front fan switch on. (Type B) TYPE A FRONT FAN SWITCH FRONT A/C SWITCH...
  • Page 440 OUTLINE OUTLINE SUPPLEMENTAL SERVICE INFORMATION AVF850201038W04 • The following changes and additions, or both have been made since publication of the RANGER Repair Manual. Refrigerant • Charging procedure has been modified. Blower unit (Type B) • Disassembly/assembly procedure has been modified. Air filter •...
  • Page 441 REFRIGERANT SYSTEM SERVICE PROCEDURES REFRIGERANT SYSTEM SERVICE PROCEDURES CHARGING AVF851478834W02 Caution • • • • Do not exceed the specification when charging the system with refrigerant. Doing so will decrease the efficiency of the air conditioner or damage the refrigeration cycle parts. Charging Recycled R-134a Refrigerant 1.
  • Page 442 REFRIGERANT SYSTEM SERVICE PROCEDURES Airtightness Check 1. Stop the vacuum pump and wait for 5 min. 2. Check the high- and low-pressure side readings of the SST (49 C061 001). • If the reading has changed, inspect for leakage and go to Evacuation. (See U–10 Evacuation.) •...
  • Page 443 REFRIGERANT SYSTEM SERVICE PROCEDURES 7. Open the low-pressure side valve of the SST (49 49 C061 001 C061 001) and charge with refrigerant until the weight of refrigerant tank has decreased 350 g {12.4 oz} from the amount in Step 2. OPEN A6E8514W010 8.
  • Page 444 LOCATION INDEX LOCATION INDEX BASIC SYSTEM AVF850001040W01 R.H.D. L.H.D. AVF8500W006 Blower unit Heater hose (See U–16 BLOWER UNIT DISASSEMBLY/ Refrigerant lines ASSEMBLY) (See U–20 REFRIGERANT LINES REMOVAL/ Cooling unit INSTALLATION) Heater unit Rear cooler duct (See U–18 REAR COOLER DUCT REMOVAL/ A/C compressor INSTALLATION) (See U–18 A/C COMPRESSOR REMOVAL/...
  • Page 445 LOCATION INDEX CONTROL SYSTEM AVF850001042W01 FRONT R.H.D. L.H.D. AVF8500W008 Front blower motor A/C relay Front resistor Condenser fan relay (For coastal areas and other places with intense heat) Evaporator temperature sensor Climate control unit Refrigerant pressure switch (SeeU–26 CLIMATE CONTROL UNIT REMOVAL/ (SeeU–25 REFRIGERANT PRESSURE SWITCH INSTALLATION) INSPECTION)
  • Page 446 LOCATION INDEX REAR AVF8500W010 Rear blower motor Rear fan switch (SeeU–23 REAR BLOWER MOTOR REMOVAL/ (SeeU–26 REAR FAN SWITCH REMOVAL/ INSTALLATION) INSTALLATION) (SeeU–23 REAR BLOWER MOTOR INSPECTION) (SeeU–27 REAR FAN SWITCH DISASSEMBLY/ ASSEMBLY) Rear blower relay (SeeU–27 REAR FAN SWITCH INSPECTION) Rear resistor (SeeU–23 REAR RESISTOR REMOVAL/ INSTALLATION)
  • Page 447 BASIC SYSTEM BASIC SYSTEM BLOWER UNIT DISASSEMBLY/ASSEMBLY AVF851661140W01 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. Front blower motor Air filter Front resistor Blower harness Blower case (1) Blower case (2) Blower case (3) AVF8540W021 End Of Sie...
  • Page 448 BASIC SYSTEM REAR A/C UNIT REMOVAL/INSTALLATION End Of Sie AVF85166187XW01 1. Disconnect the negative battery cable. 2. Discharge the refrigerant from the system. 3. Remove the third-row seat. 4. Remove the trunk side trim (LH) and C-pillar trim. 5. Remove the rear cooler duct No.5. Caution •...
  • Page 449 BASIC SYSTEM Rear Evaporator Assembly Note 1. When installing a new rear evaporator, add FD46XG compressor oil from the inlet. Supplemental amount (approximate quantity) 40 ml {40 cc, 1.4 fl oz} End Of Sie REAR EVAPORATOR INSPECTION AVF851661210W01 1. Remove the rear evaporator from the rear A/C unit. 2.
  • Page 450 BASIC SYSTEM 4. Remove in the order indicated in the table. Cooler hose (HI) 8—12 N·m (See U–22 Refrigerant Lines Removal Note) {82—122 kgf·cm, (See U–22 Refrigerant Lines Installation Note) 71—106 in·lbf} Cooler hose (LO) (See U–22 Refrigerant Lines Removal Note) (See U–22 Refrigerant Lines Installation Note) Connector A/C compressor...
  • Page 451 BASIC SYSTEM REFRIGERANT LINES REMOVAL/INSTALLATION AVF851661460W01 1. Disconnect the negative battery cable. 2. Discharge the refrigerant from the system. 3. Remove the following parts, depending on pipe and hose to be removed. Parts to be removed Cooler pipe/hose to be removed R.H.D.
  • Page 452 BASIC SYSTEM L.H.D. TO REAR LINES TO REAR LINES A: 8—12 N·m {82—122 kgf·cm, 71—106 in·lbf} B: 10—20 N·m {1.1—2.0 kgf·m, 7.4—14.7 ft·lbf} C: 20—30 N·m {2.1—3.0 kgf·m, 14.8—22.1 ft·lbf} AVF8516W010 Front cooler pipe No.1 Cooler hose (HI) (See U–22 Refrigerant Lines Removal Note) (See U–22 Refrigerant Lines Removal Note) (See U–22 Refrigerant Lines Installation Note) (See U–22 Refrigerant Lines Installation Note)
  • Page 453 BASIC SYSTEM REAR TO FRONT LINE TO REAR A/C UNIT A: 8—12 N·m {82—122 kgf·cm, 71—106 in·lbf} B: 10—20 N·m {1.1—2.0 kgf·m, 7.4—14.7 ft·lbf} C: 20—30 N·m {2.1—3.0 kgf·m, 14.8—22.1 ft·lbf} AVF8516W006 Rear cooler pipe No.1 Rear cooler pipe No.3 (See U–22 Refrigerant Lines Removal Note) (See U–22 Refrigerant Lines Removal Note) (See U–22 Refrigerant Lines Installation Note)
  • Page 454 CONTROL SYSTEM CONTROL SYSTEM REAR BLOWER MOTOR REMOVAL/INSTALLATION AVF854061280W01 1. Disconnect the negative battery cable. 2. Remove the third-row sheet. 3. Remove the trunk side trim (LH). 4. Remove in the order indicated in the table. Rear blower motor connector Rear blower motor 5.
  • Page 455 CONTROL SYSTEM CONDENSER FAN REMOVAL/INSTALLATION AVF854061221W02 For Coastal Areas And Other Places With Intense Heat 1. Disconnect the negative battery cable. 2. Remove the radiator grille. 3. Remove in the order indicated in the table. Condenser fan connector Condenser fan 4.
  • Page 456 CONTROL SYSTEM REFRIGERANT PRESSURE SWITCH INSPECTION AVF854061503W02 1. Install the gas charging set. 2. Disconnect the refrigerant pressure switch connector. 3. Verify the high-pressure side reading of the manifold gauge and continuity between the terminals of the refrigerant pressure switch. •...
  • Page 457 CONTROL SYSTEM CLIMATE CONTROL UNIT REMOVAL/INSTALLATION AVF854061325W01 1. Disconnect the negative battery cable. 2. Remove the glove compartment. 3. Disconnect the A/C amplifier connectors. 4. Remove in the order indicated in the table. Climate control unit Climate control unit connector 5.
  • Page 458 CONTROL SYSTEM REAR FAN SWITCH DISASSEMBLY/ASSEMBLY AVF854061340W02 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. Dial Panel Rear fan switch Bulb AVF8540W012 End Of Sie REAR FAN SWITCH INSPECTION AVF854061340W03 1. Inspect for continuity between the rear fan switch terminals using a tester. •...
  • Page 459 TROUBLESHOOTING TROUBLESHOOTING FOREWORD AVF858001038W01 • The areas for inspection (steps) are given according to various circuit malfunctions. Use the chart below to verify the symptoms of the trouble in order to diagnose the appropriate area. End Of Sie TROUBLESHOOTING INDEX AVF858001038W02 TROUBLESHOOTING ITEM DESCRIPTION...
  • Page 460 TROUBLESHOOTING End Of Sie NO.2 NO BLOWN AIR IN ANY AIRFLOW MODE/BLOWN AIR VOLUME DOES NOT CHANGE AT ANY FAN SPEED AVF858001038W04 No blown air in any airflow mode. Blown air volume does not change at any fan speed. DESCRIPTION •...
  • Page 461 TROUBLESHOOTING STEP INSPECTION ACTION VERIFY THAT AIRFLOW MODE WIRE FROM Yes Go to next step. HEATER UNIT IS POSITIONED SECURELY Adjust airflow mode wire or install it correctly, then go to AND CORRECTLY Step 6. • Is airflow mode wire positioned securely and correctly in relation to the front heater unit's airflow mode main link? INSPECT FRONT CLIMATE CONTROL UNIT...
  • Page 462 TROUBLESHOOTING STEP INSPECTION ACTION VERIFY THAT ALL AIR INTAKE DOOR Yes Check door for cracks or damage, then go to next step. WITHIN FRONT BLOWER UNIT IS Install malfunction door securely in proper position, then go POSITIONED SECURELY AND PROPERLY to next step.
  • Page 463 TROUBLESHOOTING NO.6 AIR FROM VENT NOT COLD ENOUGH AVF858001038W08 Air from vent not cold enough DESCRIPTION • Magnetic clutch operates but A/C system malfunctions. • Drive belt malfunction (Step 1) • Malfunction in front and/or rear blower unit or condenser (Steps 4, 5) •...
  • Page 464 TROUBLESHOOTING STEP INSPECTION ACTION INSPECT REFRIGERANT LINES Yes Go to next step. • Inspect refrigerant lines as follows. If piping or an A/C component is damaged or cracked, — Is piping free of damage and cracks? replace it. Then go to Step 21. —...
  • Page 465 TROUBLESHOOTING STEP INSPECTION ACTION VERIFY THAT AIR MIX ACTUATOR IS Yes Go to next step. INSTALLED SECURELY AND PROPERLY Repair or install rod, link, cranks and shaft securely in • Are heater unit's air mix rod, link, cranks and proper position, then go to Step 21. shaft securely and properly installed? ADJUST COMPRESSOR OIL Yes Go to next step.
  • Page 466 TROUBLESHOOTING STEP INSPECTION ACTION INSPECT REFRIGERANT AMOUNT Yes Go to next step. • Inspect refrigerant amount. Add or subtract refrigerant to specified level, then go to Step • Is it okay? INSPECT A/C SWITCH INDICATOR LIGHT Yes WL or WL turbo: Go to Step 8. G6: Go to Step 7.
  • Page 467 TROUBLESHOOTING STEP INSPECTION ACTION VERIFY WHETHER MALFUNCTION IS IN Yes Undo short, then go to next step. EVAPORATOR TEMPERATURE SENSOR WL or WL turbo: Undo short, then go to Step 14. AND WIRING HARNESS (BETWEEN FUSE G6: Undo short, then go to Step 13. BLOCK AND EVAPORATOR TEMPERATURE SENSOR FOR CONTINUITY) OR ELSEWHERE...
  • Page 468 TROUBLESHOOTING STEP INSPECTION ACTION VERIFY WHETHER MALFUNCTION IS IN PCM Yes WL or WL turbo: Go to next step. G6: Inspect wiring harness between PCM and refrigerant OR WIRING HARNESS (BETWEEN PCM AND pressure switch, then go to Step 27. REFRIGERANT PRESSURE SWITCH FOR CONTINUITY) Inspect PCM, then go to Step 27.
  • Page 469 TROUBLESHOOTING STEP INSPECTION ACTION INSPECT WIRING HARNESS BETWEEN Yes Go to next step. FUSE BLOCK AND A/C RELAY Repair wiring harness between A/C relay and refrigerant (SWITCH-SIDE) FOR CONTINUITY pressure switch, then go to Step 27. • Turn ignition switch to ON position. •...
  • Page 470 TROUBLESHOOTING STEP INSPECTION ACTION INSPECT DRIVE BELT Yes Go to next step. • Inspect drive belt. Adjust or replace drive belt, then go to Step 13. • Is it okay? INSPECT DRIVE BELT CONDITION Yes Remove obstruction, remove oil, or replace drive belt, then go to Step 13.
  • Page 472 T ECHNICAL DATA TECHNICAL DATA ..........TD-2 FUEL AND EMISSION CONTROL SYSTEMS ........TD-2 FRONT AND REAR AXLE ........ TD-2 BRAKING SYSTEM .......... TD-2 SUSPENSION........... TD-3 BODY ELECTRICAL SYSTEM ......TD-3 HEATER AND AIR CONDITIONER SYSTEMS..... TD-4 TD–1...
  • Page 473 TECHNICAL DATA TECHNICAL DATA FUEL AND EMISSION CONTROL SYSTEMS AVF931001001W01 Engine Item Idle speed (rpm) 730—770 (750±20) 700—800 (750±50) E/L ON Idle-up speed 700—800 (750±50) (rpm) P/S ON 780—880 (830±50) A/C ON *1 : Excludes temporary idle speed drop just after the electrical loads (E/L) are turned on. *2 : Headlight is on, blower control switch is above 1st, cooling fan is operating, rear window defroster is on.
  • Page 474 TECHNICAL DATA SUSPENSION AVF931001013W01 Suspension Item Specification Drive type Inner 31°30′—35°30′ Maximum steering angle Outer 27°00′—32°00′ Tire [Tolerance 3 {0.12} (mm {in}) ±4 {±0.16}] Total toe-in Rim inner 1.5±2.0 {0.06±0.08} Front wheel alignment (degree) 0°15′±0°20′ (Unloaded) Caster angle (reference value) 2°02′...
  • Page 475 TECHNICAL DATA HEATER AND AIR CONDITIONER SYSTEMS AVF931001038W01 Item Specification REFRIGERANT SYSTEM Type R-134a Refrigerant Regular amount (g {oz}) 675 {23.8} (approximate quantity) BASIC SYSTEM Type FD46XG Lube A/C compressor Sealed volume (ml {cc, fl oz}) 160 {160, 5.40} (approximate quantity) CONTROL SYSTEM Magnetic clutch Clearance...
  • Page 476 S PECIAL TOOLS SPECIAL TOOLS ..........ST-2 FUEL AND EMISSION CONTROL SYSTEMS ........ST-2 PROPELLER SHAFT.........ST-2 FRONT AND REAR AXLE .........ST-2 BRAKING SYSTEM ...........ST-3 SUSPENSION............ST-3 BODY ..............ST-3 HEATER AND AIR CONDITIONER SYSTEMS ............ST-4 ST–1...
  • Page 477 SPECIAL TOOLS SPECIAL TOOLS FUEL AND EMISSION CONTROL SYSTEMS AVF941001001W01 — — End Of Sie PROPELLER SHAFT AVF941001018W01 49 S120 440 Mainshaft Holder — — End Of Sie FRONT AND REAR AXLE AVF941001018W02 49 T028 3A0 49 T028 303 49 T028 304 Ball joint puller Body (Part of Attachment...
  • Page 478 SPECIAL TOOLS 49 S033 107 Oil seal installer — — End Of Sie BRAKING SYSTEM AVF941001020W01 49 0259 770B 49 U043 0A0A 49 U043 004A Flare nut Oil pressure Oil pressure wrench gauge set gauge (Part of 49 U043 0A0A) 49 U043 005 49 U043 006 49 0221 600C...
  • Page 479 SPECIAL TOOLS HEATER AND AIR CONDITIONER SYSTEMS AVF941001038W01 49 C061 0A0B 49 C061 013 Gas Charge Set Gas Leak Tester — End Of Sie ST–4...
  • Page 480 Numbers (VIN), shown on the following page. Suspension Body Body Electrical System Heater and Air Conditioner Systems Technical Data Special Tools There are explanations given only for the sections marked with shadow ( © 2003 Ford Motor Company PRINTED IN , JULY 2003 F187–10–03G...
  • Page 481 VEHICLE IDENTIFICATION NUMBERS (VIN) MNB BS4D40?W 100001 — MNB LS4D40?W 100001 — MNB BS4D70?W 100001 — MNB LS4D70?W 100001 — MNB BSYD40?W 100001 — MNB LSYD40?W 100001 — RELATED MATERIALS RANGER Repair Manual RANGER Training Manual RANGER Repair Manual Supplement ....F165–10–99J RANGER Repair Manual Supplement .
  • Page 482 G ENERAL INFORMATION VIN CODE ............. GI-2 VIN CODE............GI-2 HOW TO USE THIS MANUAL ......GI-3 RANGE OF TOPICS .......... GI-3 NEW STANDARDS ..........GI-4 NEW STANDARDS TABLE ....... GI-4 ABBREVIATIONS ..........GI-6 ABBREVIATIONS ..........GI-6 SCHEDULED MAINTENANCE ......GI-7 SCHEDULED MAINTENANCE TABLE .....
  • Page 483 Y= New pickup without box For General (L.H.D. R.H.D.), Thailand, Gulf: 4= New wagon Product source S= Japan Air bag B= Without air bag L= With air bag (Driver & Passenger) World manufacturer indication MNB= FORD (General (R.H.D.), Thailand) BVF2008W001 End Of Sie GI–2...
  • Page 484 HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL RANGE OF TOPICS BVF201000000W01 • This manual indicates only changes/additions, as it is supplemental to the related materials. Therefore it may not contain the necessary reference service procedures to perform the service indicated in this manual. End Of Sie GI–3...
  • Page 485 NEW STANDARDS NEW STANDARDS NEW STANDARDS TABLE BVF202800000W01 • The following is a comparison of the previous standard and the new standard. New Standard Previous Standard Remark Abbrevi- Abbrevi- Name Name ation ation Accelerator Pedal — Accelerator Pedal Air Cleaner —...
  • Page 486 NEW STANDARDS New Standard Previous Standard Remark Abbrevi- Abbrevi- Name Name ation ation Open Loop — Open Loop — Output Speed Sensor — Vehicle Speed Sensor 1 Oxidation Catalytic Converter — Catalytic Converter Oxygen Sensor — Oxygen Sensor Park/Neutral Position —...
  • Page 487 ABBREVIATIONS ABBREVIATIONS ABBREVIATIONS BVF203000000W01 Automatic Transmission Automatic Transmission Fluid Emergency locking retractor EC-AT Electronic Controlled Automatic Transmission Overdrive Special Service Tool Transmission Fluid Temperature First Gear Second Gear 4×4 4 wheel-4 drive End Of Sie GI–6...
  • Page 488 SCHEDULED MAINTENANCE SCHEDULED MAINTENANCE SCHEDULED MAINTENANCE TABLE BVF203400000W02 For Thailand Maintenance Interval (Number of months or kilometers (miles), whichever comes first) Months Maintenance Item ×1000 km ×1000 miles ENGINE Engine valve clearance Replace every 100,000 km Engine timing belt Drive belts *2 Engine oil Engine oil filter COOLING SYSTEM...
  • Page 489 • To ensure efficient operation of the engine and all systems related to emission control, the ignition and fuel systems must be serviced regularly. It is strongly recommended that all servicing related to these systems be done by an authorized Ford Dealer.
  • Page 490 C OOLING SYSTEM FEATURES OUTLINE ..............E-2 OUTLINE OF CONSTRUCTION......E-2 FEATURES ............E-2 SERVICE OUTLINE ..............E-2 SUPPLEMENTAL SERVICE INFORMATION ..E-2 RADIATOR ............. E-3 RADIATOR REMOVAL/INSTALLATION ..... E-3 E–1...
  • Page 491 OUTLINE OUTLINE OUTLINE OF CONSTRUCTION BVF360201004W01 • The construction and operation of the cooling system for the new RANGER is the same as that of the current RANGER except for the following features. (See RANGER Training Manual F326-10-99A.) End Of Sie FEATURES BVF360201004W02 Improved cooling performance...
  • Page 492 RADIATOR RADIATOR RADIATOR REMOVAL/INSTALLATION BVF361615200W01 1. Disconnect the negative battery cable. 2. Drain the engine coolant. 3. Remove the oil hose. 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 6. Refill the radiator with the specified amount and type of engine coolant. 7.
  • Page 494 F UEL AND EMISSION CONTROL SYSTEMS (WL Turbo) FEATURES OUTLINE .............. F2-2 OUTLINE OF CONSTRUCTION......F2-2 FEATURES ............F2-2 SPECIFICATIONS ..........F2-2 SERVICE OUTLINE .............. F2-2 SUPPLEMENTAL SERVICE INFORMATION ... F2-2 ENGINE TUNE-UP ..........F2-3 IDLE SPEED ADJUSTMENT......F2-3 F2–1...
  • Page 495 OUTLINE OUTLINE OUTLINE OF CONSTRUCTION BVF400202000W01 • An AT (RA4AX-EL) model has been adopted. • The construction and operation of the fuel and emission control system is essentially carried over from that of the current EVEREST MT model, except for the following features. (See RANGER Training Manual F326-10- 99A.) End Of Sie FEATURES...
  • Page 496 ENGINE TUNE-UP ENGINE TUNE-UP IDLE SPEED ADJUSTMENT BVF400802000W01 WL Turbo 1. Perform "Engine tune-up preparation". Caution • Turning the idle switch with its connector connected can break the harness. Be sure to disconnect the connector when turning the idle switch more than one rotation. 2.
  • Page 498 EVEREST Repair Manual Supplement (F187–10–03G) A UTOMATIC TRANSMISSION (RA4AX-EL) FEATURES SERVICE OUTLINE .............. K1-3 OUTLINE ............K1-43 OUTLINE OF CONSTRUCTION ....... K1-3 SUPPLEMENTAL SERVICE FEATURES............K1-3 INFORMATION ..........K1-43 SPECIFICATIONS ..........K1-3 LOCATION INDEX ..........K1-44 AUTOMATIC TRANSMISSION ......K1-4 AUTOMATIC TRANSMISSION OUTLINE ............
  • Page 499 EVEREST Repair Manual Supplement (F187–10–03G) TRANSMISSION FLUID TEMPERATURE NO.12 TORQUE CONVERTER (TFT) SWITCH INSPECTION ....K1-64-5 CLUTCH (TCC) NON-OPERATION ...K1-132 NO.13 NO KICKDOWN........K1-132 TCM INSPECTION ........K1-64-6 NO.14 ENGINE FLARES UP OR TCM REMOVAL/INSTALLATION ....K1-68 SLIPS WHEN UPSHIFTING OR AUTOMATIC TRANSMISSION DOWNSHIFTING ........K1-133 REMOVAL/INSTALLATION ......
  • Page 500 OUTLINE OUTLINE OUTLINE OF CONSTRUCTION BVF560201034W01 • The RA4AX-EL type electronically controlled automatic transmission with four-speeds and a TCC mechanism combining advanced electronic and mechanical technologies has been adopted. End Of Sie FEATURES BVF560201034W02 Improved marketability • Electronically controlled automatic transmission has been adopted. Improved drivability •...
  • Page 501 AUTOMATIC TRANSMISSION AUTOMATIC TRANSMISSION OUTLINE BVF561001030W01 Outline of operation • The outline of the electronically-controlled automatic transmission is classified into three systems: the powertrain system (includes the torque converter mechanism), the hydraulic control system, and the electronic control system. Powertrain system •...
  • Page 502 AUTOMATIC TRANSMISSION Operation of Shift pattern Transmission solenoid valve Brake band Reverse Non- HOLD HOLD Non- HOLD HOLD Non- HOLD HOLD : Operating. : Transmits the torque only when driving. BCF0513T038 *1 : Hydraulic pressure is applied to both 2GR applied side and 3GR release side of band servo piston. However, because area of 3GR release side is larger than 2GR applied side, brake band does not operate.
  • Page 503 AUTOMATIC TRANSMISSION End Of Sie CROSS-SECTIONAL VIEW BVF561001030W02 OIL PUMP BRAKE BAND FRONT FORWARD ONE-WAY CLUTCH PLANETARY CARRIER REVERSE HIGH FORWARD CLUTCH CLUTCH CLUTCH LOW AND REVERSE BRAKE REAR OVERRUNNING PLANETARY CLUTCH LOW ONE-WAY CLUTCH CARRIER INPUT SHAFT OUTPUT SHAFT TORQUE CONVERTER CONTROL VALVE PARKING GEAR...
  • Page 504 EVEREST Repair Manual Supplement (F187–10–03G) AUTOMATIC TRANSMISSION Structure OUTPUT SPEED SENSOR NE SENSOR TR SWITCH DROPPING RESISTOR ECT SENSOR AUTOMATIC TRANSMISSION OIL COOLER VEHICLE SPEEDOMETER SENSOR HOLD SOLENOID VALVE HOLD INDICATOR TFT SENSOR ACCELERATOR POSITION SENSOR TFT SWITCH IDLE SWITCH HOLD SWITCH BVF5600WC002 End Of Sie...
  • Page 505 EVEREST Repair Manual Supplement (F187–10–03G) AUTOMATIC TRANSMISSION AUTOMATIC TRANSAXLE CONTROL SYSTEM WIRING DIAGRAM BVF561001030W04 ACCELERATOR POSITION SENSOR *1 CONTROL LEVER POSITION SENSOR *2 ACCELERATOR POSITION SHIFT SOLENOID A CORRECTIVE RESISTOR TFT SENSOR SHIFT SOLENOID B ECT SENSOR OVERRUNNING CLUTCH SOLENOID TCC SOLENOID PRESSURE CONTROL SOLENOID...
  • Page 506 EVEREST Repair Manual Supplement (F187–10–03G) AUTOMATIC TRANSMISSION AUTOMATIC TRANSAXLE BLOCK DIAGRAM BVF561001030W05 INPUT SIGNAL OUTPUT SIGNAL . PRESSURE CONTROL SOLENOID OUTPUT SPEED SENSOR . SHIFT SOLENOID A . SHIFT SOLENOID B . OVERRUNNING NE SENSOR CLUTCH SOLENOID . TCC SOLENOID TR SWITCH HOLD SWITCH INSTRUMENT CLUSTER...
  • Page 507 EVEREST Repair Manual Supplement (F187–10–03G) AUTOMATIC TRANSMISSION Component Description (Electronic Control) Part name Function • Detects output shaft revolution speed Input system Output speed sensor • Detects vehicle speed • If output speed sensor fails, vehicle speed sensor acts as a Vehicle speedometer sensor substitute •...
  • Page 508 AUTOMATIC TRANSMISSION POWERTRAIN DESCRIPTION BVF561001030W07 Outline • In the powertrain system, hydraulic pressure is transported from the control valves to operate the clutches and brakes and the planetary gear changes the gear ratio according to the vehicle driving condition. • The powertrain system of the RA4AX-EL type consists of six pairs of clutches, two pairs of brakes, two pair of one-way clutch, and two pairs of single type planetary gears.
  • Page 509 AUTOMATIC TRANSMISSION Powerflow R position LOW AND REVERSE BRAKE FREE FRONT INTERNAL GEAR FRONT PLANETARY CARRIER FRONT PINION GEAR FRONT SUN GEAR OUTPUT SHAFT INPUT SHAFT REAR PLANETARY CARRIER REVERSE CLUTCH ALL DIRECTIONS OF ROTATION ARE VIEWED FROM THE ENGINE. Input shaft rotates clockwise Reverse clutch engaged Front sun gear rotates clockwise...
  • Page 510 AUTOMATIC TRANSMISSION FORWARD CLUTCH FORWARD ONE-WAY LOCK CLUTCH LOCK LOW ONE-WAY CLUTCH OUTPUT SHAFT INPUT SHAFT REAR SUN GEAR REAR PLANETARY CARRIER REAR PINION GEAR REAR INTERNAL GEAR ALL DIRECTIONS OF ROTATION ARE VIEWED FROM THE ENGINE. Input shaft rotates clockwise Rear sun gear rotates clockwise Rear pinion gear rotates counterclockwise Counterclockwise rotation of rear internal gear prevented...
  • Page 511 AUTOMATIC TRANSMISSION 1GR (engine braking) LOW AND REVERSE BRAKE OVERRUNNING CLUTCH OUTPUT SHAFT REAR SUN GEAR INPUT SHAFT REAR PLANETARY CARRIER REAR PINION GEAR REAR INTERNAL GEAR ALL DIRECTIONS OF ROTATION ARE VIEWED FROM THE ENGINE. Output shaft rotates clockwise Rear planetary carrier rotates clockwise Rotation of rear internal gear prevented by low and reverse brake via overrunning clutch...
  • Page 512 AUTOMATIC TRANSMISSION FORWARD CLUTCH LOCK FORWARD FREE ONE-WAY CLUTCH FRONT INTERNAL GEAR FRONT PLANETARY CARRIER FRONT PINION GEAR OUTPUT SHAFT FRONT SUN GEAR REAR SUN GEAR REAR PLANETARY CARRIER INPUT SHAFT REAR PINION GEAR REAR INTERNAL GEAR BRAKE BAND ALL DIRECTIONS OF ROTATION ARE VIEWED FROM THE ENGINE. Input shaft rotates clockwise Front internal gear rotates clockwise Front pinion gear walks clockwise around...
  • Page 513 AUTOMATIC TRANSMISSION 2GR (engine braking) OVERRUNNING CLUTCH FORWARD CLUTCH FRONT INTERNAL GEAR FRONT PLANETARY CARRIER FRONT PINION GEAR FRONT SUN GEAR REAR SUN GEAR INPUT SHAFT REAR PLANETARY CARRIER REAR PINION GEAR REAR INTERNAL GEAR BRAKE BAND ALL DIRECTIONS OF ROTATION ARE VIEWED FROM THE ENGINE. Output shaft rotates clockwise Rear planetary carrier rotates clockwise Front internal gear rotates clockwise...
  • Page 514 AUTOMATIC TRANSMISSION LOCK FORWARD CLUTCH FORWARD FREE ONE-WAY CLUTCH FRONT PLANETARY CARRIER HIGH-CLUTCH OUTPUT SHAFT REAR SUN GEAR INPUT SHAFT REAR PLANETARY CARRIER REAR PINION GEAR REAR INTERNAL GEAR ALL DIRECTIONS OF ROTATION ARE VIEWED FROM THE ENGINE. Input shaft rotates clockwise High clutch engaged Front planetary carrier rotates clockwise Forward clutch engaged...
  • Page 515 AUTOMATIC TRANSMISSION 3GR (engine braking) OVERRUNNING CLUTCH FORWARD CLUTCH FRONT PLANETARY CARRIER HIGH-CLUTCH OUTPUT SHAFT INPUT SHAFT REAR SUN GEAR REAR PLANETARY CARRIER REAR PINION GEAR REAR INTERNAL GEAR ALL DIRECTIONS OF ROTATION ARE VIEWED FROM THE ENGINE. Output shaft rotates clockwise Rear planetary carrier rotates clockwise Rear pinion gear fixed...
  • Page 516 AUTOMATIC TRANSMISSION FREE FRONT PLANETARY CARRIER FRONT INTERNAL GEAR FRONT PINION GEAR FRONT SUN GEAR OUTPUT SHAFT INPUT SHAFT REAR PLANETARY CARRIER HIGH-CLUTCH BRAKE BAND ALL DIRECTIONS OF ROTATION ARE VIEWED FROM THE ENGINE. Input shaft rotates clockwise High clutch engaged Front planetary carrier rotates clockwise Rotation of front sun gear prevented by brake band Front pinion gear walks clockwise around sun gear while...
  • Page 517 AUTOMATIC TRANSMISSION TORQUE CONVERTER DESCRIPTION BVF561019100W01 Outline • The RA4AX–EL type torque converter adopts a TCC mechanism. • The TCC mechanism mechanically engages the pump impeller and the turbine runner under certain conditions, and transmits the power, not through the fluid, but directly, preventing the slip loss of the torque converter.
  • Page 518 AUTOMATIC TRANSMISSION OIL PUMP DESCRIPTION BVF561019220W01 Function • A variable-capacity-vane type oil pump has been adopted to improve fuel economy. • In an involute gear type oil pump, discharge volume goes up in proportion to the engine speed; however, the variable-capacity- vane type fixes oil discharge volume when the engine speed reaches or exceeds a certain level to eliminate torque loss caused by feeding more than the required volume of oil.
  • Page 519 AUTOMATIC TRANSMISSION CONTROL VALVE BODY DESCRIPTION BVF561021100W01 Outline Features • The control valve body governs the hydraulic pressure from the oil pump, operates the inner valves according to the level of each hydraulic pressure, and operates each functional part. UPPER VALVE BODY RETURN SPRING SHUTTLE SHIFT VALVE S...
  • Page 520 AUTOMATIC TRANSMISSION Construction • The control valve body comprises an upper control valve body and a lower control valve body. • Each oil passage inside of the control valve is designed like a maze, and each valve is located within these passages.
  • Page 521 AUTOMATIC TRANSMISSION HOLD SWITCH DESCRIPTION BVF561046030W01 Outline • The HOLD switch is attached to the selector lever knob. HOLD mode can be selected by ON/OFF of the HOLD switch. HOLD SWITCH HOLD SWITCH SELECTOR LEVER BCF0513T047 Operation • The PCM detects usage of the HOLD switch and selects the HOLD mode. •...
  • Page 522 AUTOMATIC TRANSMISSION End Of Sie CONTROL LEVER POSITION SENSOR AND IDLE SWITCH DESCRIPTION BVF561046030W03 Outline • The control lever position sensor inputs the depressing amount of the accelerator pedal to the TCM. The TCM detects the signal inputted from the control lever position sensor as a FIP control lever opening signal. position.
  • Page 523 EVEREST Repair Manual Supplement (F187–10–03G) AUTOMATIC TRANSMISSION VEHICLE SPEEDOMETER SENSOR DESCRIPTION BVF561046030W05 Outline • The vehicle speedometer sensor is located in the speedometer (instrument cluster). • The vehicle speedometer sensor acts as a substitute for output speed sensor if it malfunction. VEHICLE SPEEDOMETER SENSOR BVF0513T048 End Of Sie...
  • Page 524 EVEREST Repair Manual Supplement (F187–10–03G) AUTOMATIC TRANSMISSION AUTOMATIC TRANSMISSION K 1 A UTOMATIC TRANSMISSION (RA4AX-EL) K1–1–1 ACCELERATOR POSITION SENSOR, IDLE SWITCH DESCRIPTION BVF561019200W02 Accelerator Position Sensor Outline • The accelerator position sensor is installed on the accelerator pedal, and detects how much the accelerator pedal is being depressed from the change in the resistance value (variable resistance).
  • Page 525 EVEREST Repair Manual Supplement (F187–10–03G) AUTOMATIC TRANSMISSION Structure/Operation • When the push rod is pushed in (the accelerator pedal is released) a preset amount, the contact of (ACCELERATOR the idle switch closes, and the TCM determines (ACCELERATOR IDLE SWITCH PEDAL IS PEDAL IS that the engine is idling.
  • Page 526 AUTOMATIC TRANSMISSION Structure/Operation • The TFT sensor is a thermistor type and the resistance changes according to the ATF temperature. • The characteristic of the resistance is as shown in the figure below: when the ATF temperature increases, the resistance decreases, and when the ATF temperature decreases, the resistance increases. •...
  • Page 527 AUTOMATIC TRANSMISSION SOLENOID VALVE DESCRIPTION BVF561019900W01 Outline • The solenoid valves are located on the control valve body. • The solenoids have the following functions. Function chart Solenoid Type Application Pressure control solenoid Duty cycle type • Switches line pressure between high and low Shift solenoid A ON/OFF type •...
  • Page 528 AUTOMATIC TRANSMISSION NEEDLE VALVE DRAIN FILTER BCF0513T016 Shift solenoid A/Shift solenoid B • The shift solenoids control pilot pressure (line pressure adjusted by the pilot valve) applied to the shift valve A and the shift valve B. • The shift solenoids are switched ON/OFF by electrical signals from the TCM. •...
  • Page 529 AUTOMATIC TRANSMISSION TCC solenoid • The TCC solenoids controls TCC control valve operation. • The TCC solenoid is a duty cycle type which freely controls the ratio of ON time to OFF time in one cycle from 5 to 95%. It repeats ON/OFF at a frequency of 50 Hz (0.02 s cycles) and opens and closes the drain circuit to control pilot pressure.
  • Page 530 AUTOMATIC TRANSMISSION Overrunning clutch solenoid • The overrunning clutch solenoid controls the overrunning clutch (engine braking). • The TCM signals switch the overrunning clutch solenoid ON/OFF. Condition ATF flow Operation • The TCM applies an electronic current to the solenoid valve Hydraulic pressure retention •...
  • Page 531 EVEREST Repair Manual Supplement (F187–10–03G) AUTOMATIC TRANSMISSION SHIFT CONTROL DESCRIPTION BVF561018901W02 Outline • The TCM selects and determines the shift diagram based on the signals from TR switch and HOLD switch. Then, based on the shift diagram, the TCM sends the signal to the duty-cycle type solenoid valves and the ON/ OFF type solenoid valves, according to the output speed sensor signal (vehicle speed signal) and the depressing amount of accelerator pedal, to perform shifting.
  • Page 532 EVEREST Repair Manual Supplement (F187–10–03G) AUTOMATIC TRANSMISSION LINE PRESSURE CONTROL DESCRIPTION BVF561018901W03 Outline • The TCM controls the pressure control solenoid to regulate throttle pressure based on electronic signals received from the control lever position sensor or accelerator position sensor which detects the depressing amount of accelerator pedal.
  • Page 533 EVEREST Repair Manual Supplement (F187–10–03G) AUTOMATIC TRANSMISSION Operation Normal condition • Line pressure is adjusted to meet the required pressure for each clutch and minimizes oil pump R POSITION driving loss. D, S AND L RANGES ACCELERATOR OPENING BVF5610WC015 When engine braking •...
  • Page 534 AUTOMATIC TRANSMISSION TORQUE CONVERTER CLUTCH (TCC) CONTROL DESCRIPTION BVF561018901W04 Outline • Based on vehicle speed, the depressing amount of accelerator pedal, ATF temperature and the result of range determination, the TCM determines the TCC diagram and sends signals to the TCC solenoid. •...
  • Page 535 AUTOMATIC TRANSMISSION Operation TCC engagement • When the TCM determines TCC engagement, it sends signals of 95% duty ratio (50 Hz ON time ratio) to the TCC solenoid. Subsequently the pilot pressure applied to the right end of the TCC control valve is drained. •...
  • Page 536 AUTOMATIC TRANSMISSION TCC release • When the TCM determines TCC release, it sends signals of approximately 5% duty ratio (50 Hz ON time ratio) to the TCC solenoid. The pilot pressure applied to the right end of the TCC control valve and the TCC control valve is pushed to the left side by pilot pressure and spring force.
  • Page 537 AUTOMATIC TRANSMISSION ENGINE BRAKING CONTROL (OVERRUNNING CLUTCH) DESCRIPTION BVF561018901W05 Outline • The forward one-way clutch is employed to reduce shift shock during down shifting. Operation • Drive force from the engine is transmitted to the rear wheels by the forward one-way clutch, but reverse- direction drive force from the rear wheels is not transmitted to the engine because the one-way clutch freewheels.
  • Page 538 AUTOMATIC TRANSMISSION COOLING SYSTEM DESCRIPTION BVF561019900W02 Outline • A water cooling type AT oil cooler is adopted and installed in the radiator. The oil cooler cools the ATF heated in the AT body. • A air cooling type AT oil cooler is adopted and installed in front of the radiator. RADIATOR (IN TANK OIL COOLER) AIR COOLING TYPE OIL COOLER...
  • Page 539 EVEREST Repair Manual Supplement (F187–10–03G) ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC (OBD) SYSTEM DESCRIPTION BVF567001030W01 • If a malfunction occurs, the OBD system warns the driver by flashing the HOLD indicator and records it in the TCM. • The recorded DTC is output on the HOLD indicator by short the TAT terminal of the DLC to the GND. •...
  • Page 540 EVEREST Repair Manual Supplement (F187–10–03G) ON-BOARD DIAGNOSTIC Display of DTC • When the TAT terminal of the DTC is short to the GND with the ignition switch ON, the HOLD indicator will flash the DTC recorded by the TCM. • The TCM displays each service code currently in memory one time in numerical order starting with the lowest number.
  • Page 541 EVEREST Repair Manual Supplement (F187–10–03G) ON-BOARD DIAGNOSTIC Fail-safe Function • If any malfunction is detected by the self-diagnosis function, the TCM will preserve driveability as much as possible. Output speed sensor • If a malfunction occurs in the output speed sensor, signals from the vehicle speedometer sensor control the shift.
  • Page 542 OUTLINE OUTLINE SUPPLEMENTAL SERVICE INFORMATION BVF560201034W04 • The following changes and/or additions have been made since publication of the EVEREST Repair Manual (F183–10–03A). Automatic Transmission • RA4AX-EL type automatic transmission has been adopted. End Of Sie K1–43...
  • Page 543 EVEREST Repair Manual Supplement (F187–10–03G) LOCATION INDEX LOCATION INDEX AUTOMATIC TRANSMISSION LOCATION INDEX BVF560001074W01 HOLD BVF5600WC001 K1–44 Revised 1/2006 (Ref. No. LF001/06)
  • Page 544 EVEREST Repair Manual Supplement (F187–10–03G) LOCATION INDEX Oil seal Automatic transmission fluid (ATF) (See K1–75 OIL SEAL REPLACEMENT.) (See K1–51 AUTOMATIC TRANSMISSION FLUID (ATF) INSPECTION.) Control valve body (See K1–53 AUTOMATIC TRANSMISSION FLUID (See K1–76 CONTROL VALVE BODY REMOVAL/ (ATF) REPLACEMENT.) INSTALLATION.) HOLD switch Oil cooler...
  • Page 545 AUTOMATIC TRANSMISSION AUTOMATIC TRANSMISSION MECHANICAL SYSTEM TEST BVF561001030W08 Mechanical System Test Preparation 1. Engage the parking brake and use wheel chocks at the front and rear of the wheels. 2. Inspect the engine coolant level. (See Section E.) 3. Inspect the engine oil level. (See Section E.) 4.
  • Page 546 EVEREST Repair Manual Supplement (F187–10–03G) AUTOMATIC TRANSMISSION Warning • Removing the square head plug when the ATF is hot can be dangerous. Hot ATF can come out of the opening and badly burn you. Before removing the square head plug, allow the ATF to cool. 15.
  • Page 547 AUTOMATIC TRANSMISSION Evaluation of stall test Condition Possible cause Insufficient line pressure Worn oil pump In all forward ranges and R Poor adjustment or malfunction of TR switch position Oil leakage from oil pump, control valve, or transmission case Pressure regulator valve sticking Forward clutch slippage In D and S ranges Forward one-way clutch slippage...
  • Page 548 AUTOMATIC TRANSMISSION Road Test Preparation 1. Inspect the engine coolant level. (See Section E.) 2. Inspect the engine oil level. (See Section E.) 3. Inspect the ATF level. (See K1–52 Automatic Transmission Fluid (ATF) Level Inspection.) 4. Inspect the idle speed in the P position. (See Section F2.) 5.
  • Page 549 AUTOMATIC TRANSMISSION 11. Verify that 3→2, and 2→3 shift can be obtained. The shift points must be as shown in the table below. • If there is any malfunction, inspect the TCM and AT. (See K1–121 SYMPTOM TROUBLESHOOTING ITEM TABLE.) 12.
  • Page 550 AUTOMATIC TRANSMISSION Shift point table Depressing amount of Vehicle speed Turbine speed Range Mode accelerator Shift (km/h {mph}) (rpm) pedal condition 32—38 {20—23} 3,350—3,900 →S Fully depress 66—74 {41—45} 3,700—4,100 →S 13—21 {9—13} 1,350—2,150 →S Half depress 24—39 {15—24} 1,350—2,150 →S NORMAL 16—22 {10—13}...
  • Page 551 AUTOMATIC TRANSMISSION AUTOMATIC TRANSMISSION FLUID (ATF) INSPECTION BVF561019001W01 Automatic Transmission Fluid (ATF) Condition Inspection 1. Inspect the ATF for the following to determine whether the transmission should be disassembled. • The ATF is muddy. • The ATF smells strange or unusual. ATF Condition Condition Possible cause...
  • Page 552 AUTOMATIC TRANSMISSION 7. Shift back to P position. Note • If the ATF level is too high or too low when the engine is hot, the following malfunctions may occur. ATF level Condition Possible cause Air in transmission oil Line pressure is passage causes slipping or Too low lower than the...
  • Page 553 AUTOMATIC TRANSMISSION HOLD SWITCH INSPECTION BVF561046030W09 Operating Inspection 1. Turn the engine switch to the ON position (engine OFF). 2. Verify that the HOLD indicator light is not illuminated. Depress the HOLD switch and verify that the HOLD indicator light illuminates. •...
  • Page 554 AUTOMATIC TRANSMISSION 5. Connect the HOLD switch connector. 6. Install the console. 7. Install the shift lever knob. 8. Connect the negative battery cable. HOLD SWITCH CONNECTOR BCF5610W007 End Of Sie HOLD SWITCH REMOVAL/INSTALLATION BVF561046030W10 1. Disconnect the negative battery cable. 2.
  • Page 555 AUTOMATIC TRANSMISSION TRANSMISSION RANGE (TR) SWITCH INSPECTION BVF561046030W11 Operating Inspection 1. Verify that the starter operates only with the engine switch is turned to the START position with the selector lever in the P or N position. • If there is any malfunction, adjust the TR switch. (See K1–57 TRANSMISSION RANGE (TR) SWITCH ADJUSTMENT.) 2.
  • Page 556 AUTOMATIC TRANSMISSION TRANSMISSION RANGE (TR) SWITCH REMOVAL/INSTALLATION BVF561046030W12 Caution • Water or foreign material entering the connector can cause a poor connection or corrosion. Be sure that water or foreign material do not enter the connector when disconnecting it. 1. Disconnect the negative battery cable. 2.
  • Page 557 AUTOMATIC TRANSMISSION 6. Loosen the TR switch mounting bolts. 7. Align the holes of the TR switch and the manual shaft lever. 8. Insert an approx. 4.0 mm {0.157 in} outer diameter pin through the holes. BCF5610W008 9. Tighten the mounting bolts, then remove the pin. PIN DIAMETER : Tightening torque 4.0mm {0.157 in}...
  • Page 558 AUTOMATIC TRANSMISSION TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR REMOVAL/INSTALLATION BVF561046030W15 Warning • A hot transmission and ATF can cause severe burn. Turn off the engine and wait until they are cool before replacing the ATF. 1. Disconnect the negative battery cable. 2.
  • Page 559 AUTOMATIC TRANSMISSION OUTPUT SPEED SENSOR REMOVAL/INSTALLATION BVF561046030W17 1. Disconnect the negative battery cable. 2. Disconnect the output speed sensor connector. 3. Remove the output speed sensor. 4. Apply ATF to a new O-ring and install it on the output speed sensor. 5.
  • Page 560 AUTOMATIC TRANSMISSION TCC Solenoid Valve 1. Connect the (+) and (–) terminals of a dwell meter to terminals 1I and 1B (GND) of the TCM. 2. Drive the vehicle. Note • The dwell meter indicates the OFF duty ratio. 3. Verify the duty ratio in the TCC condition. •...
  • Page 561 AUTOMATIC TRANSMISSION Continuity Inspection 1. Disconnect the negative battery cable. 2. Disconnect the instrument cluster connector. 3. Inspect for continuity between terminal 3A and the TCM 3A terminal. • If there is any malfunction, inspect the wiring harness (instrument cluster—TCM). Terminals Continuity 3A—3A...
  • Page 562 EVEREST Repair Manual Supplement (F187–10–03G) AUTOMATIC TRANSMISSION VEHICLE SPEED SENSOR (VSS) INSPECTION BVF561021280W06 1. Remove the VSS. (See K1–63 VEHICLE SPEED SENSOR (VSS) REMOVAL/INSTALLATION.) 2. Measure voltage between terminals of the VSS while the gear is turning. Voltmeter needle Action Repair wiring harness Moves slightly under 5V (Instrument cluster-vehicle...
  • Page 563 EVEREST Repair Manual Supplement (F187–10–03G) AUTOMATIC TRANSMISSION NE SENSOR REMOVAL/INSTALLATION BVF561019200W04 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. Connector 7.8—10.8 N·m {80—110 kgf·cm, Bolt 70—95 in·lbf} NE sensor 3. Install in the reverse order of removal. BVF5610WC004 End Of Sie ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION...
  • Page 564 EVEREST Repair Manual Supplement (F187–10–03G) AUTOMATIC TRANSMISSION AUTOMATIC TRANSMISSION K 1 A UTOMATIC TRANSMISSION (RA4AX-EL) K1–64 ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION BVF561019200W06 1. Disconnect the negative battery cable. 2. Disconnect the ECT sensor connector 3. Remove the ECT sensor. WATER OUTLET GASKET 4.
  • Page 565 EVEREST Repair Manual Supplement (F187–10–03G) AUTOMATIC TRANSMISSION Circuit open/short inspection 5. Disconnect the TCM connector. (See K1–68 TCM REMOVAL/INSTALLATION.) 6. Disconnect the accelerator position sensor connector. 7. Inspect for an open or short circuit in the following wiring harnesses. • If there is an open or short circuit, repair or replace wiring harnesses.
  • Page 566 EVEREST Repair Manual Supplement (F187–10–03G) AUTOMATIC TRANSMISSION Circuit open/short inspection 1. Disconnect the TCM connector. (See K1–68 TCM REMOVAL/INSTALLATION.) 2. Disconnect the idle switch connector. 3. Inspect for an open or short circuit in the following wiring harnesses. • If there is an open or short circuit, repair or IDLE SWITCH replace wiring harnesses.
  • Page 567 EVEREST Repair Manual Supplement (F187–10–03G) AUTOMATIC TRANSMISSION ACCELERATOR POSITION SENSOR, IDLE SWITCH ADJUSTMENT BVF561019200W09 Caution • Adjusting the accelerator position sensor and idle switch unnecessarily may adversely affect engine control. Therefore, adjust accelerator position sensor and/or idle switch only when it is replaced.
  • Page 568 EVEREST Repair Manual Supplement (F187–10–03G) AUTOMATIC TRANSMISSION 7. While fully depressing the accelerator pedal until it contacts the stopper rubber, adjust the stopper rubber installation position so that the TP and TP2 V value is between 3.4 to 3.8 V (target value STOPPER RUBBER 3.6 V).
  • Page 569 EVEREST Repair Manual Supplement (F187–10–03G) AUTOMATIC TRANSMISSION TCM INSPECTION BVF561018901W06 Terminal Voltage Table (Reference) Note • Use the ground of terminal 3B and 3U of the TCM when measuring terminal voltage, as an error may occur when connecting the negative circuit tester to ground. TCM HARNESS SIDE CONNECTOR 2F 2D BCF5610W024...
  • Page 570 EVEREST Repair Manual Supplement (F187–10–03G) AUTOMATIC TRANSMISSION K 1 A UTOMATIC TRANSMISSION (RA4AX-EL) AUTOMATIC TRANSMISSION Terminal Signal Connected to Condition Voltage (V) Inspection item(s) Battery back • Related harness Battery Constant up supply — — — — — — — —...
  • Page 571 EVEREST Repair Manual Supplement (F187–10–03G) AUTOMATIC TRANSMISSION Terminal Signal Connected to Condition Voltage (V) Inspection item(s) — — — — — — — — — — • TR switch D range (See K1–56 TRANSMISSION D range TR switch Engine switch ON RANGE (TR) signal (D range)
  • Page 572 AUTOMATIC TRANSMISSION Inspection Using An Oscilloscope (Reference) Pressure solenoid valve control • TCM terminal: 1E (+)—1B (–) • Oscilloscope setting: 5V/DIV (Y) 5ms/DIV (X) • Measuring condition: N position, Idle BCF5610W060 • TCM terminal: 1E (+)—1B (–) • Oscilloscope setting: 5V/DIV (Y) 5ms/DIV (X) •...
  • Page 573 AUTOMATIC TRANSMISSION TCM REMOVAL/INSTALLATION BVF561018901W07 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. 4. Connect the negative battery cable. 3.3—4.9 N·m {34—49 kgf·cm,, 30—42 in·lbf} BCF5610W025 TCM connector End Of Sie...
  • Page 574 AUTOMATIC TRANSMISSION AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION BVF561019090W01 1. Disconnect the negative battery cable. 2. Drain the ATF. (See K1–53 AUTOMATIC TRANSMISSION FLUID (ATF) REPLACEMENT.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. 5.
  • Page 575 AUTOMATIC TRANSMISSION 1.5—2.9 N·m {15—30 kgf·cm, 13—26 in·lbf} 7.9—10.7 N·m {80—110 kgf·cm, 70—95 in·lbf} 7.9—10.7 N·m {80—110 kgf·cm, 70—95 in·lbf} 7.9—10.7 N·m {80—110 kgf·cm, 70—95 in·lbf} 28—30 {2.8—3.1, 21—22} 28—30 {2.8—3.1, 21—22} 24—35 {2.4—3.6 , 18—25} 7.9—10.7 N·m {80—110 kgf·cm, 70—95 in·lbf} 37—52 {3.8—5.3, 28—38}...
  • Page 576 AUTOMATIC TRANSMISSION Front propeller shaft Crossmember (See K1–72 Crossmember Removal Note.) Rear propeller shaft Oil filter tube, Dipstick VSS connector Connector Selector cable (See K1–71 Selector Cable Removal Note.) Transmission installation bolt (See K1–74 Selector Cable Installation Note.) Transmission Starter (See K1–73 Transmission Removal Note.) (See K1–73 Transmission Installation Note.) Oil pipe, oil hose...
  • Page 577 AUTOMATIC TRANSMISSION Torque Converter Installation Bolts Removal Note Caution • Do not remove the drive plate installation nuts. 1. Lock the drive plate using a flathead screwdriver as shown in the figure. 2. Remove the torque converter installation bolts. BCF5610W030 Crossmember Removal Note 1.
  • Page 578 AUTOMATIC TRANSMISSION Transmission Removal Note Warning • Verify that the transmission is securely supported by the jack. If the transmission falls, serious injury or death and damage to the vehicle could result. Before removing the transmission make sure that the jack is securely supporting the transmission. Caution •...
  • Page 579 AUTOMATIC TRANSMISSION Torque Converter Installation Bolts Installation Note 1. Align the holes by turning the torque converter. 2. Lock the drive plate using a flathead screwdriver. Caution • Loosely and equally tighten the torque converter bolts, then further tighten them to the specified tightening torque.
  • Page 580 AUTOMATIC TRANSMISSION TRANSFER REMOVAL/INSTALLATION BVF561019090W02 1. Disconnect the negative battery cable. 2. Remove the following parts. (1) Shift lever knob (2) Selector lever knob component (3) Console (4) Insulator plate, boot (5) 4 × 4 shift lever (6) Crossmember (7) Front propeller shaft (8) Rear propeller shaft (9) Speedometer cable (10)Under cover (transfer side)
  • Page 581 AUTOMATIC TRANSMISSION CONTROL VALVE BODY REMOVAL/INSTALLATION BVF561021100W02 On-Vehicle Removal/Installation Warning • A hot transmission and ATF can cause severe burns. Turn off the engine and wait until they are cool before replacing ATF. • Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear protective eye wear whenever using compressed air.
  • Page 582 AUTOMATIC TRANSMISSION 12. Separate the solenoid harness from the harness clip. BCF5610A116 13. Remove bolts A and B and the bracket as shown in the figure. BRACKET BRACKET BCF5610A368 14. Remove the clip. 15. Separate the solenoid connectors. BCF5610A118 16. Carefully remove the control valve body component and accumulator springs.
  • Page 583 AUTOMATIC TRANSMISSION 17. If necessary, remove the solenoid connector from the transmission case. 18. Install the solenoid connector into the transmission case if removed. 19. Connect the solenoid connector to the solenoids. 20. Install the clip. O-RING BCF5610A121 21. Set the accumulator springs into the control valve body as shown in the figure.
  • Page 584 AUTOMATIC TRANSMISSION 25. Tighten the bolts in sequence. BRACKET Tightening torque 6.9—8.8 N·m {70—90 kgf·cm, 61—78 in·lbf} 26. Apply ATF to the new O-ring and install it onto the oil strainer. BRACKET BCF5610A368 27. Install the oil strainer. Bolt length (Measured from below the head) 52 mm {2.03 in} Tightening torque 6.9—8.8 N·m {70—90 kgf·cm, 61—78 in·lbf}...
  • Page 585 AUTOMATIC TRANSMISSION 35. Tighten the new bolts evenly and quickly. Tightening torque 6.9—8.8 N·m {70—90 kgf·cm, 61—78 in·lbf} 36. Install the front propeller shaft. 37. Add ATF and, with the engine idling, inspect the ATF level and inspect for leakage. (See K1–53 AUTOMATIC TRANSMISSION FLUID (ATF) REPLACEMENT.) (See K1–52 Automatic Transmission Fluid (ATF) Level Inspection.) 38.
  • Page 586 AUTOMATIC TRANSMISSION Back flushing 1. Using the power flushing equipment manufacturer's instructions, connect equipment so the flushing fluid flows in the opposite direction of normal fluid flow. 2. Flush oil cooler/lines until discharge fluid is clean. FLUSHING FLUID OUT Caution •...
  • Page 587 AUTOMATIC TRANSMISSION 24—35 {2.4—3.6, 18—25} 7.9—10.7 N·m {80—110 kgf·cm, 70—95 in·lbf} 24—35 {2.4—3.6, 18—25} 7.9—10.7 N·m {80—110 kgf·cm, 70—95 in·lbf} 7.9—10.7 N·m {80—110 kgf·cm, 70—95 in·lbf} N·m {kgf·m, ft·lbf} BCF5610W043 Connector bolt Oil hose (See K1–83 Oil Pipe, Hose clamp, Oil hose Washer Installation Note.) Oil pipe...
  • Page 588 AUTOMATIC TRANSMISSION Radiator (In Tank Oil Cooler) Installation Note 1. The automatic transmission oil cooler flushing must be performed whenever a transmission is removed for service because the existing fluid may be contaminated, and to prevent contamination of new fluid. Note •...
  • Page 589 AUTOMATIC TRANSMISSION OIL COOLER DISASSEMBLY/ASSEMBLY BVF561019900W05 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. 0.7—1.2 N·m {72—122 kgf·cm, 63—105 in·lbf} BCF5610W048 Mount rubber Packing Radiator outer tank (in-tank oil cooler) ATF cooler (See K1–84 Radiator Outer Tank (In-Tank Oil Radiator Cooler) Disassembly Note.)
  • Page 590 AUTOMATIC TRANSMISSION 3. Pivot the screwdriver to pry the tab away from the tank and repeat the procedure for each tab. Note • If any header tabs are missing from the core, SCREWDRIVER replace the radiator. 4. Remove the radiator outer tank and O-ring (gasket) from the core header when all of the tabs are opened.
  • Page 591 AUTOMATIC TRANSMISSION 4. Squeeze the header tabs down in the order as RADIATOR TANK shown in the figure against the lip of the radiator outer tank base with the locking-type pliers while rotating the pliers toward the tank. LOCKING TYPE PLIERS AEA5714W083 5.
  • Page 592 AUTOMATIC TRANSMISSION DRIVE PLATE REMOVAL/INSTALLATION BVF561019020W01 1. Remove the transmission (See K1–69 AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. THREAD- LOCKING COMPOUND 162—171 {16.5—17.5, 120—126} N·m {kgf·m, ft·lbf} BCF5610W044 Bolt Drive plate...
  • Page 593 AUTOMATIC TRANSMISSION Flywheel Installation Note 1. Install the flywheel and the drive plate to the crankshaft. 2. When reusing the bolts, clean threads and hole, then apply locking compound to the threads. Note • No locking compound is needed when using new bolts. 3.
  • Page 594 AUTOMATIC TRANSMISSION SHIFT MECHANISM AUTOMATIC TRANSMISSION SHIFT MECHANISM SELECTOR LEVER INSPECTION BVF561246102W01 1. Turn the engine switch to the ON position (engine OFF). 2. With the brake pedal depressed, verify that there is a “click” at each range when shifted. 3.
  • Page 595 AUTOMATIC TRANSMISSION SHIFT MECHANISM 5. Press the selector lever forward with 40—98 N {4—10 kgf, 9—22 lbf}, tighten lockbolt C while maintaining force. Tightening torque 7.9—10.7 N·m {80—110 kgf·cm, 70—95 in·lbf} 6. Turn locknut A by hand until it contacts the spacer.
  • Page 596 AUTOMATIC TRANSMISSION SHIFT MECHANISM 1.5—2.9 {15—30, 13—26} 7.9—10.7 {80—110, 70—95} 7.9—10.7 {80—110, 70—95} 7.9—10.7 {80—110, 70—95} 7.9—10.7 {80—110, 70—95} TRANSMISSION SIDE N·m {kgf·cm, in·lbf} BCF5712W006 K1–91...
  • Page 597 AUTOMATIC TRANSMISSION SHIFT MECHANISM Shift lever knob Indicator panel (See K1–93 Indicator Panel Installation Note.) Selector lever knob component Selector cable Console (See K1–92 Selector Cable Removal Note.) Insulator plate, boot (See K1–92 Selector Cable Installation Note.) (See K1–93 Insulator Plate, Boot Installation Note.) Selector lever Selector Cable Removal Note 1.
  • Page 598 AUTOMATIC TRANSMISSION SHIFT MECHANISM 5. Install the selector cable to selector lever as shown in the figure. 6. Adjust the selector lever position. (See K1–89 Selector Lever Position.) SELECTOR CABLE BCF5712W021 Indicator Panel Installation Note 1. Install the indicator panel. 2.
  • Page 599 AUTOMATIC TRANSMISSION SHIFT MECHANISM SELECTOR LEVER DISASSEMBLY/ASSEMBLY BVF561246102W04 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. 12—17 {1.3—1.7, 8.9—12.5} N·m {kgf·m, ft·lbf} BCF5712W007 Rod component Spindle Selector lever End Of Sie K1–94...
  • Page 600 ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC FOREWORD BVF567018901W01 • When the customer reports vehicle malfunction, check the HOLD indicator light flash, and diagnostic trouble code (DTC), then diagnose the malfunction according to following flowchart. — If the DTC exists, diagnose the applicable DTC inspection. (See K1–97 DTC TABLE.) —...
  • Page 601 ON-BOARD DIAGNOSTIC Using the HOLD indicator light 1. Turn the ignition switch off. Caution • Connecting to the wrong DLC terminal may cause a malfunction. Carefully connect only to the specified terminal. 2. Connect the DLC located in the engine compartment terminal TAT and ground using a jumper wire.
  • Page 602 EVEREST Repair Manual Supplement (F187–10–03G) ON-BOARD DIAGNOSTIC DTC TABLE BVF567018901W04 X: Applicable HOLD indicator Memory DTC No. Condition Page light function flashes NE sensor circuit malfunction (See K1–98 DTC 01) Output speed sensor circuit malfunction (See K1–100 DTC 06) Vehicle speedometer circuit malfunction (See K1–102 DTC 07) Engine coolant temperature (ECT) sensor circuit malfunction (See K1–104 DTC 09)
  • Page 603 ON-BOARD DIAGNOSTIC DTC 01 BVF567018901W05 DTC 01 NE sensor circuit malfunction • Signal from NE sensor is not input to TCM when engine running. Diagnostic support note: DETECTION CONDITION • HOLD indicator light flash. • DTC is stored in TCM memory. •...
  • Page 604 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT NE SENSOR SIGNAL CIRCUIT FOR Yes Go to next step. OPEN Repair or replace wiring, then go to Step 6. • Verify that NE sensor connector and TCM connector are disconnected. • Check continuity between NE sensor connector terminal A and TCM connector terminal 2F.
  • Page 605 ON-BOARD DIAGNOSTIC DTC 06 BVF567018901W06 DTC 06 Output speed sensor circuit malfunction • Signal from output speed sensor is not input to TCM when vehicle moving. Diagnostic support note: DETECTION CONDITION • HOLD indicator light flash. • DTC is stored in TCM memory. •...
  • Page 606 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION INSPECT OUTPUT SPEED SENSOR Yes Go to next step. • Inspect output speed sensor. Repair or replace output speed sensor, then go to Step 8. (See K1–59 OUTPUT SPEED SENSOR INSPECTION.) • Is result normal? INSPECT OUTPUT SPEED SENSOR Yes Go to next step.
  • Page 607 ON-BOARD DIAGNOSTIC DTC 07 BVF567018901W07 DTC 07 Vehicle speedometer sensor circuit malfunction • Signal from vehicle speedometer sensor is not input to TCM when vehicle moving. Diagnostic support note: DETECTION CONDITION • HOLD indicator light flashes. • DTC is stored in TCM memory. •...
  • Page 608 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION INSPECT VEHICLE SPEEDOMETER SENSOR Yes Go to next step. • Inspect speedometer. Repair or replace speedometer, then go to Step 6. (See Section T.) • Is result normal? INSPECT INSTRUMENT CLUSTER Yes Go to next step. CONNECTOR AND TCM CONNECTOR Repair terminals or replace instrument cluster, then go to •...
  • Page 609 ON-BOARD DIAGNOSTIC DTC 09 BVF567018901W08 DTC 09 Engine coolant temperature (ECT) sensor circuit malfunction • Signal from ECT sensor is not input to TCM. Diagnostic support note: DETECTION CONDITION • HOLD indicator light flashes. • DTC is stored in TCM memory. •...
  • Page 610 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION INSPECT ECT SENSOR Yes Go to next step. • Inspect ECT sensor. Repair or replace ECT sensor, then go to Step 7. (See section F2.) • Is result normal? INSPECT ECT SENSOR CONNECTOR AND Yes Go to next step.
  • Page 611 EVEREST Repair Manual Supplement (F187–10–03G) ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC K 1 A UTOMATIC TRANSMISSION (RA4AX-EL) STEP INSPECTION ACTION INSPECT ACCELERATOR POSITION SENSOR Yes Go to next step. CONNECTOR AND TCM CONNECTOR Repair terminals or replace accelerator position sensor, • Turn the engine switch off. then go to Step 9.
  • Page 612 EVEREST Repair Manual Supplement (F187–10–03G) ON-BOARD DIAGNOSTIC DTC 12 BVF567018901W09 WL Turbo Stage-III DTC 12 Accelerator position sensor circuit malfunction • When all condition below satisfied. — Idle switch is ON. — Accelerator position sensor signal voltage is 0.1 V or below or 4.9 V or above. DETECTION Diagnostic support note: CONDITION...
  • Page 613 EVEREST Repair Manual Supplement (F187–10–03G) ON-BOARD DIAGNOSTIC Except WL Turbo Stage-III DTC 12 Control lever position sensor circuit malfunction • When all condition below satisfied. — Idle switch is ON. — Control lever position sensor signal voltage is 0.1 V or below or 4.9 V or above. DETECTION Diagnostic support note: CONDITION...
  • Page 614 EVEREST Repair Manual Supplement (F187–10–03G) ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC K 1 A UTOMATIC TRANSMISSION (RA4AX-EL) Diagnostic procedure STEP INSPECTION ACTION INSPECT CONTROL LEVER POSITION Yes Go to next step. SENSOR CONNECTOR AND TCM CONNECTOR Repair terminals or replace control lever position sensor, •...
  • Page 615 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY AFTER REPAIR PROCEDURE Yes Go to applicable DTC inspection. • Perform “After Repair Procedure”. Troubleshooting completed. (See K1–96 AFTER REPAIR PROCEDURE.) • Is there any DTC present? End Of Sie DTC 56 BVF567018901W10 DTC 56 Transmission fluid temperature (TFT) sensor circuit malfunction •...
  • Page 616 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION INSPECT TFT SENSOR Yes Go to next step. • Inspect TFT sensor. Repair or replace TFT sensor, then go to Step 7. (See K1–58 TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR INSPECTION.) • Is result normal? INSPECT TFT SENSOR CONNECTOR AND Yes Go to next step.
  • Page 617 ON-BOARD DIAGNOSTIC DTC 60 BVF567018901W11 DTC 60 Shift solenoid A malfunction • Open or short in shift solenoid A signal circuit. Diagnostic support note: DETECTION CONDITION • HOLD indicator light flashes. • DTC is stored in TCM memory. • Open circuit between solenoid valve connector terminal B and TCM terminal 1F •...
  • Page 618 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION INSPECT SHIFT SOLENOID A Yes Go to next step. • Inspect shift solenoid A. Repair or replace shift solenoid A, then go to Step 6. (See K1–60 SOLENOID VALVE INSPECTION.) • Is result normal? INSPECT SOLENOID VALVE CONNECTOR Yes Go to next step.
  • Page 619 ON-BOARD DIAGNOSTIC DTC 61 BVF567018901W12 DTC 61 Shift solenoid B malfunction • Open or short in shift solenoid B signal circuit. Diagnostic support note: DETECTION CONDITION • HOLD indicator light flashes. • DTC is stored in TCM memory. • Open circuit between solenoid valve connector terminal C and TCM terminal 1H •...
  • Page 620 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION INSPECT SHIFT SOLENOID B Yes Go to next step. • Inspect shift solenoid B. Repair or replace shift solenoid B, then go to Step 6. (See K1–60 SOLENOID VALVE INSPECTION.) • Is result normal? INSPECT SOLENOID VALVE CONNECTOR Yes Go to next step.
  • Page 621 ON-BOARD DIAGNOSTIC DTC 62 BVF567018901W13 DTC 62 Overrunning clutch solenoid malfunction • Open or short in overrunning clutch solenoid signal circuit. Diagnostic support note: DETECTION CONDITION • HOLD indicator light flashes. • DTC is stored in TCM memory. • Open circuit between solenoid valve connector terminal D and TCM terminal 1J •...
  • Page 622 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION INSPECT OVERRUNNING CLUTCH SOLENOID Yes Go to next step. • Inspect overrunning clutch solenoid. Repair or replace overrunning clutch solenoid, then go to (See K1–60 SOLENOID VALVE Step 6. INSPECTION.) • Is result normal? INSPECT SOLENOID VALVE CONNECTOR Yes Go to next step.
  • Page 623 ON-BOARD DIAGNOSTIC DTC 63 BVF567018901W14 DTC 63 Torque converter clutch (TCC) solenoid malfunction • Open or short in TCC solenoid signal circuit. Diagnostic support note: DETECTION CONDITION • HOLD indicator light flashes. • DTC is stored in TCM memory. • Open circuit between solenoid valve connector terminal F and TCM terminal 1I •...
  • Page 624 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION INSPECT TCC SOLENOID Yes Go to next step. • Inspect TCC solenoid. Repair or replace TCC solenoid, then go to Step 6. (See K1–60 SOLENOID VALVE INSPECTION.) • Is result normal? INSPECT SOLENOID VALVE CONNECTOR Yes Go to next step.
  • Page 625 ON-BOARD DIAGNOSTIC DTC 64 BVF567018901W15 DTC 64 Pressure control solenoid malfunction • Open or short in pressure control solenoid signal circuit. Diagnostic support note: DETECTION CONDITION • HOLD indicator light flashes. • DTC is stored in TCM memory. • Open circuit between solenoid valve connector terminal E and TCM terminal 1E •...
  • Page 626 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION INSPECT PRESSURE CONTROL SOLENOID Yes Go to next step. • Inspect pressure control solenoid. Repair or replace pressure control solenoid, then go to (See K1–60 SOLENOID VALVE Step 6. INSPECTION.) • Is result normal? INSPECT SOLENOID VALVE CONNECTOR Yes Go to next step.
  • Page 627 TROUBLESHOOTING TROUBLESHOOTING FOREWORD BVF568001030W01 • When the customer reports a vehicle malfunction, check the HOLD indicator light flash, and diagnostic trouble code (DTC), then diagnose the malfunction according to following flowchart. — If the DTC exists, diagnose the applicable DTC inspection. (See K1–97 DTC TABLE.) —...
  • Page 628 TROUBLESHOOTING STEP INSPECTION ACTION Inspect the voltage at the following TCM Yes Perform the symptom troubleshooting and follow the terminals. procedures. (See K1–64 TCM INSPECTION.) Repair or replace any malfunctioning parts according to the • Terminal 2J (TFT sensor) inspection result. •...
  • Page 629 TROUBLESHOOTING TROUBLESHOOTING ITEM DESCRIPTION PAGE No kickdown Does not downshift when accelerator pedal (See K1–132 NO.13 NO is fully depressed when within kickdown KICKDOWN.) range. Engine flares up or slips when When accelerator pedal is depressed, (See K1–133 NO.14 ENGINE upshifting or downshifting engine speed increases normally but vehicle FLARES UP OR SLIPS WHEN...
  • Page 630 EVEREST Repair Manual Supplement (F187–10–03G) TROUBLESHOOTING End Of Sie QUICK DIAGNOSIS CHART BVF568001030W04 : Applied Vehicle does not move in D, S, L ranges, or in R Position Vehicle moves in N position Vehicle moves in P position, or parking gear does not disengage when shifted out of P position Excessive creep No creep at all Low maximum speed and poor acceleration...
  • Page 631 TROUBLESHOOTING : Applied Vehicle does not move in D, S, L ranges, or in R Position Vehicle moves in N position Vehicle moves in P position, or parking gear does not disengage when shifted out of P position Excessive creep No creep at all Low maximum speed and poor acceleration No shifting...
  • Page 632 EVEREST Repair Manual Supplement (F187–10–03G) TROUBLESHOOTING NO.1 VEHICLE DOES NOT MOVE IN D, S, L RANGES, OR IN R POSITION BVF568001030W05 Vehicle does not move in D, S, L ranges, or in R position • Vehicle does not move when accelerator pedal is depressed. DESCRIPTION •...
  • Page 633 TROUBLESHOOTING NO.2 VEHICLE MOVES IN N POSITION BVF568001030W06 Vehicle moves in N position • Vehicle creeps in N position. DESCRIPTION • Vehicle creeps if brake pedal not depressed in N position. • If vehicle moves in N position, basically, malfunction is in AT. Since a malfunction in sensor circuit or output circuit is cause of malfunction in AT, inspect sensors, output circuit, and related harnesses.
  • Page 634 TROUBLESHOOTING NO.5 NO CREEP AT ALL BVF568001030W09 No creep at all DESCRIPTION • Vehicle does not move in D, S, L ranges, or R position when idling on flat paved road. • Either engine output low or there is clutch circuit slippage. —...
  • Page 635 EVEREST Repair Manual Supplement (F187–10–03G) TROUBLESHOOTING NO.6 LOW MAXIMUM SPEED AND POOR ACCELERATION BVF568001030W10 Low maximum speed and poor acceleration • Vehicle acceleration poor at start. DESCRIPTION • Delayed acceleration when accelerator pedal depressed while driving. • If clutch is stuck or does not stay in 3GR, malfunction is in engine circuit. —...
  • Page 636 EVEREST Repair Manual Supplement (F187–10–03G) TROUBLESHOOTING NO.7 NO SHIFTING BVF568001030W11 No shifting • Single shift range only. DESCRIPTION • Sometimes it shifts correctly. • When gear position is fixed in 3GR due to the fail-safe operation, malfunction is in the AT. •...
  • Page 637 EVEREST Repair Manual Supplement (F187–10–03G) TROUBLESHOOTING Diagnostic procedure STEP INSPECTION ACTION • Turn the ignition switch to the ON position. Go to next step. • Does HOLD indicator light indication Go to symptom troubleshooting No.26 “HOLD indicator light correspond to HOLD switch operation? does not illuminate when HOLD switch is turned on”, or No.27 “HOLD indicator light illuminates when HOLD switch is not turned on”.
  • Page 638 EVEREST Repair Manual Supplement (F187–10–03G) TROUBLESHOOTING Diagnostic procedure STEP INSPECTION ACTION • Inspect continuity between TCM connector Go to next step. terminals 2M and 2Q and transmission case. Repair or replace ground circuit. • Is there continuity? • Stop engine. Inspect TCM connector terminal for bend, damage, •...
  • Page 639 EVEREST Repair Manual Supplement (F187–10–03G) TROUBLESHOOTING NO.12 TORQUE CONVERTER CLUTCH (TCC) NON-OPERATION BVF568001030W16 Torque converter clutch (TCC) non-operation • TCC does not operate when vehicle reaches TCC operation range. DESCRIPTION • Basically, TCC does not operate when fail-safe is operating. Verify DTC at first. If TCC operates when driving at high speeds only, the malfunction (improper adjustment) is in HOLD switch circuit or TR switch circuit.
  • Page 640 EVEREST Repair Manual Supplement (F187–10–03G) TROUBLESHOOTING End Of Sie NO.14 ENGINE FLARES UP OR SLIPS WHEN UPSHIFTING OR DOWNSHIFTING BVF568001030W18 Engine flares up or slips when upshifting or downshifting • When accelerator pedal depressed for driveway, engine speed increases but vehicle speed increase DESCRIPTION slowly.
  • Page 641 EVEREST Repair Manual Supplement (F187–10–03G) TROUBLESHOOTING NO.16 JUDDER UPON TORQUE CONVERTER CLUTCH (TCC) OPERATION BVF568001030W20 Judder upon torque converter clutch (TCC) operation • Vehicle jolts when TCC engaged. DESCRIPTION • Poor TCC engagement due to either slippage because TCC piston is stuck or line pressure is low. Caution •...
  • Page 642 EVEREST Repair Manual Supplement (F187–10–03G) TROUBLESHOOTING STEP INSPECTION ACTION • Stop engine and turn the ignition switch to • Overhaul control valve body and repair or replace any the ON position. defective parts. • Inspect pressure control solenoid circuit. (See AT Workshop Manual.) •...
  • Page 643 TROUBLESHOOTING Diagnostic procedure STEP INSPECTION ACTION • Inspect engine condition. Yes Go to appropriate symptom troubleshooting. • Is any engine concern (e.g. Rough idle)? Replace basic inspection and repair or replace any defective parts according to inspection result • Verify test results. —...
  • Page 644 EVEREST Repair Manual Supplement (F187–10–03G) TROUBLESHOOTING NO.23 TRANSMISSION OVERHEATS BVF568001030W27 TRANSMISSION OVERHEATS • Burnt smell emitted from transmission. DESCRIPTION • Smoke emitted from transmission. • Malfunction is restricted to hindrance of coolant at oil cooler. In addition, overheating of transmission may be caused by a malfunction of TFT sensor.
  • Page 645 TROUBLESHOOTING NO.24 ENGINE STALLS WHEN SHIFTED TO D, S, L RANGES, OR IN R POSITION BVF568001030W28 Engine stalls when shifted to D, S, L ranges, or in R position DESCRIPTION • Engine stalls when shifting from N or P position to D, S, L ranges or R position at idle. •...
  • Page 646 TROUBLESHOOTING NO.26 HOLD INDICATOR LIGHT DOES NOT ILLUMINATE WHEN HOLD SWITCH IS TURNED ON BVF568001030W30 HOLD indicator light does not illuminate when HOLD switch is turned ON • HOLD indicator light on instrument cluster does not illuminate when HOLD switch is turned on and DESCRIPTION ignition switch at ON.
  • Page 648 A UTOMATIC TRANSMISSION (Transfer) FEATURES TRANSFER............K2-2 OUTLINE OF CONSTRUCTION......K2-2 SPECIFICATIONS ..........K2-2 K2–1...
  • Page 649 TRANSFER TRANSFER OUTLINE OF CONSTRUCTION BVF571827500W01 • The construction and operation of the transfer are the same as those of the current Ranger EC-AT model. (See RANGER Repair Manual Supplement F184-10-03C.) End Of Sie SPECIFICATIONS BVF571827500W02 transmission Item RA4AX–EL Trasfer type Constant mesh Trasfer control Floor shift...
  • Page 650 P ROPELLER SHAFT FEATURES OUTLINE ..............L-2 OUTLINE OF CONSTRUCTION......L-2 SPECIFICATIONS ..........L-2 L–1...
  • Page 651 OUTLINE OUTLINE OUTLINE OF CONSTRUCTION BVF610225002W01 • A dynamic damper has been eliminated (WL Turbo 4×4 AT model). • The construction and operation of the propeller shaft for the new EVEREST AT model is the same as that of the current EVEREST exept for the following features. (See EVEREST Repair Manual F183–10–03A.) End Of Sie SPECIFICATIONS BVF610225002W02...
  • Page 652 B ODY ELECTRICAL SYSTEM FEATURES OUTLINE ..............T-2 OUTLINE OF CONSTRUCTION......T-2 FEATURES ............T-2 WARNING AND INDICATOR SYSTEM ....T-3 OUTLINE.............. T-3 INSTRUMENT CLUSTER........T-3 T–1...
  • Page 653 OUTLINE OUTLINE OUTLINE OF CONSTRUCTION BVF810218510W03 • The construction and operation of the body electrical system for the new EVEREST is the same as that of the current EVEREST except for the following features. (See EVEREST Repair Manual Supplement F183-10- 03A.) End Of Sie FEATURES...
  • Page 654 WARNING AND INDICATOR SYSTEM WARNING AND INDICATOR SYSTEM OUTLINE BVF811818510W01 • A hold indicator light has been added. (vehicles with RA4AX-EL type automatic transmission) End Of Sie INSTRUMENT CLUSTER BVF811818510W02 Structural View HOLD INDICATOR LIGHT BVF0922W003 System Wiring Diagram TO HOLD SWITCH RELAY INSTRUMENT CLUSTER HOLD INDICATOR...
  • Page 656 T ECHNICAL DATA TECHNICAL DATA ..........TD-2 AUTOMATIC TRANSMISSION......TD-2 TD–1...
  • Page 657 TECHNICAL DATA TECHNICAL DATA AUTOMATIC TRANSMISSION BVF931000000W02 Automatic transmission type Item RA4AX-EL ® Type ATF M-III or equivalent (e.g. Dexron III ) Capacity (Approx. quantity) 8.6 {9.1, 7.6} (L {US qt, lmp qt}) Idle 490—529 {5.0—5.4, 71—77} D, S, L range Line pressure Stall 1,197—1,275 {12.2—13.0, 174—185}...
  • Page 658 S PECIAL TOOLS SPECIAL TOOLS ..........ST-2 AUTOMATIC TRANSMISSION......ST-2 ST–1...
  • Page 659 SPECIAL TOOLS SPECIAL TOOLS AUTOMATIC TRANSMISSION BVF941000000W01 49 B019 901B 49 0378 400B 49 H019 002 Oil pressure Oil pressure Adapter gauge gauge set 49 0877 435 49 U027 003 49 G030 797 Wrench Oil seal installer Handle 49 E011 1A0 49 B019 9A1A 49 B019 9A0 Ring gear brake...
  • Page 660 Service Information. Ford Motor Company Ford Motor Company PRINTED IN AUG.
  • Page 661 VEHICLE IDENTIFICATION NUMBERS (VIN) (CHASSIS NUMBER) MNB BS4D40*W 100956— MNB BSYD40*W 100956— MNB LS4D40*W 100956— MNB LSYD40*W 100956— WIRING COLOR CODE COLOR CODE COLOR CODE BLACK ORANGE BLUE PINK BROWN DARK BLUE SKY BLUE DARK GREEN GRAY VIOLET GREEN WHITE LIGHT BLUE YELLOW LIGHT GREEN...
  • Page 662 SYSTEM INDEX GENERAL INFORMATION ........2 INTERIOR LIGHTING SYSTEM ILLUMINATION LIGHT .........60 GROUND POINT............ 16 INTERIOR LIGHT..........62 ELECTRICAL WIRING SCHEMATIC ....18 EXTERIOR LIGHTING SYSTEM ENGINE-RELATED SYSTEM HEADLIGHT............36 CHARGING SYSTEM .......... 20 LICENSE PLATE LIGHT ........38 STARTING SYSTEM..........20 PARKING LIGHT ..........38 ENGINE CONTROL SYSTEM ......
  • Page 663 Wiring Diagrams Contents of wiring diagrams • This manual comprises the sections shown below. A how-to on using and reading wiring diagrams, General information of using test equipment,checking harness and wiring diagrams connectors,and finding trouble spots Ground points Ground routes from and to the battery Electrical wiring Shows main fuses and other fuses for each schematic...
  • Page 664 Reading Wiring Diagrams Ground points • This shows ground points of the harness. GROUND POINTS(4SD) JC-01 JOINT CONNECTOR(F) JC-02 JOINT CONNECTOR(F) JC-03 JOINT CONNECTOR(D) (WITHOUT AIR BAG SYSTEM) (WITH AIR BAG SYSTEM) WITH ABS B(D) B(EM) JC-03 B(D) B(D) B(EM) JC-01 B(D) B(F)
  • Page 665 Reading Wiring Diagrams System circuit diagram/connector diagram • These diagrams show the circuits for each system, from the power supply to the ground. The power supply side is on the upper part of the page, the ground side on the lower part. The diagrams describe circuits with the ignition switch off.
  • Page 666 Reading Wiring Diagrams The number indicates that the circuit continues to the related system System code diagram. Multiplex communication B-1a Indicates communication with connected parts. Signals are transmitted back and forth between DATA LINK connected parts. B/W(D) CONNECTOR(DLC) (SECTION U) B(D) X-03 ENGINE SWITCH...
  • Page 667 Reading Wiring Diagrams Routing diagram • The routing diagram shows where electrical components are on the system circuit diagram by call out line and connector symbols. Connector symbol Component name Ground symbol Shows the system that uses the Shows the names of components Shows the ground in system connector.
  • Page 668 Reading Wiring Diagrams Harness symbols DESCRIPTION OF HARNESS SYMBOL DESCRIPTION OF HARNESS SYMBOL FRONT HARNESS DOOR NO.1 HARNESS (DR1) FRONT NO.2 HARNESS (F2) DOOR NO.2 HARNESS (DR2) ENGINE HARNESS DOOR NO.3 HARNESS (DR3) DASH HARNESS DOOR NO.4 HARNESS (DR4) REAR HARNESS FLOOR HARNESS (FR) REAR NO.2 HARNESS...
  • Page 669 Reading Wiring Diagrams Symbols Symbol Meaning Symbol Meaning Battery • Generates electricity through chemical Light • Emits light and generates heat when reaction. current flows through filament. • Supplies direct current to circuits. 3.4W Ground (1) • Connecting point to vehicle body or Resistance •...
  • Page 670 Reading Wiring Diagrams Symbol Meaning Symbol Meaning Switch (1) • Allows or breaks current flow by Harness opening and closing curcuits. Connection When circuit C-D Normally open (NO) is connected to circuit A-B, the connection D is indicated by a For vehicles with ABS, use the A-B black dot.
  • Page 671 Reading Wiring Diagrams Symbol Meaning Extent of the change in the wiring position (1) • The wiring position can be exchanged freely within the connector. Extent of the change in the wiring position (2) • The wiring position can be exchanged according to the following combinations only.
  • Page 672 Reading Wiring Diagrams GROUND RIGHT FRONT HEATER/DEFROSTER RIGHT HAND HEAT HEATER REVOLUTIONS PER MINUTE HIGH RIGHT REAR HO2S HEATED OXYGEN SENSOR SOPHISTICATED AIR BAG SENSOR HYDRAULIC UNIT SEQUENTIAL MULTIPOINT FUEL INJECTION IDLE AIR CONTROL INTAKE AIR TEMPERATURE SOLENOID IGNITION SPILL VALVE ILLUMI ILLUMINATION START...
  • Page 673 Electrical System General Procedures ELECTRICAL PARTS B6U000000006W03 Battery cable • Before disconnecting connectors or removing electrical parts, disconnect the negative battery cable. WGIWXX0007E Wiring Harness • To remove the wiring harness from the clip in the engine room, pry up the hook of the clip using a flathead screwdriver.
  • Page 674 Electrical System General Procedures • Connectors can be disconnected by pressing or pulling the lock lever as shown. WGIWXX0042E Locking connector • When locking connectors, listen for a click indicating they are securely locked. X3U000WB1 Inspection • When a tester is used to inspect for continuity or measuring voltage, insert the tester probe from the wiring harness side.
  • Page 675 Electrical System General Procedures Terminals Inspection • Pull lightly on individual wires to verify that they are secured in the terminal. X3U000WB4 Replacement • Use the appropriate tools to remove a terminal as shown. When installing a terminal, be sure to insert it until it locks securely.
  • Page 676 Electrical System General Procedures • When replacing a pullout fuse, use the fuse puller. YMU000WAK ELECTRICAL TROUBLESHOOTING TOOLS Jumper wire • A jumper wire is used to create a temporary circuit. Connect the jumper wire between the terminals of a circuit to bypass a switch.
  • Page 677 EVEREST WIRING DIAGRAMS (F187-20-03H) Revised 9/2004 (Ref. No. LF017/04)
  • Page 678 EVEREST WIRING DIAGRAMS (F187-20-03H) Revised 9/2004 (Ref. No. LF017/04)
  • Page 679 EVEREST WIRING DIAGRAMS (F187-20-03H) Revised 9/2004 (Ref. No. LF017/04)
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  • Page 683 EVEREST WIRING DIAGRAMS (F187-20-03H) Revised 9/2004 (Ref. No. LF017/04)
  • Page 685 EVEREST WIRING DIAGRAMS (F187-20-03H) Revised 9/2004 (Ref. No. LF017/04)
  • Page 711 EVEREST WIRING DIAGRAMS (F187-20-03H) Revised 9/2004 (Ref. No. LF017/04)
  • Page 712 EVEREST WIRING DIAGRAMS (F187-20-03H) Revised 9/2004 (Ref. No. LF017/04)
  • Page 713 EVEREST WIRING DIAGRAMS (F187-20-03H) Revised 9/2004 (Ref. No. LF017/04)
  • Page 715 EVEREST WIRING DIAGRAMS (F187-20-03H) Revised 9/2004 (Ref. No. LF017/04)
  • Page 716 EVEREST WIRING DIAGRAMS (F187-20-03H) Revised 9/2004 (Ref. No. LF017/04)
  • Page 735 AIR BAG SYSTEM SERVICE WARNINGS Air Bag Mudule Handling Component Disassembly • A live (undeployed) air bag module may • Disassembling and reassembling the components accidentally deploy when it is handled and cause of the air bag system can render the system serious injury.
  • Page 736 SAS Unit Handling • Disconnecting the SAS unit connector or removing the SAS unit with the ignition switch at ON position can cause the air bag modules to deploy, which may seriously injure you. Before disconnecting the SAS unit connector or removing the SAS unit, turn the ignition switch to LOCK position, then disconnect the negative battery cable and wait for more than 1 minute to allow the backup power...
  • Page 749 EVEREST WIRING DIAGRAMS (F187-20-03H) Revised 9/2004 (Ref. No. LF017/04)
  • Page 752 EVEREST WIRING DIAGRAMS (F187-20-03H) Revised 9/2004 (Ref. No. LF017/04)
  • Page 753 ALPHABETICAL INDEX 4X4 INDICATOR SWITCH ........56 G SENSOR..............72 GENERAL INFORMATION ........2 GENERATOR............20 A/C AMPLIFIER............46 GLOW PLUG............22 A/C MAIN SWITCH..........48 GLOW PLUG RELAY ..........22 A/C RELAY ............. 46 GROUND POINT.............16 A/C UNIT ..............48 ABBREVIATION ............. 10 ABS HU/CM ............72 HAZARD WARNING SWITCH ........40 ABS WHEEL-SPEED SENSOR ......
  • Page 754 ALPHABETICAL INDEX REAR POWER WINDOW REGULATOR ....64 REAR RESISTOR........... 48 REAR TURN LIGHT ..........40 REAR WASHER MOTOR ........34 REAR WINDOW DEFROSTER RELAY ....58 REAR WINDOW DEFROSTER SWITCH ....58 REAR WIPER AND WASHER SWITCH....34 REAR WIPER MOTOR ........... 34 REFRIGERANT PRESSURE SWITCH ....
  • Page 755 Service Information. Ford Motor Company Ford Motor Company PRINTED IN OCT.
  • Page 756 VEHICLE IDENTIFICATION NUMBERS (VIN) (CHASSIS NUMBER) MNB BS4D40*W 100001— MNB BS4D70*W 100001— MNB BSYD40*W 100001— MNB LS4D40*W 100001— MNB LS4D70*W 100001— MNB LSYD40*W 100001— WIRING COLOR CODE COLOR CODE COLOR CODE BLACK ORANGE BLUE PINK BROWN DARK BLUE SKY BLUE DARK GREEN GRAY VIOLET...
  • Page 757 EVEREST WIRING DIAGRAMS (F190-30-03J) SYSTEM INDEX GENERAL INFORMATION ........2 INTERIOR LIGHTING SYSTEM GROUND POINT............ 16 ILLUMINATION LIGHT .........96 ELECTRICAL WIRING SCHEMATIC ....20 INTERIOR LIGHT..........98 ENGINE-RELATED SYSTEM EXTERIOR LIGHTING SYSTEM CHARGING SYSTEM HEADLIGHT............66 MT ..............22 LICENSE PLATE LIGHT ........68 AT ..............
  • Page 758 Wiring Diagrams Contents of wiring diagrams • This manual comprises the sections shown below. A how-to on using and reading wiring diagrams, General information of using test equipment,checking harness and wiring diagrams connectors,and finding trouble spots Ground points Ground routes from and to the battery Electrical wiring Shows main fuses and other fuses for each schematic...
  • Page 759 Reading Wiring Diagrams Ground points • This shows ground points of the harness. GROUND POINTS(4SD) JC-01 JOINT CONNECTOR(F) JC-02 JOINT CONNECTOR(F) JC-03 JOINT CONNECTOR(D) (WITHOUT AIR BAG SYSTEM) (WITH AIR BAG SYSTEM) WITH ABS B(D) B(EM) JC-03 B(D) B(D) B(EM) JC-01 B(F) B(D)
  • Page 760 Reading Wiring Diagrams System circuit diagram/connector diagram • These diagrams show the circuits for each system, from the power supply to the ground. The power supply side is on the upper part of the page, the ground side on the lower part. The diagrams describe circuits with the ignition switch off.
  • Page 761 Reading Wiring Diagrams The number indicates that the circuit continues to the related system System code diagram. Multiplex communication B-1a Indicates communication with connected parts. Signals are transmitted back and forth between DATA LINK connected parts. B/W(D) CONNECTOR(DLC) (SECTION U) B(D) X-03 ENGINE SWITCH...
  • Page 762 Reading Wiring Diagrams Routing diagram • The routing diagram shows where electrical components are on the system circuit diagram by call out line and connector symbols. Connector symbol Component name Ground symbol Shows the system that uses the Shows the names of components Shows the ground in system connector.
  • Page 763 Reading Wiring Diagrams Harness symbols DESCRIPTION OF HARNESS SYMBOL DESCRIPTION OF HARNESS SYMBOL FRONT HARNESS DOOR NO.1 HARNESS (DR1) FRONT NO.2 HARNESS (F2) DOOR NO.2 HARNESS (DR2) ENGINE HARNESS DOOR NO.3 HARNESS (DR3) DASH HARNESS DOOR NO.4 HARNESS (DR4) REAR HARNESS FLOOR HARNESS (FR) REAR NO.2 HARNESS...
  • Page 764 Reading Wiring Diagrams Symbols Symbol Meaning Symbol Meaning Battery • Generates electricity through chemical Light • Emits light and generates heat when reaction. current flows through filament. • Supplies direct current to circuits. 3.4W Ground (1) • Connecting point to vehicle body or Resistance •...
  • Page 765 Reading Wiring Diagrams Symbol Meaning Symbol Meaning Switch (1) • Allows or breaks current flow by Harness opening and closing curcuits. Connection When circuit C-D Normally open (NO) is connected to circuit A-B, the connection D is indicated by a For vehicles with ABS, use the A-B black dot.
  • Page 766 Reading Wiring Diagrams Symbol Meaning Extent of the change in the wiring position (1) • The wiring position can be exchanged freely within the connector. Extent of the change in the wiring position (2) • The wiring position can be exchanged according to the following combinations only.
  • Page 767 Reading Wiring Diagrams GROUND RIGHT FRONT HEATER/DEFROSTER RIGHT HAND HEAT HEATER REVOLUTIONS PER MINUTE HIGH RIGHT REAR HO2S HEATED OXYGEN SENSOR SOPHISTICATED AIR BAG SENSOR HYDRAULIC UNIT SEQUENTIAL MULTIPOINT FUEL INJECTION IDLE AIR CONTROL INTAKE AIR TEMPERATURE SOLENOID IGNITION SPILL VALVE ILLUMI ILLUMINATION START...
  • Page 768 Electrical System General Procedures ELECTRICAL PARTS B6U000000006W03 Battery cable • Before disconnecting connectors or removing electrical parts, disconnect the negative battery cable. WGIWXX0007E Wiring Harness • To remove the wiring harness from the clip in the engine room, pry up the hook of the clip using a flathead screwdriver.
  • Page 769 Electrical System General Procedures • Connectors can be disconnected by pressing or pulling the lock lever as shown. WGIWXX0042E Locking connector • When locking connectors, listen for a click indicating they are securely locked. X3U000WB1 Inspection • When a tester is used to inspect for continuity or measuring voltage, insert the tester probe from the wiring harness side.
  • Page 770 Electrical System General Procedures Terminals Inspection • Pull lightly on individual wires to verify that they are secured in the terminal. X3U000WB4 Replacement • Use the appropriate tools to remove a terminal as shown. When installing a terminal, be sure to insert it until it locks securely.
  • Page 771 Electrical System General Procedures • When replacing a pullout fuse, use the fuse puller. YMU000WAK ELECTRICAL TROUBLESHOOTING TOOLS Jumper wire • A jumper wire is used to create a temporary circuit. Connect the jumper wire between the terminals of a circuit to bypass a switch.
  • Page 772 GROUND POINT...
  • Page 773 HARNESS SYMBOL: [WL Turbo EXCEPT Stage- X-04 (F)-(R) [G6] [WL Turbo Stage- X-04 (F)-(R)
  • Page 774 GROUND POINT...
  • Page 775 HARNESS SYMBOL: [WL Turbo AT] [BLACK] (R)-(R4) X-29 [G6]...
  • Page 776 ELECTRICAL WIRING SCHEMATIC...
  • Page 778 CHARGING SYSTEM (MT) / STARTING SYSTEM (MT)
  • Page 779 HARNESS SYMBOL: [GRAY] (F)-(E) X-08 [GRAY] [WL Turbo] (F)-(E) X-09 MAIN FUSE BLOCK X-01 X-02 IGNITION SWITCH ENGINE SWITCH WL Turbo [GLAY] A1-02 A1-01 GENERATOR GENERATOR A1-02 STARTER [GLAY] GENERATOR A1-02 A1-02 [G6] [GRAY] (F)-(E) STARTER GENERATOR A1-01 X-08 [GRAY] (F)-(E) X-09 MAIN FUSE BLOCK...
  • Page 780 CHARGING SYSTEM (AT) / STARTING SYSTEM (AT)
  • Page 781 HARNESS SYMBOL: [GRAY] (F)-(E) X-08 (F)-(E) [GRAY] X-30 TRANSMISSION (F)-(E) RANGE SWITCH A2-03 X-09 MAIN FUSE BLOCK X-01 A2-01 A2-02 STARTER GENERATOR [GRAY] A2-02 GENERATOR X-02 ENGINE SWITCH...
  • Page 782 ENGINE CONTROL SYSTEM ("WL Turbo MT" WITHOUT IMMOBILIZER SYSTEM) / B-1a GLOW SYSTEM ("WL Turbo MT" WITHOUT IMMOBILIZER SYSTEM)
  • Page 783 HARNESS SYMBOL: [GRAY] (F)-(E) FICD SOLENOID X-08 VALVE No.2 B1-06 GLOW PLUG RELAY [GRAY] B1-02 ENGINE COOLANT TEMPERATURE SENSOR B1-07 MAIN FUSE BLOCK X-01 B1-05 FICD SOLENOID VALVE No.1 [BLACK] B1-02 GLOW PLUG RELAY B1-04 [BROWN] GLOW PLUG B1-08 NE SENSOR [GRAY] B1-09 FUEL CUT VALVE...
  • Page 784 ENGINE CONTROL SYSTEM ("WL Turbo MT" WITHOUT IMMOBILIZER SYSTEM) / B-1b GLOW SYSTEM ("WL Turbo MT" WITHOUT IMMOBILIZER SYSTEM)
  • Page 785 HARNESS SYMBOL: B1-01 [BLACK] B-1b...
  • Page 786 ENGINE CONTROL SYSTEM ("WL Turbo MT" WITH IMMOBILIZER SYSTEM) / B-2a GLOW SYSTEM ("WL Turbo MT" WITH IMMOBILIZER SYSTEM)
  • Page 787 HARNESS SYMBOL: [GRAY] FICD SOLENOID (F)-(E) VALVE No.2 X-08 B2-06 [GRAY] GLOW PLUG ENGINE COOLANT RELAY TEMPERATURE SENSOR B2-02 B2-07 MAIN FUSE BLOCK X-01 B2-05 FICD SOLENOID VALVE No.1 [BLACK] B2-02 GLOW PLUG RELAY [BROWN] B2-09 INJECTION PUMP [GRAY] B2-08 B2-04 NE SENSOR [GRAY]...
  • Page 788 ENGINE CONTROL SYSTEM ("WL Turbo MT" WITH IMMOBILIZER SYSTEM) / B-2b GLOW SYSTEM ("WL Turbo MT" WITH IMMOBILIZER SYSTEM)
  • Page 789 HARNESS SYMBOL: [GREEN] EGR SOLENOID VALVE B2-10 B2-01 B-2b...
  • Page 790 B-3a ENGINE CONTROL SYSTEM (G6)
  • Page 791 HARNESS SYMBOL: MAIN FUSE BLOCK X-01 MAIN RELAY B3-02 X-10 (F)-(INJ) B3-04 [BLACK] CONDENSER [BLACK] B3-03 B3-06 CAMSHAFT IGNITION COIL POSITION SENSOR [GRAY] B3-05 IGNITER [GRAY] X-03 FUSE BLOCK X-02 IGNITION SWITCH B3-01 [YELLOW] B-3a...
  • Page 792 B-3b ENGINE CONTROL SYSTEM (G6)
  • Page 793 HARNESS SYMBOL: [BLACK] PURGE SOLENOID [GLAY] VALVE FUEL B3-12 INJECTOR No.2 B3-07 [ORANGE] PRC SOLENOID [BLACK] VALVE INTAKE AIR B3-11 [BLACK] TEMPERATURE IAC VALVE [GLAY] B3-14 SENSOR FUEL B3-15 THROTTLE INJECTOR No.1 POSITION SENSOR B3-09 B3-16 B3-08 FUEL INJECTOR No.4 [GLAY] B3-17 SENSOR...
  • Page 794 B-3c ENGINE CONTROL SYSTEM (G6)
  • Page 795 HARNESS SYMBOL: [GRAY] (F)-(E) X-08 [GRAY] (F)-(E) NEUTRAL SWITCH X-09 B3-21 B3-19 CLOSED THROTTLE POSITION SWITCH B3-22 POWER STEERING PRESSURE SWITCH B3-01 [YELLOW] B3-20 CLUTCH SWITCH B-3c...
  • Page 796 B-4a ENGINE CONTROL SYSTEM ("WL Turbo AT" THAILAND) / GLOW SYSTEM ("WL Turbo AT" THAILAND)
  • Page 797 HARNESS SYMBOL: [GRAY] (F)-(E) X-08 [GRAY] ENGINE COOLANT TEMPERATURE SENSOR MAIN FUSE BLOCK FICD SOLENOID B4-07 GLOW PLUG VALVE No.2 X-01 RELAY B4-06 B4-02 [GRAY] INJECTION PUMP B4-09 [GRAY] NE SENSOR B4-08 B4-05 FICD SOLENOID VALVE No.1 [BLACK] B4-02 GLOW PLUG RELAY [BROWN] B4-04...
  • Page 798 B-4b ENGINE CONTROL SYSTEM ("WL Turbo AT" THAILAND) / GLOW SYSTEM ("WL Turbo AT" THAILAND)
  • Page 799 HARNESS SYMBOL: [GREEN] EGR SOLENOID VALVE B4-10 B4-01 [BLACK] B-4b...
  • Page 800 ENGINE CONTROL SYSTEM ("WL Turbo AT" EXCEPT THAILAND) / B-5a GLOW SYSTEM ("WL Turbo AT" EXCEPT THAILAND)
  • Page 801 HARNESS SYMBOL: [GRAY] (F)-(E) X-08 FICD SOLENOID VALVE No.2 [GRAY] B5-06 [BROWN] ENGINE COOLANT GLOW PLUG GLOW PLUG TEMPERATURE SENSOR RELAY RELAY B5-07 B5-02 B5-02 MAIN FUSE BLOCK X-01 B5-09 INJECTION PUMP [GRAY] B5-05 B5-08 FICD SOLENOID NE SENSOR VALVE No.1 [GRAY] [BLACK] B5-04...
  • Page 802 ENGINE CONTROL SYSTEM ("WL Turbo AT" EXCEPT THAILAND) / B-5b GLOW SYSTEM ("WL Turbo AT" EXCEPT THAILAND)
  • Page 803 HARNESS SYMBOL: B5-01 [BLACK] B-5b...
  • Page 804 FUEL CONTROL SYSTEM...
  • Page 805 HARNESS SYMBOL: MAIN FUSE BLOCK X-01 (R)-(R2) X-19 C1-04 FUEL PUNP [GRAY] X-04 (F)-(R) X-03 FUSE BLOCK X-02 IGNITION SWITCH X-04 (F)-(R) B6-01 FUEL PUMP RELAY...
  • Page 806 B-7a ENGINE CONTROL SYSTEM (WL Turbo Stage- ) / GLOW SYSTEM (WL Turbo Stage-...
  • Page 807 HARNESS SYMBOL: [BLACK] EGR SOLENOID VALVE(VACUUM) B7-07 GLOW PLUG RELAY B7-03 [BLACK] EGR SOLENOID VALVE (VENT) [GRAY] B7-08 (F)-(E) [GRAY] [GRAY] [BLACK] X-08 INJECTION PUMP (F)-(E) INTAKE SHUTTER B7-10 SOLENOID VALVE X-09 B7-06 MAIN FUSE BLOCK [BROWN] GLOW PLUG RELAY NEUTRAL SWITCH X-01 B7-13...
  • Page 808 B-7b ENGINE CONTROL SYSTEM (WL Turbo Stage- ) / GLOW SYSTEM (WL Turbo Stage-...
  • Page 809 HARNESS SYMBOL: [GRAY] INJECTION PUMP [GRAY] B7-14 (F)-(E) X-08 [GRAY] [GRAY] ENGINE COOLANT (F)-(E) TEMPERATURE SENSOR B7-15 X-09 [BLACK] INTAKE AIR TEMPERATURE SENSOR No.2 B7-16 B7-18 BOOST SENSOR [BLACK] B7-17 EGR VALVE POSITION SENSOR [GRAY] B7-01 X-31 JOINT CONNECTOR B7-19 ACCELERATOR POSITION SENSOR [BLACK]...
  • Page 810 B-7c ENGINE CONTROL SYSTEM (WL Turbo Stage- ) / GLOW SYSTEM (WL Turbo Stage-...
  • Page 811 HARNESS SYMBOL: [GRAY] INJECTION PUMP B7-20 [GRAY] TDC SENSOR B7-22 B7-21 MASS AIR FLOW/ INTAKE AIR TEMPERATURE SENSOR [BLACK] B7-01 X-31 JOINT CONNECTOR B-7c...
  • Page 812 C-1a INSTRUMENT CLUSTER (MT)
  • Page 813 HARNESS SYMBOL: [GRAY] [GLAY] [GLAY] (F)-(E) VEHICLE VEHICLE X-08 [WL Turbo] SPEEDOMETER SPEEDOMETER INSTRUMENT CLUSTER SENSOR SENSOR C1-01 C1-03 C1-03 [BLACK] MAIN FUSE BLOCK INSTRUMENT X-01 CLUSTER C1-01 X-03 FUSE BLOCK X-02 IGNITION SWITCH ENGINE SWITCH WL Turbo X-04 (F)-(R) C1-02 WATER TEMPERATURE SENDER UNIT...
  • Page 814 C-1b INSTRUMENT CLUSTER (MT)
  • Page 815 HARNESS SYMBOL: [BLACK] [GRAY] INSTRUMENT BRAKE FLUID INSTRUMENT SEDIMENTOR [GRAY] CLUSTER LEVEL SENSOR CLUSTER SWITCH C1-01 (F)-(E) C1-07 C1-05 C1-01 X-09 [WL Turbo] (F)-SHORT CORD C1-09 C1-08 PARKING BRAKE SWITCH BRAKE FLUID [GRAY] LEVEL SENSOR (F)-(E) C1-07 X-09 [G6] OIL PRESSURE C1-06 SWITCH C1-06...
  • Page 816 C-1c INSTRUMENT CLUSTER (MT)
  • Page 817 HARNESS SYMBOL: INSTRUMENT CLUSTER [BLACK] C1-01 INSTRUMENT CLUSTER C1-01 C-1c...
  • Page 818 C-2a INSTRUMENT CLUSTER (AT)
  • Page 819 HARNESS SYMBOL: [GLAY] [WL Turbo EXCEPT Stage- VEHICLE SPEEDOMETER INSTRUMENT CLUSTER SENSOR C2-01 [GRAY] C2-03 [GLAY] [BLACK] (F)-(E) VEHICLE INSTRUMENT CLUSTER SPEEDOMETER MAIN FUSE BLOCK X-08 C2-01 SENSOR X-01 C2-03 X-03 FUSE BLOCK X-02 ENGINE SWITCH X-04 (F)-(R) C2-02 WATER TEMPERATURE SENDER UNIT [WL Turbo Stage- [GRAY]...
  • Page 820 C-2b INSTRUMENT CLUSTER (AT)
  • Page 821 HARNESS SYMBOL: [GRAY] SEDIMENTOR SWITCH C2-05 [GRAY] BRAKE FLUID (F)-(E) LEVEL SENSOR X-09 C2-07 [BLACK] INSTRUMENT CLUSTER C2-01 INSTRUMENT CLUSTER C2-01 (F)-SHORT CORD C2-06 C2-09 OIL PRESSURE SWITCH C2-08 PARKING BRAKE SWITCH C-2b...
  • Page 822 C-2c INSTRUMENT CLUSTER (AT)
  • Page 823 HARNESS SYMBOL: INSTRUMENT CLUSTER [BLACK] C2-01 INSTRUMENT CLUSTER C2-01 C-2c...
  • Page 824 WINDSHIELD WIPER AND WASHER...
  • Page 825 HARNESS SYMBOL: MAIN FUSE BLOCK WINDSHIELD WIPER MOTOR X-01 D1-03 WINDSHIELD WASHER MOTOR D1-01 D1-02 WINDSHIELD WIPER AND WASHER SWITCH WIPER AND WASHER SWITCH RIGHT SIDE X-03 D1-02 FUSE BLOCK WINDSHIELD WIPER AND WASHER SWITCH WIPER AND WASHER SWITCH LEFT SIDE X-02 IGNITION SWITCH ENGINE SWITCH...
  • Page 826 REAR WIPER AND WASHER...
  • Page 827 HARNESS SYMBOL: (R)-(R4) X-28 REAR WASHER MOTOR D2-02 REAR WIPER MOTOR D2-03 MAIN FUSE BLOCK X-01 X-05 (F)-(R) X-03 FUSE BLOCK X-02 IGNITION SWITCH X-05 ENGINE SWITCH WL Turbo (F)-(R) D2-01 REAR WIPER AND WASHER SWITCH [BLUE]...
  • Page 828 HEADLIGHT...
  • Page 829 HARNESS SYMBOL: MAIN FUSE BLOCK X-01 E1-03 HEADLIGHT RH X-04 (F)-(R) E1-02 HEADLIGHT LH E1-01 HEADLIGHT SWITCH LIGHT SWITCH RIGHT SIDE X-03 FUSE BLOCK E1-01 HEADLIGHT SWITCH LIGHT SWITCH LEFT SIDE X-04 (F)-(R)
  • Page 830 LICENSE PLATE LIGHT / PARKING LIGHT / TAILLIGHT...
  • Page 831 HARNESS SYMBOL: E2-02 PARKING LIGHT RH [BLACK] [GRAY] TAILLIGHT RH (R)-(R4) TAILLIGHT RH(BACK DOOR) E2-06 E2-08 X-29 LICENSE PLATE LIGHT E2-03 TAILLIGHT LH E2-05 [GRAY] (R)-(R2) TAILLIGHT LH(BACK DOOR) E2-07 E2-01 X-19 PARKING LIGHT LH...
  • Page 832 TURN AND HAZARD WARNING LIGHT (EXCEPT THAILAND)
  • Page 833 HARNESS SYMBOL: REAR TURN LIGHT RH E2-06 FRONT SIDE TURN REAR TURN LIGHT RH LIGHT LH F1-05 E2-05 MAIN FUSE BLOCK X-01 F1-06 FRONT SIDE TURN LIGHT LH F1-03 FRONT TURN LIGHT RH [BLACK] X-04 (F)-(R) F1-04 FRONT TURN LIGHT LH [BLACK] FLASHER UNIT F1-01...
  • Page 834 TURN AND HAZARD WARNING LIGHT (THAILAND)
  • Page 835 HARNESS SYMBOL: REAR TURN LIGHT RH E2-06 FRONT SIDE TURN REAR TURN LIGHT RH LIGHT LH F2-05 E2-05 MAIN FUSE BLOCK X-01 F2-03 F2-06 FRONT TURN LIGHT RH FRONT SIDE [BLACK] TURN LIGHT LH X-04 (F)-(R) F2-04 FRONT TURN LIGHT LH [BLACK] FLASHER UNIT F2-01...
  • Page 836 BACK-UP LIGHT...
  • Page 837 HARNESS SYMBOL: [GRAY] (F)-(E) [WL Turbo] BACK-UP X-08 LIGHT SWITCH F3-01 MAIN FUSE BLOCK X-01 X-03 FUSE BLOCK X-02 IGNITION SWITCH ENGINE SWITCH WL Turbo X-04 (F)-(R) BACK-UP LIGHT RH F3-03 [GRAY] [G6] (F)-(E) BACK-UP BACK-UP LIGHT LH LIGHT SWITCH X-08 F3-02 F3-01...
  • Page 838 BRAKE LIGHT / HORN...
  • Page 839 HARNESS SYMBOL: BRAKE LIGHT RH HIGH-MOUNT [GRAY] E2-06 BRAKE LIGHT BRAKE LIGHT RH F4-07 (BACK DOOR) E2-08 BRAKE LIGHT LH MAIN FUSE BLOCK E2-05 X-01 [GRAY] BRAKE LIGHT LH (BACK DOOR) E2-07 (R)-(R2) X-19 F4-05 HORN RH [BLACK] X-04 (F)-(R) F4-06 HORN LH [BLACK]...
  • Page 840 FRONT HEATER AND AIR CONDITIONER (WL Turbo)
  • Page 841 HARNESS SYMBOL: A/C RELAY G1-07 [GRAY] (F)-(E) X-09 MAIN FUSE BLOCK X-01 G1-09 REFRIGERANT PRESSURE SWITCH [BLACK] [BLACK] FRONT A/C SWITCH G1-08 G1-11 MAGNETIC CLUTCH FRONT RESISTOR G1-04 X-03 FUSE BLOCK X-02 ENGINE SWITCH G1-01 FRONT FAN SWITCH G1-10 [BLACK] A/C AMPLIFIER G1-05 FRONT RESISTOR...
  • Page 842 FRONT HEATER AND AIR CONDITIONER (G6)
  • Page 843 HARNESS SYMBOL: MAIN FUSE BLOCK X-01 G2-07 A/C RELAY G2-09 REFRIGERANT PRESSURE SWITCH [BLACK] G2-08 [BLACK] MAGNETIC FRONT A/C SWITCH CLUTCH G2-11 FRONT RESISTOR G2-04 X-03 FUSE BLOCK X-02 IGNITION SWITCH G2-01 FRONT FAN SWITCH [BLACK] G2-10 A/C AMPLIFIER G2-03 G2-05 (F)-BLOWER UNIT FRONT RESISTOR...
  • Page 844 REAR HEATER AND AIR CONDITIONER (EXCEPT THAILAND)
  • Page 845 HARNESS SYMBOL: REAR FAN SWITCH G3-05 REAR BLOWER RELAY G3-02 MAIN FUSE BLOCK REAR BLOWER X-01 MOTOR G3-03 G3-04 REAR RESISTOR G3-06 (FR)-SHORT CORD X-06 X-07 (F)-(FR) (F)-(FR) X-03 FUSE BLOCK X-02 IGNITION SWITCH ENGINE SWITCH WL Turbo G3-01 REAR A/C SWITCH X-06 (F)-(FR) X-07...
  • Page 846 REAR HEATER AND AIR CONDITIONER (THAILAND)
  • Page 847 HARNESS SYMBOL: REAR FAN SWITCH G4-05 REAR BLOWER MAIN FUSE BLOCK RELAY X-01 G4-02 REAR BLOWER MOTOR G4-03 G4-04 REAR RESISTOR G4-06 (FR)-SHORT CORD X-06 X-07 (F)-(FR) (F)-(FR) X-03 FUSE BLOCK X-02 ENGINE SWITCH G4-01 REAR A/C MAIN SWITCH X-06 (F)-(FR) X-07 (F)-(FR)
  • Page 848 H-1a 4EAT CONTROL SYSTEM...
  • Page 849 HARNESS SYMBOL: H1-01 [WL Turbo EXCEPT Stage- (F)-(E) X-30 [GRAY] (F)-(E) MAIN TRANS CONNECTOR X-09 H1-04 MAIN FUSE BLOCK X-01 X-03 FUSE BLOCK X-02 H1-05 ENGINE SWITCH HOLD SWITCH RELAY [WL Turbo Stage- (F)-(E) X-32 (F)-(E) MAIN TRANS CONNECTOR X-30 H1-04 MAIN FUSE BLOCK X-01...
  • Page 850 H-1b 4EAT CONTROL SYSTEM...
  • Page 851 HARNESS SYMBOL: [WL Turbo EXCEPT Stage- H1-01 (F)-(E) X-30 TRANSMISSION RANGE SWITCH [GRAY] A2-03 (F)-(E) X-08 H1-12 IDLE SWITCH [GRAY] H1-06 HOLD SWITCH CONNECTOR [WL Turbo Stage- TRANSMISSION RANGE SWITCH (F)-(E) A2-03 X-32 (F)-(E) X-30 H-1b...
  • Page 852 H-1c 4EAT CONTROL SYSTEM...
  • Page 853 HARNESS SYMBOL: [WL Turbo EXCEPT Stage- H1-01 DEVICE RESISTOR [GRAY] [GRAY] H1-09 (F)-(E) ACCELERATOR X-09 POSITION SENSOR H1-13 (F)-SHORT CORD OUTPUT SPEED SENSOR H1-08 H1-07 [WL Turbo Stage- [GRAY] (F)-(E) H1-10 X-08 ENGINE COOLANT TEMPERATURE SENSOR (F)-(E) [GRAY] X-32 OUTPUT SPEED SENSOR H1-07 (F)-SHORT CORD H1-08...
  • Page 854 REMOTE FREEWHEEL CONTROL SYSTEM...
  • Page 855 HARNESS SYMBOL: [GRAY] [GRAY] (F)-(E) [BLUE] (F)-(E) [BLUE] [GRAY] X-08 LOCK SOLENOID LOCK SOLENOID (F)-(E) X-08 H2-02 [GRAY] H2-02 [BLACK] X-09 4 4 INDICATOR SWITCH TRANSFER [GRAY] H2-06 [WL Turbo MT] NEUTRAL SWITCH (F)-(E) FREE SOLENOID FREE SOLENOID H2-07 H2-03 X-09 H2-03 [BLACK]...
  • Page 856 CIGARETTE LIGHTER / REAR WINDOW DEFROSTER...
  • Page 857 HARNESS SYMBOL: [BLACK] (R)-(R4) FILAMENT [BLACK] X-28 I1-03 FILAMENT I1-03 MAIN FUSE BLOCK X-01 [BLACK] OUTLET I1-06 X-04 (F)-(R) X-07 REAR WINDOW (F)-(FR) DEFROSTER RELAY I1-04 X-03 FUSE BLOCK X-02 X-04 IGNITION SWITCH ENGINE SWITCH WL Turbo (F)-(R) I1-01 CIGARETTE LIGHTER [BLACK] I1-05 I1-02...
  • Page 858 CLOCK / ILLUMINATION LIGHT...
  • Page 859 HARNESS SYMBOL: REAR A/C ILLUMINATION I2-04 MAIN FUSE BLOCK X-01 G3-06 G4-06 (FR)-SHORT CORD [BLACK] INSTRUMENT CLUSTER INSTRUMENT CLUSTER X-07 ILLUMINATION ILLUMINATION HAZARD C1-01 (F)-(FR) C1-01 WARNING SWITCH C2-01 C2-01 ILLUMINATION CLOCK F1-02 I2-01 F2-02 AUDIO UNIT ILLUMINATION J-01 I2-02 PANEL LIGHT CONTROL SWITCH X-03...
  • Page 860 INTERIOR LIGHT...
  • Page 861 HARNESS SYMBOL: (R)-(R4) [BLACK] INTERIOR LIGHT DOOR SWITCH X-28 INTERIOR LIGHT (CENTER) (BACK DOOR) I3-01 (FRONT) I3-04 I3-07 [BLACK] DOOR SWITCH RR I3-03 [BLACK] MAIN FUSE BLOCK DOOR SWITCH RF X-01 I3-02 G3-06 G4-06 (FR)-SHORT CORD I3-06 DOOR SWITCH LR [BLACK] X-04 I3-05...
  • Page 862 AUDIO SYSTEM...
  • Page 863 HARNESS SYMBOL: REAR DOOR SPEAKER RH (R)-(DR3) J-04 X-22 MAIN FUSE BLOCK X-01 FRONT DOOR SPEAKER RH J-03 (F)-(DR1) X-13 J-05 REAR DOOR SPEAKER LH X-24 (FR)-(DR4) J-02 X-04 FRONT DOOR SPEAKER LH (F)-(R) X-16 X-07 (F)-(DR2) (F)-(FR) (F)-(DR1) [BLACK] X-13 AUDIO UNIT J-01...
  • Page 864 POWER WINDOW SYSTEM...
  • Page 865 HARNESS SYMBOL: REAR POWER WINDOW REGULATOR RH POWER WINDOW K1-07 SUBSWITCH RR K1-03 (R)-(DR3) POWER WINDOW X-22 MAIN SWITCH K1-01 MAIN FUSE BLOCK (R)-(DR3) X-01 X-23 [BLUE] FRONT POWER WINDOW REGULATOR RH K1-05 (F)-(DR1) X-13 (F)-(DR1) X-15 K1-08 REAR POWER WINDOW REGULATOR LH K1-04 POWER WINDOW...
  • Page 866 K-2a POWER DOOR LOCK SYSTEM...
  • Page 867 HARNESS SYMBOL: MAIN FUSE BLOCK X-01 DOOR LOCK-LINK SWITCH K2-02 (F)-(DR1) X-15 DOOR LOCK TIMER UNIT K2-01 (F)-(DR1) X-15 X-03 FUSE BLOCK K-2a...
  • Page 868 K-2b POWER DOOR LOCK SYSTEM...
  • Page 869 HARNESS SYMBOL: DOOR LOCK TIMER UNIT K2-01 [BLACK] DOOR LOCK (R)-(R4) X-05 ACTUATOR RR X-29 K2-05 (F)-(R) X-18 (F)-(DR2) (R)-(DR3) BACK DOOR LOCK X-23 ACTUATOR K2-06 X-07 (F)-(FR) K2-04 DOOR LOCK X-25 ACTUATOR LR X-05 (FR)-(DR4) (F)-(R) K2-03 DOOR LOCK ACTUATOR LF X-18 X-07...
  • Page 870 POWER OUTSIDE MIRROR...
  • Page 871 HARNESS SYMBOL: MAIN FUSE BLOCK X-01 POWER OUTSIDE MIRROR RH L-02 (F)-(DR1) X-14 L-03 POWER OUTSIDE MIRROR LH X-17 (F)-(DR2) (F)-(DR1) X-14 L-01 POWER OUTSIDE X-03 MIRROR SWITCH FUSE BLOCK X-02 IGNITION SWITCH ENGINE SWITCH WL Turbo X-17 (F)-(DR2)
  • Page 872 4 WHEEL ANTILOCK BRAKE SYSTEM (4WABS)
  • Page 873 HARNESS SYMBOL: [GRAY] ABS HU/CM O-01 (F)-(F2) X-12 MAIN FUSE BLOCK (F)-(F2) X-01 X-11 X-03 FUSE BLOCK X-02 X-21 IGNITION SWITCH (F2)-(R) ENGINE SWITCH WL Turbo X-04 (F)-(R) O-03 ABS WHEEL- O-02 SPEED SENSOR RF [GRAY] ABS WHEEL- SPEED SENSOR LF [GRAY] (R)-(R2) X-19...
  • Page 874 AIR BAG SYSTEM SERVICE WARNINGS Air Bag Mudule Handling Component Disassembly • A live (undeployed) air bag module may • Disassembling and reassembling the components accidentally deploy when it is handled and cause of the air bag system can render the system serious injury.
  • Page 875 SAS Unit Handling • Disconnecting the SAS unit connector or removing the SAS unit with the ignition switch at ON position can cause the air bag modules to deploy, which may seriously injure you. Before disconnecting the SAS unit connector or removing the SAS unit, turn the ignition switch to LOCK position, then disconnect the negative battery cable and wait for more than 1 minute to allow the backup power...
  • Page 876 AIR BAG SYSTEM...
  • Page 877 HARNESS SYMBOL: MAIN FUSE BLOCK X-01 SHORT CONNECTOR [YELLOW] S1-02 PASSENGER-SIDE AIR BAG MODULE S1-04 S1-03 (F)-CLOCK SPRING S1-05 X-03 [YELLOW] DRIVER-SIDE FUSE BLOCK AIR BAG MODULE X-02 IGNITION SWITCH ENGINE SWITCH WL Turbo S1-01 SAS UNIT...
  • Page 878 IMMOBILIZER SYSTEM...
  • Page 879 HARNESS SYMBOL: [WL Turbo EXCEPT Stage- MAIN FUSE BLOCK [WL Turbo Stage- X-01 [GRAY] INJECTION PUMP B2-09 MAIN FUSE BLOCK B4-09 X-01 [G6] MAIN FUSE BLOCK X-01 IMMOBILIZER UNIT T1-01 COIL T1-02 X-03 FUSE BLOCK X-02 X-10 IGNITION SWITCH ENGINE SWITCH WL Turbo (F)-(INJ) [BLACK]...
  • Page 880 T-2a THEFT-DETERRENT SYSTEM...
  • Page 881 HARNESS SYMBOL: (R)-(R4) X-28 [BLACK] BONNET SWITCH T2-05 MAIN FUSE BLOCK X-01 DOOR KEY CYLINDER T2-08 SWITCH RF DOOR KEY CYLINDER T2-06 SWITCH(BACK DOOR) (F)-(DR1) X-15 T2-07 X-05 DOOR KEY CYLINDER (F)-(R) SWITCH LF X-18 (F)-(DR2) (F)-(DR1) KEY REMINDER SWITCH X-15 T2-02 FUSE BLOCK...
  • Page 882 T-2b THEFT-DETERRENT SYSTEM...
  • Page 883 HARNESS SYMBOL: (R)-(R4) X-28 DOOR LOCK-LINK SWITCH RR K2-05 MAIN FUSE BLOCK X-01 DOOR LOCK-LINK SWITCH (R)-(DR3) (BACK DOOR) X-26 K2-06 T2-03 THEFT-DETERRENT HORN RELAY K2-04 DOOR LOCK-LINK X-27 X-05 SWITCH LR (FR)-(DR4) (F)-(R) K2-03 DOOR LOCK-LINK SWITCH LF T2-04 THEFT-DETERRENT HORN X-16...
  • Page 884 FUEL-FILLER LID OPENER...
  • Page 885 HARNESS SYMBOL: FUEL-FILLER LID OPENER T3-02 MAIN FUSE BLOCK X-01 X-05 (F)-(R) FUEL-FILLER LID OPENER SWITCH T3-01 X-03 FUSE BLOCK X-05 (F)-(R)
  • Page 886 DATA LINK CONNECTOR...
  • Page 887 HARNESS SYMBOL: [WL Turbo] MAIN FUSE BLOCK X-01 X-03 U-01 FUSE BLOCK DATA LINK CONNECTOR X-02 [GRAY] IGNITION SWITCH ENGINE SWITCH WL Turbo [G6] MAIN FUSE BLOCK X-01 U-01 DATA LINK CONNECTOR [GRAY] X-10 (F)-(INJ) [BLACK]...
  • Page 888 COMMON CONNECTOR LIST...
  • Page 889 COMMON CONNECTOR LIST...
  • Page 890 COMMON CONNECTOR LIST...
  • Page 891 COMMON CONNECTOR LIST...
  • Page 892 EVEREST WIRING DIAGRAMS (F190-30-03J) ALPHABETICAL INDEX EVAPORATOR TEMPERATURE SENSOR ..78, 80 4X4 INDICATOR SWITCH ........92 FAN SWITCH A/C AMPLIFIER..........78, 80 (FRONT)............78, 80 A/C MAIN SWITCH..........84 (REAR) ............82, 84 A/C RELAY ............78, 80 FICD SOLENOID VALVE ......26, 30, 40, 44 A/C SWITCH FILAMENT...............94 (FRONT) ............
  • Page 893 EVEREST WIRING DIAGRAMS (F190-30-03J) ALPHABETICAL INDEX EVAPORATOR TEMPERATURE SENSOR ..78, 80 4X4 INDICATOR SWITCH ........92 FAN SWITCH (FRONT)............78, 80 A/C AMPLIFIER..........78, 80 (REAR) ............82, 84 A/C MAIN SWITCH..........84 FICD SOLENOID VALVE ......26, 30, 40, 44 A/C RELAY ............78, 80 FILAMENT...............94 A/C SWITCH FLASHER UNIT..........70, 72...
  • Page 894 As to the service points, important safety notice and general service instructions in service Ford Motor Company which are not covered by this supplement, please refer to the previous Manuals shown on the following page.
  • Page 895 VEHICLE IDENTIFICATION NUMBERS (VIN) (CHASSIS NUMBER) WIRING COLOR CODE COLOR CODE COLOR CODE BLACK ORANGE BLUE PINK BROWN DARK BLUE SKY BLUE DARK GREEN GRAY VIOLET GREEN WHITE LIGHT BLUE YELLOW LIGHT GREEN...
  • Page 896 SYSTEM INDEX GROUND POINT............2 BODY-RELATED SYSTEM ELECTRICAL WIRING SCHEMATIC ...... 6 IMMOBILIZER SYSTEM ........26 THEFT-DETERRENT SYSTEM ......28 ENGINE-RELATED SYSTEM EXTERIOR LIGHTING SYSTEM ENGINE CONTROL SYSTEM “WL Turbo AT” MALAYSIA ........8 TURN AND HAZARD WARNING LIGHT GLOW SYSTEM EXCEPT THAILAND .........18 “WL Turbo AT”...
  • Page 902 THIS PAGE INTENTIONALLY LEFT BLANK...
  • Page 928 ALPHABETICAL INDEX BONNET SWITCH ..........28 TCM ................ 20 BRAKE FLUID LEVEL SENSOR ......14 THEFT-DETERRENT CONTROL MODULE ..28 THEFT-DETERRENT HORN........30 THEFT-DETERRENT HORN RELAY..... 30 COIL................ 26 TRANSMISSION RANGE SWITCH......22 COMMON CONNECTOR LIST ......32 TURN LIGHT ............18 TURN SWITCH............
  • Page 929 Body electronic or mechanical including photocopying, recording or by any information storage and retrieval Measurement system or translation in whole or part is not permitted without written authorization from Ford Moter Company. PRINTED IN , JANUARY 2003 Manual F337–10–03A FOREWORD...
  • Page 930 VEHICLE IDENTIFICATION NUMBERS (VIN) General (L.H.D.) specs. MNB BS4D40? ? ? ? W 10001 — MNB LS4D40? ? ? ? W 10001 — MNB BS4D70? ? ? ? W 10001 — MNB LS4D70? ? ? ? W 10001 — MNB BSYD40? ? ? ? W 10001 —...
  • Page 931 G ENERAL INFORMATION HOW TO USE THIS MANUAL ........ I-2 HOW TO USE THIS MANUAL......I-2 I–1...
  • Page 932 HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL AVF201000001B01 This manual contains frame and cabin dimensions. An explanation of how to read the dimensional drawing is given below. How To Read Frame Dimensions •...
  • Page 933 HOW TO USE THIS MANUAL How To Read Cabin Dimensions • Cabin dimensions are the actual dimensions between two standard points. • When there are no specific indications, the standard points and dimensions are symmetrical in regard to the center of the vehicle. Shows vehicle section DIMENSIONS FRONT BODY DIMENSIONS...
  • Page 934 HOW TO USE THIS MANUAL Symbols of Body Dimensions • The following 8 symbols are used to indicate the standard points. SYMBOL MEANING SYMBOL MEANING Center of circular hole Panel seam, bead, etc. Center elliptical hole Bolt tip (arrow only) Edge of hole Center of rectangular-shaped hole Notch...
  • Page 935 D IMENSIONS DIMENSIONS ............II-2 FRAME DIMENSIONS......... II-2 FRONT BODY STRAIGHT-LINE DIMENSIONS (1) ..........II-4 FRONT BODY STRAIGHT-LINE DIMENSIONS (2) ..........II-5 CABIN SIDE FRAME STRAIGHT-LINE DIMENSIONS ........... II-6 ROOM STRAIGHT-LINE DIMENSIONS (1) ..II-7 ROOM STRAIGHT-LINE DIMENSIONS (2) ..II-8 ROOM STRAIGHT-LINE DIMENSIONS (3) ..
  • Page 936 DIMENSIONS DIMENSIONS FRAME DIMENSIONS AVF981638010B01 Flat-plane dimensions mm {in} {21.57} {35.94} {12.80} {22.32} {19.96} {0.98} {16.06} {3.74} {17.13} {4.09} AVF9816B001 II–2...
  • Page 937 DIMENSIONS Straight-line dimensions mm {in} {20.00} 1,252 {49.29} 1,115 {43.90} {23.62} {21.73} 1,193 {46.97} 2,141 {84.29} 1,771 1,521 {69.72} {59.88} 1,053 1,658 {65.28} {41.46} 1,352 {53.23} 1,081 {42.56} 1,756 {69.13} AVF9816B002 Hole diameter Hole diameter Point Point Designation or bolt or nut Designation or bolt or nut symbol...
  • Page 938 DIMENSIONS FRONT BODY STRAIGHT-LINE DIMENSIONS (1) AVF981653020B01 AVF9816B003 AVF9816B004 Mesured Mesured Dimensions mm{in} Dimensions mm{in} location location 1,229 {48.39} 1,410 {55.51} 714 {28.11} 509 {20.04} 1,410 {55.51} 1,125 {44.29} 1,120 {44.09} 415 {16.34} 288 {11.34} 986 {38.82} 980 {38.58} 711 {27.99} 504 {19.84} 785 {30.91} End Of Sie...
  • Page 939 DIMENSIONS FRONT BODY STRAIGHT-LINE DIMENSIONS (2) AVF981653020B02 AVF9816B005 AVF9816B006 Mesured Mesured Dimensions mm{in} Dimensions mm{in} location location 1,240 {48.82} 383 {15.08} 570 {22.44} 1,448 {57.01} 1,452 {57.17} 546 {21.50} 1,438 {56.61} 1,457 {57.36} 1,434 {56.46} 928 {36.54} 1,360 {53.54} 1,236 {48.66} 1,342 {52.83} End Of Sie II–5...
  • Page 940 DIMENSIONS CABIN SIDE FRAME STRAIGHT-LINE DIMENSIONS AVF981670010B01 AVF9816B007 AVF9816B008 Mesured Mesured Dimensions mm{in} Dimensions mm{in} location location 989 {38.94} 1,186 {46.69} 1,032 {40.63} 1,133 {44.61} 1,155 {45.47} 1,253 {49.33} 1,023 {40.28} 1,293 {50.91} 447 {17.60} 1,241 {48.86} 844 {33.23} 924 {36.38} 1,116 {43.94} 1,436 {56.54} 1,127 {44.37}...
  • Page 941 DIMENSIONS ROOM STRAIGHT-LINE DIMENSIONS (1) AVF981670001B01 AVF9816B009 AVF9816B010 Mesured Mesured Dimensions mm{in} Dimensions mm{in} location location RH:1,000 {39.37}, LH:1,012 {39.84} RH:1,239 {48.78}, LH:1,248 {49.13} RH:914 {35.98}, LH:927 {36.50} RH:1,003 {35.49}, LH:1,015 {39.96} RH:805 {31.69}, LH:820 {32.28} RH:1,002 {39.45}, LH:1,015 {39.96} End Of Sie II–7...
  • Page 942 DIMENSIONS ROOM STRAIGHT-LINE DIMENSIONS (2) AVF981670001B02 AVF9816B011 AVF9816B012 Mesured Mesured Dimensions mm{in} Dimensions mm{in} location location 1,120 {44.09} 823 {32.40} 880 {34.65} 1,774 {69.84} 793 {31.22} 1,727 {67.99} 1,190 {46.85} J-J’ 1,506 {59.29} 1,017 {40.04} End Of Sie II–8...
  • Page 943 DIMENSIONS ROOM STRAIGHT-LINE DIMENSIONS (3) AVF981670001B03 AVF9816B013 AVF9816B014 Mesured Mesured Dimensions mm{in} Dimensions mm{in} location location 1,288 {50.71} 801 {31.54} 983 {38.70} 712 {28.03} 1,050 {41.34} 483 {19.02} 1,023 {40.28} I-I’ 1,529 {60.20} End Of Sie II–9...
  • Page 944 DIMENSIONS REAR BODY STRAIGHT-LINE DIMENSIONS (1) AVF981670002B01 AVF9816B015 C',D' AVF9816B016 Mesured Mesured Dimensions mm{in} Dimensions mm{in} location location 938 {36.93} 1,417 {55.79} 325 {12.80} 1,344 {52.91} 1,139 {44.84} 1,312 {51.65} 437 {17.20} 312 {12.30} 737 {29.02} 1, 257 {49.49} 1,334 {52.52} 1,130 {44.49} 1,300 {51.18} 1,541 {60.67}...
  • Page 945 DIMENSIONS End Of Sie REAR BODY STRAIGHT-LINE DIMENSIONS (2) AVF981670002B02 AVF9816B017 C',D' AVF9816B018 Mesured Mesured Dimensions mm{in} Dimensions mm{in} location location 652 {25.67} 1,510 {59.45} 1,334 {52.52} 1,479 {58.23} 1,270 {50.00} 1,416 {55.75} 354 {13.94} 1,316 {51.81} 1,365 {53.74} 1,316 {51.81} 1,322 {52.05} 156 {6.14} 400 {15.75}...
  • Page 948 WARNING Servicing a vehicle can be dangerous. If you have not received service-related training, the risks of injury, property damage, and failure of servicing increase. The recommended servicing procedures for the vehicle in this workshop manual were developed with Mazda-trained technicians in mind. This manual may be useful to non-Mazda trained technicians, but a technician with our service-related training and experience will be at less risk when performing service operations.
  • Page 949 Automatic CONTENTS Transmission Title Section and Transfer General Information Mechanism and Operation Workshop RA4AX – EL Overhaul Manual TRANSFER Technical Data RA4AX–EL Special Tools © 2004 Mazda Motor Corporation APRIL 2004 1819–10–04D FOREWORD This manual explains the structure, operation, and service points for the above-indicated automatic Transmission.
  • Page 951 G ENERAL INFORMATION HOW TO USE THIS MANUAL ......GI-2 RANGE OF TOPICS .......... GI-2 SERVICING PROCEDURE ....... GI-2 SYMBOLS............GI-4 ADVISORY MESSAGES ........GI-4 UNITS ..............GI-5 UNITS TABLE ............ GI-5 FUNDAMENTAL PROCEDURES ......GI-6 PREPARATION OF TOOLS AND MEASURING EQUIPMENT ......
  • Page 952 HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL RANGE OF TOPICS CBG201000000A01 • This manual contains procedures for performing all required service operations. The procedures are divided into the following five basic operations: — Removal/Installation — Disassembly/Assembly — Replacement —...
  • Page 953 HOW TO USE THIS MANUAL 3. Procedure steps are numbered and the part that is the main point of the procedure is shown in the illustration with the corresponding number. Occasionally, there are important points or additional information concerning a procedure.
  • Page 954 HOW TO USE THIS MANUAL SYMBOLS CBG201000000A03 • There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. These symbols show application points or use of these materials during service. Symbol Meaning Kind New appropriate Apply oil engine oil or gear New appropriate...
  • Page 955 UNITS UNITS UNITS TABLE CBG201200000A01 Electrical current A (ampere) Electric power W (watt) Electric resistance Electric voltage V (volt) mm (millimeter) Length in (inch) kPa (kilo pascal) Negative pressure mmHg (millimeters of mercury) inHg (inches of mercury) Number of rpm (revolutions per minute) revolutions kPa (kilo pascal) kgf/cm...
  • Page 956 FUNDAMENTAL PROCEDURES FUNDAMENTAL PROCEDURES PREPARATION OF TOOLS AND MEASURING EQUIPMENT CBG201400000A01 • Be sure that all necessary tools and measuring equipment are available before starting any work. CHU0014W003 End Of Sie SPECIAL SERVICE TOOLS CBG201400000A02 • Use special service tools or equivalent when they are required.
  • Page 957 FUNDAMENTAL PROCEDURES INSPECTION DURING REMOVAL, DISASSEMBLY CBG201400000A04 • When removed, each part should be carefully inspected for malfunction, deformation, damage, and other problems. WGIWXX0028E End Of Sie ARRANGEMENT OF PARTS CBG201400000A05 • All disassembled parts should be carefully arranged for reassembly. •...
  • Page 958 FUNDAMENTAL PROCEDURES REASSEMBLY CBG201400000A07 • Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts. • If removed, these parts should be replaced with new ones: — Oil seals — Gaskets — O-rings —...
  • Page 959 FUNDAMENTAL PROCEDURES HOSE CLAMPS CBG201400000A10 • When reinstalling, position the hose clamp in the original location on the hose and squeeze the clamp lightly with large pliers to ensure a good fit. WGIWXX0035E End Of Sie TORQUE FORMULAS CBG201400000A11 • When using a torque wrench-SST or equivalent combination, the written torque must be recalculated due to the extra length that the SST or equivalent adds to the torque wrench.
  • Page 960 ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONNECTORS CBG201700000A01 Disconnecting connectors • When disconnecting connector, grasp the NO GOOD connectors, not the wires. GOOD CHU0000W014 • Connectors can be disconnected by pressing or pulling the lock lever as shown. WGIWXX0042E Locking connector • When locking connectors, listen for a click indicating they are securely locked.
  • Page 961 ELECTRICAL SYSTEM • Inspect the terminals of waterproof connectors from the connector side since they cannot be GOOD NO GOOD accessed from the wiring harness side. CHU0000W012 End Of Sie GI–11...
  • Page 962 NEW STANDARDS NEW STANDARDS NEW STANDARDS TABLE CBG202800000A01 • Following is a comparison of the previous standard and the new standard. New Standard Previous Standard Remark Abbreviation Name Abbreviation Name Accelerator Pedal — Accelerator Pedal Air Cleaner — Air Cleaner Air Conditioning —...
  • Page 963 NEW STANDARDS New Standard Previous Standard Remark Abbreviation Name Abbreviation Name Oxidation Catalytic Converter — Catalytic Converter Oxygen Sensor — Oxygen Sensor Park/Neutral Position — Park/Neutral Range — PCM Control Relay — Main Relay Power Steering Pressure — Power Steering Pressure Powertrain Control Module Engine Control Unit —...
  • Page 964 ABBREVIATIONS ABBREVIATIONS ABBREVIATIONS TABLE CBG203000000A01 First Gear Second Gear 2 Wheel 4 Wheel 4×4 4 Wheel–4 Drive Automatic Transmission Fluid Remote Free Wheel Special Service Tool Transmission Fluid Temperature End Of Sie GI–14...
  • Page 965 M ECHANISM AND OPERATION OUTLINE ..............K-2 CROSS-SECTIONAL VIEW......... K-2 SPECIFICATIONS ..........K-3 AUTOMATIC TRANSMISSION ......K-6 OUTLINE..............K-6 CONSTRUCTION ..........K-7 COMPONENT DESCRIPTIONS......K-7 REVERSE CLUTCH AND HIGH CLUTCH DESCRIPTION ......K-8 BAND SERVO PISTON AND BRAKE BAND DESCRIPTION ......K-9 FORWARD CLUTCH, OVERRUNNING CLUTCH AND LOW AND REVERSE BRAKE DESCRIPTION ........
  • Page 966 OUTLINE OUTLINE CROSS-SECTIONAL VIEW CBG560200000A01 OIL PUMP BRAKE BAND FRONT FORWARD ONE-WAY CLUTCH PLANETARY CARRIER REVERSE HIGH FORWARD CLUTCH CLUTCH CLUTCH LOW AND REVERSE BRAKE REAR OVERRUNNING PLANETARY CLUTCH LOW ONE-WAY CLUTCH CARRIER INPUT SHAFT OUTPUT SHAFT TORQUE CONVERTER CONTROL VALVE PARKING GEAR BCF5610A412 End Of Sie...
  • Page 967 OUTLINE SPECIFICATIONS CBG560200000A02 Item Specification Transmission type RA4AX-EL Transmission control Floor Shift Operation system Cable 3.027 1.619 Gear ratio 1.000 0.694 Reverse 2.272 Final gear ratio 4.444 ® Type ATF M-III or equivalent (e.g. Dexron Capacity (Approx. quantity) L {US qt, Imp qt} 10.0 {10.6, 8.8} Torque converter Stall torque ratio...
  • Page 968 OUTLINE Operation of Components Band servo piston For- Over- Shift Shift Reverse High Forward ward running sole- sole- Gear Range Mode clutch clutch reverse clutch clutch noid A noid B applied released applied brake Reverse Except HOLD HOLD Except HOLD HOLD Except HOLD...
  • Page 969 OUTLINE Non-HOLD HOLD Gear Range Gear ratio Engine Engine position Shift Shift operation brake operation brake 2.272 Reverse 3.027 1.619 1.000 0.694 3.027 1.619 1.000 0.694 3.027 1.619 *1: Indicates lock up available when high temperature mode. *1: Indicates that availability of shift up or/and down toward arrow. *1: Indicates that TCC or engine braking is possible.
  • Page 970 AUTOMATIC TRANSMISSION AUTOMATIC TRANSMISSION OUTLINE CBG561019100A01 TORQUE CONVERTER TURBINE RUNNER CLUTCH PUMP IMPELLER PUMP IMPELLER CONVERTER COVER STATOR TURBINE HUB STATOR TURBINE RUNNER TORQUE CONVERTER CLUTCH CONVERTER COVER TORSION SPRING SPLINE BCF5610A004 • The torque converter improves drivability by transmitting the drive force through the use of the transmission fluid.
  • Page 971 AUTOMATIC TRANSMISSION CONSTRUCTION CBG561019100A02 The torque converter which includes the torque converter clutch mechanism houses the turbine runner, the pump impeller, the stator, and the torque converter clutch. The torque converter clutch is spline-fitted to the turbine hub. During torque converter clutch engagement, it slides over the turbine hub and is pressed tightly together with the converter cover.
  • Page 972 AUTOMATIC TRANSMISSION REVERSE CLUTCH AND HIGH CLUTCH DESCRIPTION CBG561000000A02 Reverse clutch • When hydraulic pressure acts upon the reverse clutch piston, the drive and driven plates are pressed tightly together. The driving force transmitted from the input shaft is transmitted to the high clutch drum, reverse clutch hub, reverse clutch drum, connecting shell, and front sun gear sequentially.
  • Page 973 AUTOMATIC TRANSMISSION BAND SERVO PISTON AND BRAKE BAND DESCRIPTION CBG561000000A03 • The band servo piston component contains three chambers to which hydraulic pressure is applied. Hydraulic pressure is applied to each chamber depending on gear positions, which acts upon the piston stem for engagement and disengagement of the brake band.
  • Page 974 AUTOMATIC TRANSMISSION FORWARD CLUTCH, OVERRUNNING CLUTCH AND LOW AND REVERSE BRAKE DESCRIPTION CBG561000000A04 Forward Clutch • When hydraulic pressure acts upon the forward clutch piston, the drive and driven plates are pressed tightly together, and the front planetary carrier and forward one-way clutch outer race are connected by the forward clutch drum.
  • Page 975 AUTOMATIC TRANSMISSION ONE-WAY CLUTCH DESCRIPTION CBG561000000A05 The one-way clutches are sprag-type. Forward one-way clutch • Driven by the inner race rotating counterclockwise, the sprags stand up, causing the one-way clutch to be locked. • As a result, the forward one-way clutch, together with the low one-way clutch, prevents the rotation of the rear internal gear and front planetary carrier through the forward clutch.
  • Page 976 AUTOMATIC TRANSMISSION PARKING MECHANISM DESCRIPTION CBG561000000A06 When the selector lever is moved to P position, the parking pawl engages the parking gear, locks the output shaft and prevents rotation of the driving wheel. Construction Only in P position, the parking pawl engages the parking gear via the parking pawl shaft. In the other ranges, the return spring holds the parking pawl away from the parking gear.
  • Page 977 AUTOMATIC TRANSMISSION OIL PUMP DESCRIPTION CBG561000000A07 Outline • A variable-capacity-vane type oil pump has been added to improve fuel economy. • In an internal gear engagement type involute gear type oil pump, discharge volume goes up in proportion to the engine speed;...
  • Page 978 AUTOMATIC TRANSMISSION End Of Sie COMPONENT DESCRIPTIONS CBG561000000A08 Component Function Distributes line pressure to each circuit corresponding to each selected position. Manual valve Line pressure will be drained in position where distribution is not required Adjusts oil discharged by oil pump to optimum line pressure for corresponding driving Pressure regulator valve conditions Regulates line pressure to maintain the constant pressure (pilot pressure) required for shift...
  • Page 979 AUTOMATIC TRANSMISSION Manual Valve Outline The manual valve is operated by the gear selector and switches the passage for line pressure produced by the oil pump. Operation The manual valve determines where line pressure (5) (for P, R, N, D, S and L ranges/positions) is to be distributed. The valve is in a position where line pressures (1), (3), and (4) cannot be supplied by (5).
  • Page 980 AUTOMATIC TRANSMISSION Pilot Valve Outline The pilot valve converts the line pressure into pilot pressure. The pilot pressure is maintained at a constant level so that it can operate as a signal for the solenoid valve which is required for shift controls such as torque converter clutch and overrunning clutch.
  • Page 981 AUTOMATIC TRANSMISSION The adjusted pressure modifier pressure (6) is converted into the signal pressure and applied to the pressure regulator valve. BCF5610A018 Accumulator Control Valve Outline The accumulator control valve generates the accumulator control pressure from the line pressure, according to the fluctuation in throttle pressure.
  • Page 982 AUTOMATIC TRANSMISSION Modiier Accumulator Valve Outline The modifier accumulator valve stabilizes the pressure adjusted by the pressure modifier valve to prevent line pulsation. Operation The modifier accumulator valve is supplied with pressure modifier pressure (6) which pushes the MODIFIER ACCUMULATOR VALVE valve to the left, and the spring force which pushes the valve to the right.
  • Page 983 AUTOMATIC TRANSMISSION L range 1GR The 1GR reducing pressure which flows through hydraulic path (11) is convected into the low and reverse brake pressure in hydraulic (15), to allow low and reverse brake engagement. BCF5610A023 Conditions in 2GR and 3GR The valve is pushed to the right side because the pilot pressure (10) controlled by the shift solenoid A is not being applied to it.
  • Page 984 AUTOMATIC TRANSMISSION Shift Valve B Outline Shift valve B simultaneously switches three hydraulic paths based on the pilot pressure controlled by the shift solenoid B ON-OFF signals. It performs automatic shifting of 1GR, 2GR, 3GR and 4GR in combination with shift valve A, in response to driving conditions such as vehicle speed and control lever opening angle.
  • Page 985 AUTOMATIC TRANSMISSION Line pressure provided from oil passage (1) is applied to the band servo (3GR release hydraulic path) and to the high clutch vial oil passage (20), and to the band servo (4GR engage hydraulic path) via shift valve A. BCF5610A029 4-2 Relay Valve and 4-2 Sequence Valve Outline...
  • Page 986 AUTOMATIC TRANSMISSION Downshift from 4GR to 2GR Shift solenoid A: ON → OFF No pilot pressure is applied to shift valve A. Line pressure is applied to the end of the 4-2 relay valve via hydraulic path (17). Shift solenoid B: OFF → ON Pilot pressure is applied to shift valve B.
  • Page 987 AUTOMATIC TRANSMISSION Shuttle Shift Valve S Outline Shuttle shift valve S switches the hydraulic path to apply output voltage generated when the overrunning clutch solenoid is turned ON to either the overrunning clutch control valve or the 3-2 timing valve. Operation The spring force pushes shuttle shift valve S to the left.
  • Page 988 AUTOMATIC TRANSMISSION D range (HOLD mode with a vehicle speed of approx. 10 km/h {6 mph} or more) 1. Control lever opening angle of approx. 1/16 or less • With a control lever opening angle of approx. 1/16 or less, the overrunning clutch solenoid valve turns off and the output pressure applied to the overrunning clutch control valve dissipates.
  • Page 989 AUTOMATIC TRANSMISSION Servo Charger Valve Outline Band servo 2GR applied hydraulic circuit has accumulator and one-way orifice to dampen shock during 1-2 shift. Accordingly, during 4-3 and 3-2 downshifting, the servo charger valve activates in 3GR position or 4GR to supply band servo 2GR applied pressure, bypassing one-way orifice in order to assure sufficient flow volume.
  • Page 990 AUTOMATIC TRANSMISSION Downshift at low speed (low control lever opening) The overrunning clutch solenoid is turned OFF and no output pressure is generated. The 3-2 timing valve is pushed to the right and hydraulic paths (29) and (28) are connected. The operation pressure in the band servo 3GR release chamber is drained through the 3-2 timing valve to make the draining time faster.
  • Page 991 AUTOMATIC TRANSMISSION Overrunning Clutch Reducing Valve Outline The overrunning clutch reducing valve controls the overrunning clutch applied pressure to reduce engine braking shock. Operation The overrunning clutch reducing pressure (37) is applied to the left side of the valve, pushing it to the right. The spring force and accumulator control pressure (40) are applied to the right side of the valve, pushing it to the left.
  • Page 992 AUTOMATIC TRANSMISSION Torque Converter Clutch Control Valve Outline The torque converter clutch control valve controls torque converter clutch engagement by switching the hydraulic path of the torque converter pressure. This function is carried out under the control of the pilot pressure based on the duty signals from the TCC solenoid valve.
  • Page 993 AUTOMATIC TRANSMISSION In P, R, or N position and 1GR (in D, S, or L range) Pilot pressure (34), provided from shuttle shift valve D, is applied to the end of the torque converter clutch control valve to hold the valve to the right. The torque converter pressure that provided from hydraulic path (31) is applied to chamber F via hydraulic path (33) and the damper piston is held to...
  • Page 994 AUTOMATIC TRANSMISSION 1-2 Accumulator Outline The 1-2 accumulator reduces shift shock by moderating the rapid increase in hydraulic pressure during 1-2 shifting when the brake band is applied. Operation In 1GR, the accumulator is pushed to the right side because the line pressure (40) is applied to it. When shift solenoid A is turned OFF in order to shift into the 2GR, line pressure for brake band engage (12) is applied to the 1-2 accumulator by shift valve A.
  • Page 995 AUTOMATIC TRANSMISSION 3-4/N-R Accumulator Outline The 3-4/N-R accumulator moderates the rapid increase in hydraulic pressure during brake band engagement and reverse clutch engagement. This reduces the shift shock generated during 3-4 shifting or N-R shifting. Operation When shift solenoid A is turned ON in order to shift into the 4GR, line pressure for brake band engage (25) is applied to the 3-4/N-R accumulator.
  • Page 996 AUTOMATIC TRANSMISSION Feedback Accumulator Piston Outline The feedback accumulator piston prevents line pressure pulsation by stabilizing feedback pressure adjusted by pressure regulator valve. Operation The feedback accumulator piston is supplied with the spring force which pushes the piston to the left, and feedback pressure (7) which pushes the piston to the right.
  • Page 997 AUTOMATIC TRANSMISSION P POSITION, N POSITION CBG561000000A09 The driving force of the input shaft is transmitted to the high clutch drum. None of the clutches are operating, however, so this force is not transmitted to the output shaft. Therefore, the vehicle cannot move. The output shaft is End Of Sie locked because the parking gear is mechanically locked by the parking pawl (in P position).
  • Page 998 AUTOMATIC TRANSMISSION R POSITION CBG561000000A10 The driving force of the input shaft is transmitted to the high clutch drum, and then to the front sun gear through the reverse clutch, causing the front sun gear to rotate clockwise. The front pinion gear, however, does not revolve around the front sun gear because the planetary carrier is locked by the low and reverse brake.
  • Page 999 AUTOMATIC TRANSMISSION FIRST GEAR CBG561000000A11 The driving force of the input shaft is transmitted to the rear sun gear, causing the rear pinion gear to rotate counterclockwise. As a result, the front internal gear also tries to turn counterclockwise but is prevented from doing so due to the action of the forward one-way clutch, forward clutch and overrunning clutch on the low one-way clutch.
  • Page 1000 AUTOMATIC TRANSMISSION FIRST GEAR (ENGINE BRAKING) CBG561000000A12 The driving force of the input shaft is transmitted to the rear sun gear, causing the rear pinion gear to rotate counterclockwise. However, the internal gear does not rotate because it is locked by the overrunning clutch and low and reverse brake.
  • Page 1001 AUTOMATIC TRANSMISSION SECOND GEAR CBG561000000A13 The driving force of the input shaft is transmitted to the rear sun gear, causing the rear pinion gear to rotate counterclockwise and as in 1GR, also causes the rear planetary gear to rotate clockwise. The front internal gear rotates clockwise together with the rear planetary gear.
  • Page 1002 AUTOMATIC TRANSMISSION SECOND GEAR (ENGINE BRAKING) CBG561000000A14 The driving force of the input shaft is transmitted to the rear sun gear, causing the rear pinion gear to rotate counterclockwise and as in 1GR, also causes the rear planetary gear to rotate clockwise. The front internal gear rotates clockwise together with the rear planetary gear.
  • Page 1003 AUTOMATIC TRANSMISSION THIRD GEAR CBG561000000A15 The driving force of the input shaft is transmitted to the high clutch drum, causing the front planetary carrier to rotate clockwise. This driving force is also transmitted to the rear internal gear through the forward clutch, forward one-way clutch and overrunning clutch making it rotate clockwise.
  • Page 1004 AUTOMATIC TRANSMISSION THIRD GEAR (ENGINE BRAKING) CBG561000000A16 The driving force of the input shaft is transmitted to the high clutch drum, causing the front planetary carrier to rotate clockwise. This driving force is also transmitted to the rear internal gear through the forward clutch, forward one-way clutch and overrunning clutch making it rotate clockwise.
  • Page 1005 AUTOMATIC TRANSMISSION FOURTH GEAR (D RANGE, TCC NON-OPERATION) CBG561000000A17 The driving force of the input shaft is transmitted to the front planetary gear via the high clutch, causing it to rotate clockwise. As a result, the front pinion gear rotates clockwise. This rotation causes the front internal gear to rotate at an increased speed and the rear planetary carrier to rotate clockwise.
  • Page 1006 AUTOMATIC TRANSMISSION FOURTH GEAR (D RANGE, TCC OPERATION) CBG561000000A18 The driving force of the input shaft is transmitted to the front planetary via the high clutch, causing it to rotate clockwise. The front sun gear, however, is locked by the brake band and thus does not rotate. As a result, the front pinion gear rotates clockwise.
  • Page 1007 A UTOMATIC TRANSMISSION (RA4AX–EL) AUTOMATIC TRANSMISSION ......K1-2 TRANSMISSION UNIT DISASSEMBLY .... K1-2 TORQUE CONVERTER INSPECTION ... K1-13 TORQUE CONVERTER CLEANING....K1-13 ACCUMULATOR DISASSEMBLY/ASSEMBLY ......K1-14 OIL PUMP DISASSEMBLY/ASSEMBLY ..K1-16 REVERSE CLUTCH PREINSPECTION ..K1-20 REVERSE CLUTCH DISASSEMBLY/ASSEMBLY ......K1-21 HIGH CLUTCH AND FRONT SUN GEAR PREINSPECTION.........
  • Page 1008 AUTOMATIC TRANSMISSION AUTOMATIC TRANSMISSION TRANSMISSION UNIT DISASSEMBLY CBG571000000A01 Transmission Unit Disassembly Precaution Warning • A hot transmission and ATF can cause severe burns. Turn off the engine and wait until they are cool before replacing ATF. • Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear protective eye wear whenever using compressed air.
  • Page 1009 AUTOMATIC TRANSMISSION Transmission Unit Disassembly 1. Disassemble in the order indicated in the table. Components 1 OIL SEAL GASKET BOLT O-RING O-RING BOLT GASKET O-RING GASKET BOLT BCF5610A101 Transfer Control valve body (See K1–57 CONTROL VALVE BODY Input sleeve DISASSEMBLY.) TR switch Solenoid valve harness Output speed sensor...
  • Page 1010 AUTOMATIC TRANSMISSION Components 2 GASKET O-RING BCF5610A102 Input shaft Parking gear and bearing Oil pump Snap ring (See K1–16 OIL PUMP DISASSEMBLY/ Output shaft ASSEMBLY.) Front internal gear, rear internal gear, forward clutch Brake band and strut hub, overrunning clutch hub Reverse clutch (See K1–36 FRONT INTERNAL GEAR, REAR (See K1–21 REVERSE CLUTCH DISASSEMBLY/...
  • Page 1011 AUTOMATIC TRANSMISSION Components 3 BCF5610A103 Accumulator spring and piston Low and reverse brake piston and spring (See K1–14 ACCUMULATOR DISASSEMBLY/ (See K1–49 LOW AND REVERSE BRAKE ASSEMBLY.) DISASSEMBLY/ASSEMBLY.) Band servo (See K1–32 BAND SERVO DISASSEMBLY/ ASSEMBLY.) K1–5...
  • Page 1012 AUTOMATIC TRANSMISSION Transmission unit disassembly procedure 1. Support the transmission by placing wooden blocks under the converter housing and the adapter case. 2. Remove the oil pan and gasket. If large amounts of material are found in the oil pan, replace the torque converter and inspect the transmission for the cause.
  • Page 1013 AUTOMATIC TRANSMISSION 11. Remove the torque converter, and immediately turn it so that the hole faces upward. This will help to keep any remaining fluid from spilling. Inspect and replace the torque converter as necessary. (See K1–13 TORQUE CONVERTER INSPECTION.) BCF5610A109 12.
  • Page 1014 AUTOMATIC TRANSMISSION 19. Remove the TFT sensor. 20. Remove the oil strainer. BCF5610A371 21. Remove the O-ring from the oil strainer. BCF5610A115 22. Separate the solenoid valve harness from the harness clip. BCF5610A116 23. Remove bolts A and B and the brackets as shown BRACKET in the figure.
  • Page 1015 AUTOMATIC TRANSMISSION 24. Remove the clip carefully prying with a small flathead screwdriver. 25. Disconnect the solenoid valve connectors. BCF5610A118 26. Remove the control valve body. BCF5610A119 27. Remove the accumulator springs. ACCUMULATOR SPRINGS BCF5610A120 28. Remove the solenoid connector from the transmission case.
  • Page 1016 AUTOMATIC TRANSMISSION 32. Remove the O-ring from the input shaft. 33. Install the SST to the oil pump. 34. Slowly remove the oil pump from the transmission case by evenly sliding the weights of the SST. O-RING BCF5610A123 35. Remove the SST from the oil pump. 49 0378 390 BCF5610A124 36.
  • Page 1017 AUTOMATIC TRANSMISSION 42. Remove the brake band and hold it together with a piece of wire as shown in the figure. 43. Remove the band strut. BCF5610A128 44. Remove the reverse clutch, high clutch, and the front sun gear from the transmission case as a component.
  • Page 1018 AUTOMATIC TRANSMISSION 49. Push the output shaft slightly forward and remove the snap ring from the output shaft. BCF5610A133 50. Slide out the output shaft from the rear of the transmission case. BCF5610A134 51. Remove the front internal gear (integrated with rear planetary carrier).
  • Page 1019 AUTOMATIC TRANSMISSION TORQUE CONVERTER INSPECTION CBG571019100A01 1. Check the outside of the converter for damage and cracks. • If there is any malfunction, replace the torque converter. 2. Check for rust on the pilot hub or the boss. Remove any rust completely. TORQUE CONVERTER BCF5610A138 End Of Sie...
  • Page 1020 AUTOMATIC TRANSMISSION ACCUMULATOR DISASSEMBLY/ASSEMBLY CBG571021272A01 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. BCF5610A140 3-4/N-R accumulator spring O-ring 1-2 accumulator spring 1-2 accumulator piston (See K1–14 Accumulator Piston Disassembly Note.) 2-3 accumulator spring O-ring N-D accumulator piston (See K1–14 Accumulator Piston Disassembly Note.)
  • Page 1021 AUTOMATIC TRANSMISSION Accumulator Spring Inspection 1. Measure the spring free length. • If not as specified, replace the spring. Outer Free Wire Spring No. of dia. length dia. Specification coils FREE LENGTH mm {in} mm {in} mm {in} N-D accumulator 18.0 43.0 spring...
  • Page 1022 AUTOMATIC TRANSMISSION 3. Install each spring into its own accumulator piston. ACCUMULATOR ACCUMULATOR 3-4/N-R ACCUMULATOR ACCUMULATOR BCF5610A146 End Of Sie OIL PUMP DISASSEMBLY/ASSEMBLY CBG571019220A01 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. APPLY SPECIFIED ATF TO INDIVIDUAL PARTS 16—21 {1.6—2.1, 12—15}...
  • Page 1023 AUTOMATIC TRANSMISSION Rotor Spring seat (See K1–17 Rotor Disassembly Note.) Friction ring Vane O-ring Vane ring Pivot pin Pivot pin Control piston (See K1–17 Pivot Pin Disassembly Note.) Side seal Cam ring Oil pump housing (See K1–17 Cam Ring Disassembly Note.) Oil seal Cam ring spring Oil Pump Cover Disassembly Note...
  • Page 1024 AUTOMATIC TRANSMISSION Oil Pump Cover Inspection 1. Fit a new seal rings into the oil pump cover. 2. Measure the clearance between the seal ring and the ring groove. • If not within the specification, replace the oil pump component. Standard clearance 0.10—0.25 mm {0.0039—0.0098 in} Maximum clearance...
  • Page 1025 AUTOMATIC TRANSMISSION 3. Install the control piston and pivot pin. 4. Apply petroleum jelly to the cam ring groove and install a new O-ring and friction ring into the cam ring. BCF5610A155 5. Install the cam ring and spring while compressing FRICTION the spring against the oil pump housing.
  • Page 1026 AUTOMATIC TRANSMISSION 10. Apply petroleum jelly to the seal rings. Fit the large seal ring (yellow mark) into the bottom ring groove and the small ring (no mark) into the top ring groove. 11. Apply ATF to a new O-ring and install it onto the oil pump.
  • Page 1027 AUTOMATIC TRANSMISSION REVERSE CLUTCH DISASSEMBLY/ASSEMBLY CBG571019500A02 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. SELECTIVE SEAL RING D-RING FRONT BCF5610A400 Snap ring Spring retainer component Retaining plate Clutch piston (See K1–22 Clutch Piston Disassembly Note.) Drive and driven plates Seal ring Dished plate...
  • Page 1028 AUTOMATIC TRANSMISSION Snap Ring Disassembly Note Caution • Depress the spring retainer only enough to remove the snap ring. Overpressing will damage the retainer component edges. 1. While holding the spring retainer component down using the SSTs, remove the snap ring using 49 G019 029 snap ring pliers.
  • Page 1029 AUTOMATIC TRANSMISSION Clutch Piston Inspection 1. Shake the clutch piston and verify that the check ball is free. 2. Verify that there is no air flow when applying compressed air through the oil hole on the clutch drum side. 3. Verify that there is air flow when applying AIR FLOW compressed air through the oil hole on the return NO AIR FLOW...
  • Page 1030 AUTOMATIC TRANSMISSION 6. Install the spring retainer component. BCF5610A703 Caution • Depress the spring retainer only enough to install the snap ring. Overpressing will damage the retainer component edges. SNAP RING STOPPER BCF5610A172 7. While holding the snap ring retainer down using SSTs, install the snap ring into the spring retainer 49 G019 029 stopper.
  • Page 1031 AUTOMATIC TRANSMISSION 12. Install the retaining plate. 13. Install the snap ring. BCF5610A175 14. Measure the clearance between the retaining plate and the snap ring using a feeler gauge. • If not within the specification, adjust the clearance by selecting the correct retaining plate.
  • Page 1032 AUTOMATIC TRANSMISSION HIGH CLUTCH AND FRONT SUN GEAR PREINSPECTION CBG571019500A03 High Clutch Operation 1. Install the high clutch with seal rings onto the oil pump. Apply compressed air through the oil passage as shown in the figure. 2. Verify that the retaining plate moves toward the snap ring.
  • Page 1033 AUTOMATIC TRANSMISSION HIGH CLUTCH AND FRONT SUN GEAR DISASSEMBLY/ASSEMBLY CBG571019500A04 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. SELECTIVE APPLY PETROLEUM JELLY BCF5610A401 Front sun gear Snap ring (See K1–28 Snap Ring Disassembly Note.) Bearing race Spring retainer component Bearing...
  • Page 1034 AUTOMATIC TRANSMISSION Snap Ring Disassembly Note Caution • Depress the spring retainer only enough to remove the snap ring. Overpressing will damage the retainer component edges. 1. While holding the spring retainer component 49 G019 029 down with SSTs, remove the snap ring using 49 G019 026 snap ring pliers.
  • Page 1035 AUTOMATIC TRANSMISSION Clutch Piston Inspection 1. Shake the clutch piston and verify that the check ball is free. 2. Verify that there is no air flow when applying compressed air through the oil hole on the clutch drum side. 3. Verify that there is air flow when applying NO AIR FLOW compressed air through the oil hole on the return AIR FLOW...
  • Page 1036 AUTOMATIC TRANSMISSION 6. While holding the spring retainer down by using 49 G019 029 the SSTs, install the snap ring into the spring 49 G019 026 retainer stopper. 7. Soak new drive plates in ATF for at least two hours. 8.
  • Page 1037 AUTOMATIC TRANSMISSION 14. Install the high clutch with the seal rings onto the oil pump. Apply compressed air through the oil passage and verify clutch operation. Air pressure 392 kPa {4.0 kgf/cm , 57 psi} max. BCF5610A191 15. Apply petroleum jelly to the bearing races and BEARING RACE BEARING RACE install them in the high clutch drum as shown in...
  • Page 1038 AUTOMATIC TRANSMISSION End Of Sie BAND SERVO DISASSEMBLY/ASSEMBLY CBG571019500A06 1. Disassemble in the order shown in the figure. 2. Assemble in the reverse order of disassembly. 40—51 {4.1—5.2, 30—37} 4.0—5.8 N·m {40—60 kgf·cm, 35—52 in·lbf} 9.8—11.8 N·m {100—120 kgf·cm, 87—104 in·lbf} N·m {kgf·m, ft·lbf} CBG5710A001 Locknut...
  • Page 1039 AUTOMATIC TRANSMISSION Piston Component and Servo Piston Retainer Disassembly Note 1. Apply compressed air to the oil hole in the transmission case to remove the piston component and servo piston retainer from the transmission case. Air pressure 392 kPa {4.0 kgf/cm , 57 psi} max.
  • Page 1040 AUTOMATIC TRANSMISSION 3. Apply ATF to the servo spring retainer. Assemble them in the band servo piston. BCF5610A200 4. Assemble the band servo piston, piston stem, return spring, and spring retainer. 5. Install the retaining ring. 6. Apply ATF to the band servo piston component. BCF5610A201 7.
  • Page 1041 AUTOMATIC TRANSMISSION 13. Apply even pressure to the perimeter of the piston component, and install it into the transmission case. BCF5610A205 14. Apply ATF to the band servo retainer and a new gasket, and install them onto the transmission case. BCF5610A206 15.
  • Page 1042 AUTOMATIC TRANSMISSION End Of Sie FRONT INTERNAL GEAR, REAR INTERNAL GEAR, FORWARD CLUTCH HUB, OVERRUNNING CLUTCH HUB PREINSPECTION CBG571019500A07 Forward One-Way Clutch Operation 1. While holding the forward clutch hub, verify that REAR INTERNAL GEAR the rear internal gear rotates smoothly when turned clockwise and locks when turned counterclockwise.
  • Page 1043 AUTOMATIC TRANSMISSION Front Internal Gear, Rear Internal Gear, Forward Clutch Hub, Overrunning Clutch Hub Assembly Procedure 1. Install the snap ring into the forward clutch hub. 2. Apply ATF to the forward one-way clutch. Install it into the forward clutch hub, with the flange facing upward.
  • Page 1044 AUTOMATIC TRANSMISSION 8. Set the overrunning clutch hub on the rear internal gear. BCF5610A217 9. Apply petroleum jelly to the bearing race, and set it on the front internal gear. BEARING RACE Bearing race outer diameter 75.0 mm {2.953 in} BCF5610A219 End Of Sie FORWARD CLUTCH DRUM (FORWARD CLUTCH, OVERRUNNING CLUTCH, LOW ONE-WAY CLUTCH)
  • Page 1045 AUTOMATIC TRANSMISSION Forward Clutch and Overrunning Clutch Operation 1. Install the forward clutch drum and low one-way clutch inner race into the transmission case. Apply compressed air through the oil passage as shown in the figure. 2. Verify that the retaining plates move toward the snap rings.
  • Page 1046 AUTOMATIC TRANSMISSION 2. Assemble in the reverse order of disassembly. FRONT SELECTIVE FRONT D-RING SELECTIVE FRONT SEAL RING D-RING BCF5610A402 K1–40...
  • Page 1047 AUTOMATIC TRANSMISSION Snap ring Seal ring Snap ring D-ring Retaining plate Overrunning clutch piston (See K1–42 Forward Clutch Piston, Overrunning Drive and driven plates Clutch Piston Disassembly Note.) Dished plate D-ring Snap ring D-ring Retaining plate Snap ring Drive and driven plates Side plate Dished plate Low one-way clutch...
  • Page 1048 AUTOMATIC TRANSMISSION Forward Clutch Piston, Overrunning Clutch Piston Disassembly Note 1. Set the forward clutch drum in the transmission case. 2. Remove the piston by applying compressed air through the oil passage. Air pressure 392 kPa {4.0 kgf/cm , 57 psi} max. 3.
  • Page 1049 AUTOMATIC TRANSMISSION Overrunning Clutch Piston Inspection 1. Shake the clutch piston and verify that the check ball is free. 2. Verify that there is no air flow when applying compressed air through the oil hole on the clutch drum side. 3.
  • Page 1050 AUTOMATIC TRANSMISSION 4. Apply ATF to the side plate and snap ring, and install them into the forward clutch drum. BCF5610A230 5. Apply ATF to a new D-ring and seal ring, and install them into the forward clutch piston as shown in the figure.
  • Page 1051 AUTOMATIC TRANSMISSION 12. Install the spring retainer component. BCF5610A406 Caution STOPPER • Depress the spring retainer only enough to install the snap ring. Overpressing will damage the retainer component edges. SNAP RING BCF5610A236 13. While holding the spring retainer down using the 49 G019 029 SSTs, install the snap ring into the spring retainer 49 G019 026...
  • Page 1052 AUTOMATIC TRANSMISSION 20. Measure the clearance between the retaining plate and the snap ring using a feeler gauge. • If not within the specification, adjust the clearance by selecting the correct retaining plate. Clearance 1.0—2.0 mm {0.039—0.079 in} Retaining plate size (mm {in}) 4.0 {0.157} 4.2 {0.165}...
  • Page 1053 AUTOMATIC TRANSMISSION 28. Measure the clearance between the retaining plate and the snap ring using a feeler gauge. • If not within the specification, adjust the clearance by selecting the correct retaining plate. Clearance 0.45—2.05 mm {0.018—0.081 in} Retaining plate size (mm {in}) 8.1 {0.319} 8.3 {0.327}...
  • Page 1054 AUTOMATIC TRANSMISSION 31. Set the forward clutch drum in the transmission. 32. Apply compressed air through the oil passage as shown in the figure, and check the forward clutch operation. Air pressure 392 kPa {4.0 kgf/cm , 57 psi} max. FORWARD CLUTCH BCF5610A247 33.
  • Page 1055 AUTOMATIC TRANSMISSION Low and Reverse Brake Clearance 1. Measure the clearance between the retaining plate and the snap ring. Clearance 0.7—2.3 mm {0.028—0.091 in} 2. Select the correct retaining plate when assembling. BCF5610A250 End Of Sie LOW AND REVERSE BRAKE DISASSEMBLY/ASSEMBLY CBG571019500A12 1.
  • Page 1056 AUTOMATIC TRANSMISSION Low One-Way Clutch Inner Race Disassembly Note 1. Loosen the bolts gradually in a crisscross pattern. Hold the inner race with your free hand so that it doesn’t spring out as the last bolt is removed. 2. Remove the Allen-head bolts and low one-way clutch inner race.
  • Page 1057 AUTOMATIC TRANSMISSION Low One-Way Clutch Inner Race Inspection 1. Apply petroleum jelly to new seal rings and install them to the one-way clutch inner race. 2. Measure the clearance between each seal ring and ring groove. • If it exceeds the maximum specification, replace the low one-way clutch inner race.
  • Page 1058 AUTOMATIC TRANSMISSION 7. Verify that the spring retainer component, and low LOW ONE-WAY CLUTCH RACE one-way clutch inner race are properly positioned before securing them with the Allen-head bolts. SPRING RETAINER RETURN SPRING COMPONENT ALLEN-HEAD BOLT BCF5610A258 8. Tighten the Allen-head bolts evenly and gradually in the order as shown in the figure.
  • Page 1059 AUTOMATIC TRANSMISSION 15. Install the snap ring. BCF5610A261 16. Measure the clearance between the retaining plate and the snap ring using a feeler gauge. • If not within the specification, adjust the clearance by selecting the correct retaining plate. Clearance 0.7—2.3 mm {0.028—0.091 in} Retaining plate size (mm {in})
  • Page 1060 AUTOMATIC TRANSMISSION End Of Sie ADAPTER CASE/PARKING MECHANISM DISASSEMBLY/ASSEMBLY CBG571017071A01 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. 24—29 {2.4—3.0, 18—21} 30—39 4.0—5.8 N·m {3.0—4.0, 22—28} {40—60 kgf·cm, 35—52 in·lbf} N·m {kgf·m, ft·lbf} CBG5818A001 Adapter case Parking rod...
  • Page 1061 AUTOMATIC TRANSMISSION Oil Seal (Transmission Side) Disassembly Note 1. Remove the oil seal, being careful to not allow any metal tools to scratch the inside of the transmission case. BCF5610A266 Adapter Case/Parking Mechanism Assembly Procedure 1. Apply ATF to the lip of the new oil seal. 2.
  • Page 1062 AUTOMATIC TRANSMISSION 7. Wrap the threads of the manual shaft with tape. 8. Apply ATF to the bearing in the transmission TAPE case. OIL SEAL BCF5610A270 9. Install the manual shaft into the transmission case. 10. Push the oil seal squarely into the transmission case.
  • Page 1063 AUTOMATIC TRANSMISSION 16. While holding the manual shaft as shown in the figure, tighten the locknuts. Tightening torque 30—39 N·m {3.0—4.0 kgf·m, 22—28 ft·lbf} BCF5610A275 17. Inspect the parking mechanism operation. BCF5610A276 End Of Sie CONTROL VALVE BODY DISASSEMBLY CBG571021100A01 Caution •...
  • Page 1064 AUTOMATIC TRANSMISSION 4. Clean the removed parts with cleaning solvent, and dry them with compressed air. Clean out all holes and passages with compressed air. O-RING O-RING O-RING BCF5610A277 K1–58...
  • Page 1065 AUTOMATIC TRANSMISSION TCC solenoid valve Steel balls Side plate Upper gasket Pressure control solenoid Separator plate Overrunning clutch solenoid, shift solenoid A, and Lower gasket shift solenoid B Orifice check valve and spring Support plate Pilot filter Retaining bolt and nut Accumulator filter Bracket Manual valve...
  • Page 1066 AUTOMATIC TRANSMISSION 8. Hold the lower valve body, lower and upper gaskets, and separator plate using a large clip. 9. Separate the lower valve body from the upper valve body. BCF5610A403 10. Remove the steel balls from the upper valve body. 11.
  • Page 1067 AUTOMATIC TRANSMISSION UPPER VALVE BODY DISASSEMBLY/ASSEMBLY CBG571021100A02 Caution • Denting or scratching these precisely machined components will reduce the ability of the transmission to shift properly. When handling these components or the valve body that contains them, be careful not to drop or hit them. •...
  • Page 1068 AUTOMATIC TRANSMISSION 3. Assemble in the reverse order of disassembly. APPLY SPECIFIED ATF TO INDIVIDUAL PARTS BCF5610A408 Retainer Stopper pin (See K1–64 Retainer Disassembly Note.) (See K1–63 Stopper Pin Disassembly Note.) Torque converter relief spring Pressure regulator sleeve Torque converter relief valve Pressure regulator spring Pressure regulator plug K1–62...
  • Page 1069 AUTOMATIC TRANSMISSION Pressure regulator valve 4-2 relay plug Stopper pin 4-2 relay valve (See K1–63 Stopper Pin Disassembly Note.) 4-2 relay spring Pressure modifier plug Stopper pin Pressure modifier spring (See K1–63 Stopper Pin Disassembly Note.) Pressure modifier valve Overrunning clutch control plug Stopper pin Overrunning clutch control spring (See K1–63 Stopper Pin Disassembly Note.)
  • Page 1070 AUTOMATIC TRANSMISSION Retainer Disassembly Note 1. Push the retainer way out using a wire. 2. Hold the inside parts with a finger to prevent the valve from pepping out. 3. Remove the retainer, the valve, and the internal parts. SPRING WIRE RETAINER RETAINER...
  • Page 1071 AUTOMATIC TRANSMISSION Upper valve body assemble procedure 1. Insert the torque converter relief valve and spring. BCF5610A292 2. Install the retainer while compressing the spring. RETAINER TAPE BCF5610A293 3. Center the plug so that it fits onto the sleeve. While turning the sleeve slightly, insert the pressure regulator valve, plug, spring, and sleeve.
  • Page 1072 AUTOMATIC TRANSMISSION 7. Align the tab of the sleeve with the valve notch. 8. Insert the accumulator control valve, sleeve, spring, and plug. SLEEVE VALVE BCF5610A422 9. Insert the stopper pin while pushing the plug. 10. Insert the shuttle shift valve D and spring. BCF5610A298 11.
  • Page 1073 AUTOMATIC TRANSMISSION 15. Insert the 4-2 relay valve and spring. BCF5610A303 16. Push in the plug by using a vinyl tape-wrapped 1.5 mm {0.059 in} diameter rod and insert the stopper pin. STOPPER PIN 17. Insert shift valve B and spring. 18.
  • Page 1074 AUTOMATIC TRANSMISSION 25. Insert the stopper pin while pushing the plug. 26. Insert the TCC control valve, spring, plug, and sleeve. BCF5610A423 27. Insert the stopper pin while pushing the sleeve. 28. Insert the pilot valve and spring. BCF5610A308 29. Insert the retainer while pushing the spring. BCF5610A309 End Of Sie LOWER VALVE BODY DISASSEMBLY/ASSEMBLY...
  • Page 1075 AUTOMATIC TRANSMISSION 3. Assemble in the reverse order of disassembly. APPLY SPECIFIED ATF TO INDIVIDUAL PARTS BCF5610A310 Stopper key 3-2 timing spring Modifier accumulator spring 3-2 timing valve Modifier accumulator valve Stopper pin Retainer Servo charger plug First reducing spring Servo charger valve First reducing valve Servo charger spring...
  • Page 1076 AUTOMATIC TRANSMISSION Springs Inspection 1. Measure the spring free length. • If not within specification, replace the spring. FREE LENGTH WIRE DIAMETER BCF5610A142 Specification Spring specification Outer dia. mm {in} Free length mm {in} No. of coils Wire dia. mm {in} Modifier accumulator valve 9.8 {0.386} 31.4 {1.236}...
  • Page 1077 AUTOMATIC TRANSMISSION 8. Insert the stopper key while pushing the spring. BCF5610A314 End Of Sie CONTROL VALVE BODY ASSEMBLY CBG571021100A04 Steel ball installation positions BCF5610A315 K1–71...
  • Page 1078 AUTOMATIC TRANSMISSION Bracket, bolt and nuts installation positions BCF5610A317 Identification Torque specification Bolt and nut Length mm {in} letter N·m {kgf·cm, in·lbf} 70 {2.76} 50 {1.97} 33 {1.30} 6.9—8.8 {70—90, 61—78} 27 {1.06} 55 {2.17} 45 {1.77} K1–72...
  • Page 1079 AUTOMATIC TRANSMISSION 1. Verify that all parts are clean and free of dust or other small particles. 2. Apply ATF to all O-rings and gaskets. 3. Assemble as shown in the figure, referring to Assembly procedure. 4. Install the steel balls and reamer bolts into their proper positions of the upper valve body. (See K1–71 Steel ball installation positions.) REAMER BOLT(LONG) REAMER BOLT...
  • Page 1080 AUTOMATIC TRANSMISSION 7. Set the lower valve body onto the upper valve body. BCF5610A327 8. Install the support plates as shown in the figure. SUPPORT PLATE Bolt length (measured from below bolt head) A: 33 mm {1.30 in} B: 27 mm {1.06 in} 9.
  • Page 1081 AUTOMATIC TRANSMISSION 13. Install the side plate as shown in the figure. 14. Install the new O-rings onto the solenoids. SIDE PLATE BCF5610A330 15. Install the solenoids into the upper valve body. Tightening torque 6.9—9.8 N·m {70—100 kgf·cm, 61—87 in·lbf} 16.
  • Page 1082 AUTOMATIC TRANSMISSION TRANSMISSION UNIT ASSEMBLY CBG571000000A02 Transmission Unit Precaution 1. If the drive plates or brake band are replaced with new ones, soak in ATF for at least 2 hours before installation. 2. Before assembly, apply ATF to all seal rings, rotating parts, O-rings, D-rings, and sliding parts. 3.
  • Page 1083 AUTOMATIC TRANSMISSION Components 1 BCF5610A103 Accumulator spring and piston Low and reverse brake piston and spring Band servo K1–77...
  • Page 1084 AUTOMATIC TRANSMISSION Components 2 GASKET O-RING BCF5610A336 Input shaft Snap ring Oil pump Parking gear and bearing Brake band and strut Snap ring Reverse clutch Output shaft High clutch and front sun gear Front internal gear, rear internal gear, forward clutch hub, overrunning clutch hub Front planetary carrier Forward clutch drum (forward clutch, overrunning...
  • Page 1085 AUTOMATIC TRANSMISSION Components 3 40—51 OIL SEAL {4.1—5.2, 30—37} GASKET 36—47 {3.7—4.8, 27—34 BOLT 4.0—5.8 N·m {40—60 kgf·cm, 35—52 in·lbf} BOLTS O-RING O-RING 2.5—3.9 N·m BOLT {25—40 kgf·cm, 22—34 in·lbf} 37—47 {3.7—4.8, 74—76 5.0—6.8 N·m 27—34 {7.5—7.8, 55—56 {50—70 kgf·cm, GASKET 44—60 in·lbf} 20—25...
  • Page 1086 AUTOMATIC TRANSMISSION Transmission unit assembly procedure 1. Install the forward clutch drum while slowly turning it clockwise until its hub passes fully over FORWARD the low one-way clutch inner race. CLUTCH DRUM LOW ONE-WAY CLUTCH INNER RACE TRANSMISSION CASE BCF5610A338 2.
  • Page 1087 AUTOMATIC TRANSMISSION 8. Push the output shaft forward slightly, and install a new snap ring on the output shaft. Verify that the output shaft cannot be removed from the rear of the transmission case. BCF5610A133 9. Apply petroleum jelly to the bearing and install it to the transmission case with the black surface facing toward the rear.
  • Page 1088 AUTOMATIC TRANSMISSION 14. Verify that the bearing and bearing race are installed correctly. FRONT REAR BEARING BEARING BCF5610A345 15. While rotating the forward clutch drum clockwise, install the front planetary carrier into the forward clutch component. BCF5610A346 16. Install the reverse clutch, high clutch, and front sun gear into the transmission case as a component.
  • Page 1089 AUTOMATIC TRANSMISSION (2) Measure height A using vernier calipers and a straight edge. BCF5610A349 (3) Measure height B using vernier calipers. BCF5610A350 (4) Apply petroleum jelly to the bearing and install it on the oil pump. BEARING Bearing outer diameter 47.0 mm {1.850 in} BCF5610A160 (5) Measure height C using vernier calipers and a...
  • Page 1090 AUTOMATIC TRANSMISSION (6) Calculate the total end play using the formula GASKET below. Formula T1 = A – B – C – 0.1 mm {0.0039 in} OIL PUMP T1 : Total end play A : Distance between bearing race of front side of transmission case and reverse clutch B : Distance between front side of transmission case and oil pump gasket...
  • Page 1091 AUTOMATIC TRANSMISSION (4) Measure height F using vernier calipers and a straight edge. BCF5610A354 (5) Calculate the reverse clutch end play using the formula below. GASKET Formula T2 = E – B – F – 0.1 mm {0.0039 in} OIL PUMP T2 : Reverse clutch end play B : Distance between front side of transmission case and oil pump gasket...
  • Page 1092 AUTOMATIC TRANSMISSION 22. Apply ATF to the input shaft and install it into the transmission case. BCF5610A126 23. Apply petroleum jelly to the oil pump component as shown in the figure. 24. Install the oil pump component into the transmission case by hand only, using two converter housing bolts as guides.
  • Page 1093 AUTOMATIC TRANSMISSION 27. Apply sealant lightly as shown in the figure. 28. Remove the converter housing bolts used as SEALANT SEALANT guides. SEALANT SEALANT SEALANT SEALANT BCF5610A360 29. Install the converter housing onto the transmission case, and tighten the bolts evenly in the order as shown in the figure.
  • Page 1094 AUTOMATIC TRANSMISSION 34. Install the solenoid valve harness into the transmission case. O-RING BCF5610A365 35. Install the accumulator spring into the accumulator piston. ACCUMULATOR ACCUMULATOR Spring specifications 3-4/N-R ACCUMULATOR ACCUMULATOR Outer Free Wire Spring No. of dia. length dia. specification coils mm {in} mm {in}...
  • Page 1095 AUTOMATIC TRANSMISSION 39. Install the valve body component, and tighten the BRACKET bolts evenly. Bolt length (measured from below bolt head) A: 33 mm {1.30 in} B: 45 mm {1.77 in} Tightening torque 6.9—8.8 N·m {70—90 kgf·cm, 61—78 in·lbf} BRACKET 40.
  • Page 1096 AUTOMATIC TRANSMISSION 45. Install the clip. FLATHEAD SCREWDRIVER 46. Install the TFT switch. 47. Remove any old locking compound from the bolt CLIP holes. TFT SWITCH 48. Install the magnet to the inside of the oil pan. Caution • When installing sealant-coated bolts, tighten them immediately.
  • Page 1097 AUTOMATIC TRANSMISSION (4) Insert a 4.0 mm {0.157 in} outer diameter pin PIN O.D. through the holes of the TR switch and the 4.0 mm {0.157 in} manual shaft lever. (5) Tighten the TR switch mounting bolts. Tightening torque 2.5—3.9 N·m {25—40 kgf·cm, 22—34 in·lbf} (6) Remove the pin.
  • Page 1099 A UTOMATIC TRANSMISSION (TRANSFER) TRANSFER............K2-2 PRECAUTION............ K2-2 TRANSFER COMPONENT DISASSEMBLY ..K2-3 FRONT DRIVE SPROCKET COMPONENT DISASSEMBLY/ASSEMBLY ......K2-6 OUTPUT SHAFT COMPONENT DISASSEMBLY/ASSEMBLY ......K2-7 TRANSFER COMPONENT ASSEMBLY ... K2-9 TRANSFER INSPECTION....... K2-13 K2–1...
  • Page 1100 TRANSFER TRANSFER PRECAUTION CBG581827500A01 1. Clean the transfer exterior thoroughly using a steam cleaner or cleaning solvents before disassembly. Warning • Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear protective eye wear whenever using compressed air. Caution •...
  • Page 1101 TRANSFER TRANSFER COMPONENT DISASSEMBLY CBG581827500A02 1. Disassemble in the order indicated in the table. BCF5818A001 Stopper pin Oil passage Control cover component Roll pin Locknut Spacer (See K2–4 Locknut Disassembly Note.) H/L shift fork Companion flange H/L shift rod 4 × 4 indicator switch Roll pin Transfer neutral switch (RFW model) Roll pin...
  • Page 1102 TRANSFER Retainer O-ring Output shaft component, chain, and front drive Thrust washer sprocket component Counter gear (See K2–5 Output Shaft Component, Chain, and Bearing Front Drive Sprocket Component Disassembly Spacer Note.) Thrust washer Input shaft gear Oil seal Bearing Snap ring Adjustment shim Bearing (front drive sprocket) Adjustment shim...
  • Page 1103 TRANSFER Output Shaft Component, Chain, and Front Drive Sprocket Component Disassembly Note 1. Remove the output shaft and the front drive sprocket from the transfer case housing by lightly tapping the input shaft gear and the front drive sprocket using a plastic hammer. BCF5818A005 Counter Shaft Gear Support Disassembly Note 1.
  • Page 1104 TRANSFER FRONT DRIVE SPROCKET COMPONENT DISASSEMBLY/ASSEMBLY CBG581827500A03 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. Bearing (See K2–6 Bearing Disassembly Note.) (See K2–6 Bearing Assembly Note.) Front drive sprocket BCF5818A008 Bearing Disassembly Note 1.
  • Page 1105 TRANSFER OUTPUT SHAFT COMPONENT DISASSEMBLY/ASSEMBLY CBG581827500A04 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. BCF5818A011 Speedometer drive gear Bearing (low gear side) (See K2–8 Bearing (Low Gear Side) Disassembly Bearing (2W/4W clutch hub side) Note.) (See K2–8 Bearing (2W/4W Clutch Hub Side) (See K2–8 Bearing (Low Gear Side) Assembly...
  • Page 1106 TRANSFER Bearing (2W/4W Clutch Hub Side) Disassembly Note 1. Remove the bearing from output shaft using the SST. 49 0839 425C BCF5818A012 Bearing (Low Gear Side) Disassembly Note 1. Remove the bearing, lock washer, steel ball and low gear using the press. BCF5818A013 Bearing (Low Gear Side) Assembly Note 1.
  • Page 1107 TRANSFER TRANSFER COMPONENT ASSEMBLY CBG581827500A05 1. Assemble in the order indicated in the table. 25—34 {2.5—3.5, 18—25} 25—34 {2.5—3.5, 18—25} 19—25 SEALANT {1.9—2.6, 14—18} 19—25 {1.9—2.6, 14—18} 128—177 {13—18, 94—130} SELECTIVE USE 25—34 {2.5—3.5, 18—25} 19—25 {1.9—2.6, 19—25 14—18} {1.9—2.6, SEALANT 14—18} SEALANT...
  • Page 1108 TRANSFER Output shaft component Adjustment shim (output shaft) (See K2–12 Adjustment Shim (Output Shaft and Front drive sprocket component Front Drive Sprocket) Assembly Note.) Chain Adjustment shim (front drive sprocket) (See K2–12 Chain Assembly Note.) (See K2–12 Adjustment Shim (Output Shaft and H/L shift fork Front Drive Sprocket) Assembly Note.) Spacer...

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