1. Warm up engine.
2. Turn ignition switch OFF.
3. Using CONSULT-II, make sure no error codes are indicated for
self-diagnosis items. Refer to EC section, ªFuel Pressure
Releaseº.
IDo not disconnect CONSULT-II until the end of this operation;
it will be used to check engine rpm and for error detection at
the end of this operation.
4. Disconnect the negative battery terminal.
5. Remove the following parts.
IIntercooler
IThrottle body
IRocker cover
6. To prevent fuel from being injected during inspection, remove
fuel injection pump fuse [ENG CONT A/T (15A)] from fuse box
on the right side of engine compartment.
7. Remove glow plugs from all the cylinders.
IBefore removal, clean the surrounding area to prevent
entry of any foreign materials into the engine.
ICarefully remove glow plugs to prevent any damage or
breakage.
IHandle with care to avoid applying any shock to glow
plugs.
8. Install adapter (SST) to installation holes of glow plugs and
connect compression gauge for diesel engine.
:15-19N×m (1.5 - 2.0 kg-m, 11 - 14 ft-lb)
9. Connect battery negative terminal.
10. Set the ignition switch to ªSTARTº and crank. When gauge
pointer stabilizes, read compression pressure and engine rpm.
Repeat the above steps for each cylinder.
IAlways use a fully-charged battery to obtain specified
engine speed.
Unit: kPa (bar, kg/cm2, psi)/rpm
Standard MinimumDifference limit between
cylinders
2,942 (29.42, 30.0, 427)/
2002,452 (24.52, 25.0, 356)/
200294 (2.94, 3.0, 43)/200
IWhen engine rpm is out of the specified range, check the spe-
cific gravity of battery liquid. Measure again under corrected
conditions.
IIf engine rpm exceeds the limit, check valve clearance and
combustion chamber components (valves, valve seats, cylinder
head gaskets, piston rings, pistons, cylinder bores, cylinder
block upper and lower surfaces) and measure again.
11. Complete this operation as follows:
a. Turn the ignition switch to ªOFFº.
b. Disconnect battery negative terminal.
c. Replace glow plug oil seals and install glow plugs.
d. Install fuel injection pump fuse [ENG CONT A/T (15A)].
e. Connect battery negative terminal.
f. Using CONSULT-II make sure no error code is indicated for
items of self-diagnosis. Refer to EC section, ªTrouble Diagno-
sis Ð Indexº.
YEM039
SEM334G
MEASUREMENT OF COMPRESSION PRESSUREZD
EM-10
Terminal Arrangement
YEL275D
FUSE BLOCK Ð JUNCTION BOX (J/B)
Terminal Arrangement
YEL276D
FUSE AND FUSIBLE LINK BOX
Description
Number Item Description
q1Power conditionIThis shows the condition when the system receives battery positive voltage (can
be operated).
q2Fusible linkIThe double line shows that this is a fusible link.
IThe open circle shows current flow in, and the shaded circle shows current flow
out.
q3Fusible link/fuse locationIThis shows the location of the fusible link or fuse in the fusible link or fuse box.
For arrangement, refer to EL section (ªPOWER SUPPLY ROUTINGº).
q4FuseIThe single line shows that this is a fuse.
IThe open circle shows current flow in, and the shaded circle shows current flow
out.
q5Current ratingIThis shows the current rating of the fusible link or fuse.
q6ConnectorsIThis shows that connector
E3is female and connectorM1is male.
IThe G/R wire is located in the 1A terminal of both connectors.
ITerminal number with an alphabet (1A, 5B, etc.) indicates that the connector is
SMJ connector. Refer to GI-18.
q7Optional spliceIThe open circle shows that the splice is optional depending on vehicle application.
q8SpliceIThe shaded circle shows that the splice is always on the vehicle.
q9Page crossingIThis arrow shows that the circuit continues to an adjacent page.
IThe A will match with the A on the preceding or next page.
q10Common connectorIThe dotted lines between terminals show that these terminals are part of the same
connector.
q11Option abbreviationIThis shows that the circuit is optional depending on vehicle application.
q12RelayIThis shows an internal representation of the relay. For details, refer to EL section
(ªSTANDARDIZED RELAYº).
q13ConnectorsIThis shows that the connector is connected to the body or a terminal with bolt or
nut.
q14Wire colorIThis shows a code for the color of the wire.
B = Black BR = Brown
W = White OR = Orange
R = Red P = Pink
G = Green PU = Purple
L = Blue GY = Gray
Y = Yellow SB = Sky Blue
LG = Light Green CH = Dark Brown
DG = Dark Green
When the wire color is striped, the base color is given first, followed by the stripe
color as shown below:
Example: L/W = Blue with White Stripe
q15Option descriptionIThis shows a description of the option abbreviation used on the page.
q16SwitchIThis shows that continuity exists between terminals 1 and 2 when the switch is in
the A position. Continuity exists between terminals 1 and 3 when the switch is in
the B position.
q17Assembly partsIConnector terminal in component shows that it is a harness incorporated assem-
bly.
q18Cell codeIThis identifies each page of the wiring diagram by section, system and wiring dia-
gram page number.
HOW TO READ WIRING DIAGRAMS
GI-12
Number Item Description
q19Current flow arrowIArrow indicates electric current flow, especially where the direction of standard
flow (vertically downward or horizontally from left to right) is difficult to follow.
IA double arrow ªFÐ
Eº shows that current can flow in either direction depending on
circuit operation.
q20System branchIThis shows that the system branches to another system identified by cell code
(section and system).
q21Page crossingIThis arrow shows that the circuit continues to another page identified by cell code.
IThe C will match with the C on another page within the system other than the next
or preceding pages.
q22Shielded lineIThe line enclosed by broken line circle shows shield wire.
q23Component box in wave
lineIThis shows that another part of the component is also shown on another page
(indicated by wave line) within the system.
q24Component nameIThis shows the name of a component.
q25Connector numberIThis shows the connector number.
IThe letter shows which harness the connector is located in.
Example:M: main harness. For detail and to locate the connector, refer to EL sec-
tion (ªMain Harnessº, ªHARNESS LAYOUTº). A coordinate grid is included for com-
plex harnesses to aid in locating connectors.
q26Ground (GND)IThe line spliced and grounded under wire color shows that ground line is spliced
at the grounded connector.
q27Ground (GND)IThis shows the ground connection.
q28Connector viewsIThis area shows the connector faces of the components in the wiring diagram on
the page.
q29Common componentIConnectors enclosed in broken line show that these connectors belong to the
same component.
q30Connector colorIThis shows a code for the color of the connector. For code meaning, refer to wire
color codes, Numberq14of this chart.
q31Fusible link and fuse boxIThis shows the arrangement of fusible link(s) and fuse(s), used for connector
views of ªPOWER SUPPLY ROUTINGº in EL section.
The open square shows current flow in, and the shaded square shows current
flow out.
q32Reference areaIThis shows that more information on the Super Multiple Junction (SMJ) and Joint
Connectors (J/C) exists on the foldout page. Refer to GI-18 for details.
HOW TO READ WIRING DIAGRAMS
Description (Cont'd)
GI-13
F
Fan switch ......................................................HA-60
F/FOG - Wiring diagram .................................EL-51
Final drive disassembly............................PD-15, 37
Final drive pre-inspection .........................PD-15, 37
Final drive removal and installation ...............PD-15
Finisher, interior - See Trim ............................BT-18
Finisher, rear panel .........................................BT-18
Floor trim .........................................................BT-18
Fluid temperature sensor (A/T) .....................AT-141
Fluids .............................................MA-5, 17, 20, 36
Flywheel (clutch) .......................................CL-11, 12
Flywheel runout..............................................EM-94
Fog lamp, front .........................................EL-51, 53
Fog lamp, rear ................................................EL-54
Fork rod (M/T) ................................................MT-13
Forward clutch...............................................AT-157
Front axle ....................................................FA-4, 13
Front bumper ....................................................BT-6
Front case (Transfer) ..................................TF-9, 23
Front combination lamp removal and
installation .....................................................BT-6
Front disc brake .............................................BR-26
Front door .......................................................BT-10
Front Door Trim...............................................BT-19
Front drive shaft (Transfer) .........................TF-9, 19
Front final drive disassembly (4WD) ..............PD-14
Front final drive removal and installa-
tion (4WD) ............................................PD-12, 13
Front fog lamp ..........................................EL-51, 53
Front passenger air bag .................................RS-17
Front seat ........................................................BT-34
Front seat belt ..................................................RS-4
Front seat belt pre-tensioner ..........................RS-12
Front side air bag ...........................................RS-18
Front suspension ........................................FA-4, 29
Fuel cut control (at no load & high
engine speed) .....................................EC-22, 311
Fuel cut solenoid valve ................................EC-376
Fuel cut system ............................................EC-232
Fuel filler lid.......................................................BT-8
Fuel filter replacement...................MA-5, 20, 23, 33
Fuel gauge..................................FE-3, 6, EL-72, 80
Fuel injection system .............................EC-20, 306
Fuel injection timing feed back (Elec-
tronic Fuel Injection Pump) ......................EC-192
Fuel precautions ................................................GI-6
Fuel pump and gauge ..............................FE-3, 6, 7
Fuel system ..................................................FE-3, 6
Fuel tank .......................................................FE-3, 6
Fuel temperature sensor ......................EC-123, 372
Fuse ................................................................EL-17
Fuse and fusible link box .............................Foldout
Fuse block ....................................................Foldout
Fusible link ......................................................EL-17GGarage jack and safety stand .........................GI-32
Gauges .....................................................EL-70, 71
Gear components (M/T) ........MT-11, 14, 16, 21, 23
Generator - See Alternator .............................SC-27
GLOW - Wiring diagram...............................EC-241
Glow control system.....................EC-239, 311, 389
Glow plug .............................................EC-239, 390
Glow relay ............................................EC-241, 396
Grease .........................................MA-17, 39, 40, 44
Ground distribution..........................................EL-18
H
Harness connector ............................................EL-3
Harness connector inspection .........................GI-19
Harness layout ............EL-247, 248, 264, 276, 278,
286, 287, 288, 289, 290
Hazard warning lamp................................EL-55, 56
Headlamp ......EL-26, 29, 30, 31, 37, 38, 39, 42, 43
Headlamp aiming control .............EL-37, 38, 39, 42
Headlamp washer .........................................EL-100
Headlining - See Roof trim .............................BT-20
Heat up switch..............................................EC-258
Heated seat .......................................BT-36, EL-128
HEATER - Wiring diagram .............................HA-41
HEATUP - Wiring diagram ...........................EC-259
Height (Dimensions) ........................................GI-10
HFC134a (R134a) system precaution .............HA-3
HFC134a (R134a) system service
procedure....................................................HA-15
HFC134a (R134a) system service tools ........HA-11
High clutch ....................................................AT-155
H/LAMP - Wiring diagram ............EL-26, 31, 39, 56
Hood..................................................................BT-6
Hood lock system .............................................BT-6
Horn ..............................................................EL-104
HORN - Wiring diagram................................EL-104
How to erase DTC for OBD system ......EC-33, 321
HSEAT - Wiring diagram...............................EL-128
I
Identification .....................................................HA-2
Identification plate .....................................GI-29, 30
Idle speed...............................................EC-50, 338
Idle speed inspection ...............................MA-20, 26
ILL - Wiring diagram .......................................EL-62
Illumination ................................................EL-61, 62
Injection nozzle ......................................EC-24, 313
Injection nozzle inspection ..................MA-5, 20, 25
Injection timing control valve ........................EC-380
INJPMP - Wiring diagram ...EC-126, 164, 171, 178,
185, 195, 235
Instrument panel .............................................BT-16
INT/L - Wiring diagram....................................EL-66
ALPHABETICAL INDEX
IDX-4
Shown below are Pre-delivery Inspection items required for the new vehicle. It is recommended that
necessary items other than those listed here be added, paying due regard to the conditions in each
country.
Perform applicable items on each model. Consult text of this section for specifications.
UNDER HOOD Ð engine off
lRadiator coolant level and coolant hose connections for leaks
lBattery fluid level, specific gravity and conditions of battery terminals
lBrake and clutch reservoirs fluid level and fluid lines for leaks
lWindshield and rear window washer and headlamp cleaner reservoir fluid level
lDrive belts tension
lFuel filter for water or dust, and fuel lines and connections for leaks
lPower steering reservoir fluid level and hose connections for leaks
lEngine oil level and oil leaks
INSIDE AND OUTSIDE
lOperation of all instruments, gauges, lights, anti-theft system and accessories
lOperation of horn(s), wiper and washer
lSteering lock for operation
lAir conditioner for gas leaks
lFront and rear seats, and seat belts for operation
lAll moldings, trims and fittings for fit and alignment
lAll windows for operation and alignment
lHood, tailgate, door panels for fit and alignment
lLatches, keys and locks for operation
lWeatherstrips for adhesion and fit
lHeadlamp aiming
lTighten wheel nuts
lTire pressure (Inc. spare tire)
lCheck front wheels for toe-in
lInstall clock/room lamp fuse
lRemove wiper blade protectors (if necessary)
UNDER BODY
lManual transmission/transaxle and differential gear oil level
lBrake and fuel lines and oil/fluid reservoirs for leaks
lTighten bolts and nuts of steering linkage and gear box, suspension, propeller shafts and drive shafts
ROAD TEST
lClutch operation
lParking brake operation
lService brake operation
lSteering control and returnability
lEngine performance
lSqueaks and rattles
ENGINE OPERATING AND HOT
lAdjust idle mixture and speed (and ignition timing) (Petrol only)
FINAL INSPECTION
lInstall necessary parts (outside mirror, wheel covers, seat belts, mat, carpet or mud flaps)
lInspect for interior and exterior metal and paint damage
lCheck for spare tire, jack, tools and literature
lWash, clean interior and exterior
PRE-DELIVERY INSPECTION ITEMS
MA-3
System Description
M/T MODELS
Power is supplied at all times
Ithrough 40A fusible link (letterC, located in the fuse and fusible link box)
Ito ignition switch terminal 1.
With the ignition switch in START position, power is supplied
Ifrom ignition switch terminal 1
Ito starter motor harness connector terminal 4.
The starter motor plunger closes and provides a closed circuit between the battery and starter motor. The
starter motor is grounded to the engine block. With power and ground supplied, cranking occurs and the engine
starts.
A/T MODELS
Power is supplied at all times
Ithrough 40A fusible link (letterC, located in the fuse and fusible link box)
Ito ignition switch terminal 1.
With the ignition switch in the START position, power is supplied
Ifrom ignition switch terminal 1
Ito park/neutral position relay terminal 4.
With the ignition switch ON or START position, power is supplied
Ithrough 10A fuse [No. 8, located in the fuse block (J/B)]
Ito park/neutral position (PNP) relay terminal 1.
With the selector lever in the P or N position, ground is supplied
Ito park/neutral position relay terminal 2 through the park/neutral position switch
Ifrom body grounds, M754 and M33.
Then park/neutral position relay is energized and power is supplied
Ifrom park/neutral position relay terminal 3
Ito starter motor harness connector terminal 1.
The starter motor plunger closes and provides a closed circuit between the battery and starter motor. The
starter motor is grounded to the engine block. With power and ground supplied, cranking occurs and the engine
starts.
STARTING SYSTEM
SC-13