EC-260
< SERVICE INFORMATION >
DTC P0137, P0157 HO2S2
DTC P0137, P0157 HO2S2
Component DescriptionINFOID:0000000003531765
The heated oxygen sensor 2, after three way catalyst (manifold),
monitors the oxygen level in the exhaust gas on each bank.
Even if switching characteristics of the air fuel ratio (A/F) sensor 1
are shifted, the air-fuel ratio is controlled to stoichiometric, by the sig-
nal from the heated oxygen sensor 2.
This sensor is made of ceramic zirconia. The zirconia generates volt-
age from approximately 1V in richer conditions to 0V in leaner condi-
tions.
Under normal conditions the heated oxygen sensor 2 is not used for
engine control operation.
CONSULT-II Reference Value in Data Monitor ModeINFOID:0000000003531766
Specification data are reference values.
On Board Diagnosis LogicINFOID:0000000003531767
The heated oxygen sensor 2 has a much longer switching time
between rich and lean than the air fuel ratio (A/F) sensor 1. The oxy-
gen storage capacity of the three way catalyst (manifold) causes the
longer switching time. To judge the malfunctions of heated oxygen
sensor 2, ECM monitors whether the maximum voltage of the sensor
is sufficiently high during the various driving condition such as fuel-
cut.
DTC Confirmation ProcedureINFOID:0000000003531768
NOTE:
If DTC confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
WITH CONSULT-II
TESTING CONDITION:
For better results, perform “DTC WORK SUPPORT” at a temperature of 0 to 30 °C (32 to 86 °F).
SEF327R
MONITOR ITEM CONDITION SPECIFICATION
HO2S2 (B1)
HO2S2 (B2)• Revving engine from idle to 3,000 rpm quickly after the following conditions
are met.
- Engine: After warming up
- Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and
at idle for 1 minute under no load0 - 0.3V ←→ Approx. 0.6 - 1.0V
HO2S2 MNTR (B1)
HO2S2 MNTR (B2)LEAN ←→ RICH
PBIB1154E
DTC No. Trouble diagnosis name DTC detecting condition Possible cause
P0137
0137
(Bank 1)
Heated oxygen sensor 2
circuit low voltageThe maximum voltage from the sensor is not
reached to the specified voltage.• Harness or connectors
(The sensor circuit is open or shorted)
• Heated oxygen sensor 2
• Fuel pressure
• Fuel injector
• Intake air leaks P0157
0157
(Bank 2)
EC-270
< SERVICE INFORMATION >
DTC P0138, P0158 HO2S2
DTC P0138, P0158 HO2S2
Component DescriptionINFOID:0000000003531774
The heated oxygen sensor 2, after three way catalyst (manifold),
monitors the oxygen level in the exhaust gas on each bank.
Even if switching characteristics of the air fuel ratio (A/F) sensor 1
are shifted, the air-fuel ratio is controlled to stoichiometric, by the sig-
nal from the heated oxygen sensor 2.
This sensor is made of ceramic zirconia. The zirconia generates volt-
age from approximately 1V in richer conditions to 0V in leaner condi-
tions.
Under normal conditions the heated oxygen sensor 2 is not used for
engine control operation.
CONSULT-II Reference Value in Data Monitor ModeINFOID:0000000003531775
Specification data are reference values.
On Board Diagnosis LogicINFOID:0000000003531776
The heated oxygen sensor 2 has a much longer switching time between rich and lean than the air fuel ratio (A/
F) sensor 1. The oxygen storage capacity of the three way catalyst (manifold) causes the longer switching
time.
MALFUNCTION A
To judge the malfunctions of heated oxygen sensor 2, ECM monitors
whether the voltage is unusually high during the various driving con-
dition such as fuel-cut.
MALFUNCTION B
To judge the malfunctions of heated oxygen sensor 2, ECM monitors
whether the minimum voltage of sensor is sufficiently low during the
various driving condition such as fuel-cut.
SEF327R
MONITOR ITEM CONDITION SPECIFICATION
HO2S2 (B1)
HO2S2 (B2)• Revving engine from idle to 3,000 rpm quickly after the following conditions
are met.
- Engine: After warming up
- Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at
idle for 1 minute under no load0 - 0.3V ←→ Approx. 0.6 -
1.0V
HO2S2 MNTR (B1)
HO2S2 MNTR (B2)LEAN ←→ RICH
PBIB1848E
PBIB2376E
EC-282
< SERVICE INFORMATION >
DTC P0139, P0159 HO2S2
DTC P0139, P0159 HO2S2
Component DescriptionINFOID:0000000003531783
The heated oxygen sensor 2, after three way catalyst (manifold),
monitors the oxygen level in the exhaust gas on each bank.
Even if switching characteristics of the air fuel ratio (A/F) sensor 1
are shifted, the air-fuel ratio is controlled to stoichiometric, by the sig-
nal from the heated oxygen sensor 2.
This sensor is made of ceramic zirconia. The zirconia generates volt-
age from approximately 1V in richer conditions to 0V in leaner condi-
tions.
Under normal conditions the heated oxygen sensor 2 is not used for
engine control operation.
CONSULT-II Reference Value in Data Monitor ModeINFOID:0000000003531784
Specification data are reference values.
On Board Diagnosis LogicINFOID:0000000003531785
The heated oxygen sensor 2 has a much longer switching time
between rich and lean than the air fuel ratio (A/F) sensor 1. The oxy-
gen storage capacity of the three way catalyst (manifold) causes the
longer switching time. To judge the malfunctions of heated oxygen
sensor 2, ECM monitors whether the switching response of the sen-
sor's voltage is faster than specified during the various driving condi-
tion such as fuel-cut.
DTC Confirmation ProcedureINFOID:0000000003531786
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
WITH CONSULT-II
TESTING CONDITION:
For better results, perform “DTC WORK SUPPORT” at a temperature of 0 to 30 °C (32 to 86 °F).
SEF327R
MONITOR ITEM CONDITION SPECIFICATION
HO2S2 (B1)
HO2S2 (B2)• Revving engine from idle to 3,000 rpm quickly after the following conditions
are met.
- Engine: After warming up
- Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and
at idle for 1 minute under no load0 - 0.3V ←→ Approx. 0.6 - 1.0V
HO2S2 MNTR (B1)
HO2S2 MNTR (B2)LEAN ←→ RICH
SEF302U
DTC No. Trouble diagnosis name DTC detecting condition Possible cause
P0139
0139
(Bank 1)
Heated oxygen sensor 2
circuit slow responseIt takes more time for the sensor to respond be-
tween rich and lean than the specified time.• Harness or connectors
(The sensor circuit is open or shorted)
• Heated oxygen sensor 2
• Fuel pressure
• Fuel injector
• Intake air leaks P0159
0159
(Bank 2)
DTC P0420, P0430 THREE WAY CATALYST FUNCTION
EC-349
< SERVICE INFORMATION >
C
D
E
F
G
H
I
J
K
L
MA
EC
N
P O
DTC P0420, P0430 THREE WAY CATALYST FUNCTION
On Board Diagnosis LogicINFOID:0000000003531847
The ECM monitors the switching frequency ratio of air fuel sensor
(A/F) sensor 1 and heated oxygen sensor 2.
A three way catalyst (manifold) with high oxygen storage capacity
will indicate a low switching frequency of heated oxygen sensor 2.
As oxygen storage capacity decreases, the heated oxygen sensor 2
switching frequency will increase.
When the frequency ratio of air fuel ratio (A/F) sensor 1 and heated
oxygen sensor 2 approaches a specified limit value, the three way
catalyst (manifold) malfunction is diagnosed.
DTC Confirmation ProcedureINFOID:0000000003531848
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
WITH CONSULT-II
TESTING CONDITION:
Do not hold engine speed for more than the specified minutes below.
1. Turn ignition switch ON and select “DATA MONITOR” mode with
CONSULT-II.
2. Start engine and warm it up to the normal operating tempera-
ture.
3. Turn ignition switch OFF and wait at least 10 seconds.
4. Start engine and keep the engine speed between 3,500 and
4,000 rpm for at least 1 minute under no load.
5. Let engine idle for 1 minute.
6. Make sure that “COOLAN TEMP/S” indicates more than 70°C
(158°F).
If not, warm up engine and go to next step when “COOLAN
TEMP/S” indication reaches to 70°C (158°F).
7. Open engine hood.
PBIB2055E
DTC No. Trouble diagnosis name DTC detecting condition Possible cause
P0420
0420
(Bank 1)
Catalyst system efficien-
cy below threshold• Three way catalyst (manifold) does not oper-
ate properly.
• Three way catalyst (manifold) does not have
enough oxygen storage capacity.• Three way catalyst (manifold)
• Exhaust tube
• Intake air leaks
• Fuel injector
• Fuel injector leaks
• Spark plug
• Improper ignition timing P0430
0430
(Bank 2)
SEF189Y
EM-76
< SERVICE INFORMATION >
ENGINE ASSEMBLY
a. Before removing the drive plate, put a match mark (A) on the
crankshaft and drive plate for alignment during installation.
b. Remove the drive plate.
• Holding the crankshaft pulley bolt, lock the crankshaft to remove the drive plate bolts.
• Loosen the bolts diagonally.
CAUTION:
• Be careful not to damage the drive plate. Especially
avoid deforming and damaging of the signal plate teeth
(circumference position).
• Place the drive plate with the signal plate surface facing
other than downward.
• Keep magnetic materials away from the signal plate.
CAUTION:
Use an engine stand that has a load capacity [approximately 240kg (529 lb) or more] large enough
for supporting the engine weight.
• If the load capacity of the stand is not adequate, remove the following parts beforehand to
reduce the potential risk of overturning the stand.
- Remove the fuel tube and fuel injector assembly. Refer to EM-31, "
Removal and Installation".
- Remove the intake manifold. Refer to EM-17, "
Removal and Installation".
- Remove the ignition coil. Refer to EM-28, "
Removal and Installation".
- Remove the rocker cover. Refer to EM-35, "
Removal and Installation".
- Other removable brackets.
CAUTION:
Before removing the hanging chains, make sure the engine stand is stable and there is no risk of
overturning.
31. Remove the generator. Refer to SC-22, "
Removal and Installation".
32. Remove the engine mounting insulator and bracket using power tool.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
• When replacing an engine or transmission you must make sure the dowels are installed correctly
during re-assembly.
• Improper alignment caused by missing dowels may cause vibration, oil leaks or breakage of driv-
etrain components.
INSPECTION AFTER INSTALLATION
• Before starting the engine, check oil/fluid levels including engine coolant and engine oil. If the levels are
lower than required quantity, fill to the specified level. Refer to MA-10, "
Fluids and Lubricants".
• Use procedure below to check for fuel leakage.
• Turn ignition switch ON (with engine stopped). With fuel pressure applied to the fuel piping, check for fuel
leakage at the connection points.
ALBIA0522ZZ
KBIA2491E
SERVICE DATA AND SPECIFICATIONS (SDS)
FFD-31
< SERVICE INFORMATION >
C
E
F
G
H
I
J
K
L
MA
B
FFD
N
O
P
SERVICE DATA AND SPECIFICATIONS (SDS)
General SpecificationINFOID:0000000003532595
Inspection and AdjustmentINFOID:0000000003532596
DRIVE GEAR RUNOUT
Unit: mm (in)
SIDE GEAR CLEARANCE
Unit: mm (in)
PRELOAD TORQUE
Unit: N·m (kg-m, in-lb)
BACKLASH
Unit: mm (in)
COMPANION FLANGE RUNOUT
Unit: mm (in)
SELECTIVE PARTS
Drive Pinion Height Adjusting Washer
Applied modelVK56E
Final drive modelM205
Gear ratio3.357
Number of teeth (Drive gear/Drive pinion) 47/14
Differential gear oil capacity (Approx.)
1.6 (3 3/8 US pt, 2 7/8 Imp pt)
Number of pinion gears2
Drive pinion adjustment spacer type Collapsible
Item Runout limit
Drive gear back face 0.08 (0.0031) or less
Item Specification
Side gear back clearance (Clearance between side gear and dif-
ferential case for adjusting side gear backlash)0.20 (0.0079) or less
(Each gear should rotate smoothly without excessive resistance
during differential motion.)
Item Specification
Drive pinion bearing preload torque 2.3 - 3.4 (0.23 - 0.35, 21 - 31)
Total preload torque
(Total preload torque = drive pinion bearing preload torque + side
bearing preload torque).2.98 - 4.76 (0.31 - 0.48, 27 - 42)
Item Specification
Drive gear to drive pinion backlash 0.12 - 0.20 (0.0050 - 0.0079)
Item Runout limit
Companion flange face 0.10 (0.0039) or less
Companion flange inner side 0.13 (0.0051) or less
ENGINE OIL
LU-9
< SERVICE INFORMATION >
C
D
E
F
G
H
I
J
K
L
MA
LU
N
P O
5. Install Tools.
6. Start the engine and warm it up to normal operating temperature.
7. Check the engine oil pressure with engine running under no-load.
Engine oil pressure [Engine oil temperature at 80°C (175°F)]
Unit: kPa (kg/cm2
, psi)
CAUTION:
If the difference is extreme, check the oil passages and oil pump for leaks and blockages.
8. After the inspections, install oil pressure switch as follows:
a. Remove old liquid gasket adhering to oil pressure switch and engine.
b. Apply liquid gasket and tighten oil pressure switch to the specification.
Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-45, "
Recommended Chemical Prod-
uct and Sealant".
c. After warming up engine, make sure there is no leakage of engine oil with engine running.
Changing Engine OilINFOID:0000000003531556
CAUTION:
• Be careful not to burn yourself, as the engine oil is hot.
• Prolonged and repeated contact with used engine oil may
cause skin cancer; try to avoid direct skin contact with used
engine oil. If skin contact is made, wash thoroughly with soap
or hand cleaner as soon as possible.
1. Remove engine front undercover using power tool.
2. Warm up engine, and check for oil leakage from engine compo-
nents. Refer to LU-8, "
Inspection".
3. Stop engine and wait for 10 minutes.
4. Loosen oil filler cap, then remove drain plug.
5. Drain engine oil.
6. Install drain plug with new washer.
CAUTION:
• Be sure to clean drain plug and install with new washer.
7. Refill with new engine oil. Refer to MA-10, "
Fluids and Lubricants".
Engine oil capacity (Approximate):
Tool number : ST25051001 (J-25695-1)
: ST25052000 (J-25695-2)
WBIA0571E
Engine Speed Approximate Discharge Pressure
Idle speed More than 98 (1.0, 14)
2,000 rpm More than 294 (3.0, 43)
Oil pressure sensor torque : 14.7 N·m (1.5 kg-m, 11 ft-lb)
Oil pan drain plug : 34.3 N·m (3.5 kg-m, 25 ft-lb)
KBIA2498E
RFD-32
< SERVICE INFORMATION >
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
General SpecificationINFOID:0000000003532608
Inspection and AdjustmentINFOID:0000000003532609
DRIVE GEAR RUNOUT
Unit: mm (in)
SIDE GEAR CLEARANCE
Unit: mm (in)
PRELOAD TORQUE
Unit: N·m (kg-m, in-lb)
BACKLASH
Unit: mm (in)
COMPANION FLANGE RUNOUT
Unit: mm (in)
SELECTIVE PARTS
Side Gear Thrust Washer
Applied modelVK56DE
2WD 4WD
Final drive modelR230
Gear ratio 2.937 3.357
Number of teeth (Drive gear/Drive pinion) 47 / 16 47 / 14
Oil capacity (Approx.)
1.75 (3 3/4 US pt, 3 1/8 Imp pt)
Number of pinion gears 2
Drive pinion adjustment spacer type Collapsible
Item Runout limit
Drive gear back face0.05 (0.0020) or less
Item Specification
Side gear back clearance
(Clearance limit between side gear and differential case for adjusting
side gear backlash)0.20 (0.0079) or less
(Each gear should rotate smoothly without excessive resis-
tance during differential motion.)
Item Specification
Drive pinion bearing preload torque 1.77 − 2.64 N·m (0.18 − 0.26 kg−m, 16 − 23 in-lb)
Side bearing preload torque (reference value determined by drive
gear bolt pulling force)0.20 − 0.52 N·m (0.02 − 0.05 kg−m, 2 − 4 in-lb)
Drive gear bolt pulling force (by spring gauge) 34.2 − 39.2 N (3.5 − 4 kg, 7.7 − 8.8 lb)
Total preload torque
(Total preload torque = drive pinion bearing preload torque + Side
bearing preload torque)2.05 − 4.11 N·m (0.21 − 0.42 kg−m, 19 − 36 in-lb)
Item Specification
Drive gear to drive pinion gear 0.13 − 0.18 (0.0051 − 0.0070)
Item Runout limit
Outer side of the companion flange 0.08 (0.0031) or less