ISUZU MU-X & D-MAX 2017–2019 Workshop Service Repair Manual | Full Technical PDF

Name: ISUZU MU-X &amp; D-MAX 2017–2019 Workshop Service Repair Manual | Full Technical PDF
Brand: Isuzu
SKU: 34016
Availability: InStock
Rating: 5.00 (1 reviews)

€29,99

Comprehensive factory service and repair manual for ISUZU MU-X and ISUZU D-MAX (model years 2017–2019). Includes detailed wiring diagrams, torque specs, engine overhaul procedures, and transmission repair, ideal for professional technicians and DIY enthusiasts.

30 People watching this product now!

Rated 5.00 out of 5 based on 1 customer rating

(1 customer review)

Add to compare

Add to wishlist

Payment Methods:

🕑Recently Viewed

Description

The ISUZU MU-X & D-MAX 2017–2019 Workshop Service Repair Manual provides complete factory specifications, diagnostics, and repair information for both models. It covers all mechanical, electrical, and body systems in full detail, ensuring accurate maintenance and troubleshooting for your vehicle.

General Information: Model overview, safety precautions, tightening torques
Engine System: Complete disassembly and assembly procedures, timing, fuel system, turbocharger servicing
Transmission & Drivetrain: Automatic and manual gearbox overhaul, differential and transfer case repair
Electrical System: Wiring diagrams, ECU pinouts, sensor values, and fault code charts
Suspension & Steering: Alignment specs, control arm service, and steering gear adjustments
Brakes: Hydraulic circuits, ABS system troubleshooting, and replacement guides
Body & Interior: Trim removal, air conditioning, and instrument panel details
Maintenance Schedule: Periodic service intervals, lubricants, and capacities

Technical Details

Models Covered: ISUZU MU-X / D-MAX
Years: 2017, 2018, 2019
Engines: 1.9L RZ4E-TC / 3.0L 4JJ1-TCX Diesel
File Format: PDF (searchable, printable)
Language: English
Pages: 7,000+

📦 Delivery

Digital download available instantly after purchase.
No physical shipping required.
Accessible on any device or printed for workshop use.

⚠️ Disclaimer

This manual is intended for professional mechanics and qualified users. Always follow safety guidelines and use proper tools and equipment when performing repairs.

ISUZU MU-X & D-MAX Manual Full Content

00 GENERAL INFORMATION

INTRODUCTION & SAFETY
SERVICE INFORMATION

abbreviations
contents included in service information
handling electronic parts
PLASTIGAUGE
Preliminary and post procedures
recommended liquid gasket
recommended thread locking agent
standard bolts
term
using the ETM
wiring repair

VEHICLE INFORMATION

chassis number
engine number
lifting instruction
vehicle identification number
vehicle identification plate
maintenance schedule
oil viscosity chart
recommended fluids, lubricants and diesel fuels

1B ENGINE MECHANICAL (4JJ1 WITHOUT DPD)

camshaft removal (4JJ1 without DPD)
camshaft inspection (4JJ1 without DPD)
camshaft installation (4JJ1 without DPD)
Crankcase removal (4JJ1 without DPD)
Crankcase disassembly (4JJ1 without DPD)
Crankcase inspection (4JJ1 without DPD)
Crankcase reassembly (4JJ1 without DPD)
Crankcase installation (4JJ1 without DPD)
crankshaft removal (4JJ1 without DPD)
crankshaft disassembly (4JJ1 without DPD)
crankshaft inspection (4JJ1 without DPD)
crankshaft reassembly (4JJ1 without DPD)
crankshaft installation (4JJ1 without DPD)
crankshaft front oil seal removal (4JJ1 without DPD)
crankshaft front oil seal installation (4JJ1 without DPD)
Crankshaft pulley removal (4JJ1 without DPD)
Crankshaft pulley installation (4JJ1 without DPD)
Crankshaft rear oil seal removal (4JJ1 without DPD)
Crankshaft rear oil seal installation (4JJ1 without DPD)
Cylinder block removal (4JJ1 without DPD)
Cylinder block inspection (4JJ1 without DPD)
Cylinder block installation (4JJ1 without DPD)
cylinder head cover removal (4JJ1 without DPD)
cylinder head cover installation (4JJ1 without DPD)
cylinder head removal (4JJ1 without DPD)
cylinder head disassembly (4JJ1 without DPD)
cylinder head inspection (4JJ1 without DPD)
cylinder head reassembly (4JJ1 without DPD)
cylinder head installation (4JJ1 without DPD)
Engine removal (4JJ1 without DPD)
Engine installation (4JJ1 without DPD)
Engine mounting removal (4JJ1 without DPD)
Engine mounting installation (4JJ1 without DPD)
Exhaust manifold removal (4JJ1 without DPD)
Exhaust manifold inspection (4JJ1 without DPD)
Exhaust manifold installation (4JJ1 without DPD)
Flywheel removal (4JJ1 without DPD)
Flywheel disassembly (4JJ1 without DPD)
Flywheel inspection (4JJ1 without DPD)
Flywheel reassembly (4JJ1 without DPD)
Flywheel installation (4JJ1 without DPD)
Idle gear removal (4JJ1 without DPD)
Idle gear inspection (4JJ1 without DPD)
Idle gear installation (4JJ1 without DPD)
Inlet manifold removal (4JJ1 without DPD)
Inlet manifold installation (4JJ1 without DPD)
Intake throttle valve removal (4JJ1 without DPD)
Intake throttle valve installation (4JJ1 without DPD)
Piston removal (4JJ1 without DPD)
Piston disassembly (4JJ1 without DPD)
Piston inspection (4JJ1 without DPD)
Piston reassembly (4JJ1 without DPD)
Piston installation (4JJ1 without DPD)
rear plate removal (4JJ1 without DPD)
rear plate installation (4JJ1 without DPD)
rocker arm shaft removal (4JJ1 without DPD)
rocker arm shaft installation (4JJ1 without DPD)
swirl control solenoid valve removal (4JJ1 without DPD)
swirl control solenoid valve installation (4JJ1 without DPD)
Timing chain removal (4JJ1 without DPD)
Timing chain installation (4JJ1 without DPD)
Timing gear case removal (4JJ1 without DPD)
Timing gear case installation (4JJ1 without DPD)
Supplementary Information (4JJ1 without DPD)

1B ENGINE MECHANICAL RZ4E

camshaft removal (RZ4E-TC)
camshaft disassembly (RZ4E-TC)
camshaft inspection (RZ4E-TC)
camshaft reassembly (RZ4E-TC)
camshaft installation (RZ4E-TC)
Crankcase removal (RZ4E-TC)
Crankcase inspection (RZ4E-TC)
Crankcase installation (RZ4E-TC)
crankshaft removal (RZ4E-TC)
crankshaft disassembly (RZ4E-TC)
crankshaft inspection (RZ4E-TC)
crankshaft reassembly (RZ4E-TC)
crankshaft installation (RZ4E-TC)
Crankshaft pulley removal (RZ4E-TC)
Crankshaft pulley installation (RZ4E-TC)
Crankshaft rear oil seal removal (RZ4E-TC)
Crankshaft rear oil seal installation (RZ4E-TC)
crankshaft front oil seal removal (RZ4E-TC)
crankshaft front oil seal installation (RZ4E-TC)
Cylinder block removal (RZ4E-TC)
Cylinder block inspection (RZ4E-TC)
Cylinder block installation (RZ4E-TC)
cylinder head cover removal (RZ4E-TC)
cylinder head cover installation (RZ4E-TC)
cylinder head removal (RZ4E-TC)
cylinder head disassembly (RZ4E-TC)
cylinder head inspection (RZ4E-TC)
cylinder head reassembly (RZ4E-TC)
cylinder head installation (RZ4E-TC)
Engine removal (RZ4E-TC)
Engine installation (RZ4E-TC)
Engine mounting removal (RZ4E-TC)
Engine mounting installation (RZ4E-TC)
Exhaust manifold removal (RZ4E-TC)
Exhaust manifold inspection (RZ4E-TC)
Exhaust manifold installation (RZ4E-TC)
Flywheel removal (RZ4E-TC)
Flywheel disassembly (RZ4E-TC)
Flywheel inspection (RZ4E-TC)
Flywheel reassembly (RZ4E-TC)
Flywheel installation (RZ4E-TC)
Flywheel housing removal (RZ4E-TC)
Flywheel housing installation (RZ4E-TC)
front cover removal (RZ4E-TC)
front cover installation (RZ4E-TC)
Idle gear removal (RZ4E-TC)
Idle gear inspection (RZ4E-TC)
Idle gear installation (RZ4E-TC)
inlet cover removal (RZ4E-TC)
inlet cover installation (RZ4E-TC)
Intake throttle valve removal (RZ4E-TC)
Intake throttle valve installation (RZ4E-TC)
Piston removal (RZ4E-TC)
Piston disassembly (RZ4E-TC)
Piston inspection (RZ4E-TC)
Piston reassembly (RZ4E-TC)
Piston installation (RZ4E-TC)
Timing chain removal (RZ4E-TC)
Timing chain installation (RZ4E-TC)
Supplementary Information (RZ4E-TC)

1C ENGINE FUEL SYSTEM (4JJ1 WITHOUT DPD)

fuel inspection (4JJ1 without DPD)
fuel air bleed (4JJ1 without DPD)
fuel drain water (4JJ1 without DPD)
common rail (fuel rail) removal (4JJ1 without DPD)
common rail (fuel rail) installation (4JJ1 without DPD)
filler neck removal (4JJ1 without DPD)
filler neck installation (4JJ1 without DPD)
FRP regulator removal (4JJ1 without DPD)
FRP regulator installation (4JJ1 without DPD)
fuel filler cap removal (4JJ1 without DPD)
fuel filler cap inspection (4JJ1 without DPD)
fuel filler cap installation (4JJ1 without DPD)
fuel filter element removal (4JJ1 without DPD)
fuel filter element installation (4JJ1 without DPD)
fuel filter removal (4JJ1 without DPD)
fuel filter inspection (4JJ1 without DPD)
fuel filter installation (4JJ1 without DPD)
fuel supply pump removal (4JJ1 without DPD)
fuel supply pump installation (4JJ1 without DPD)
fuel tank removal (4JJ1 without DPD)
fuel tank installation (4JJ1 without DPD)
fuel tank unit removal (4JJ1 without DPD)
fuel tank unit inspection (4JJ1 without DPD)
fuel tank unit installation (4JJ1 without DPD)
fuel tube removal (4JJ1 without DPD)
fuel tube inspection (4JJ1 without DPD)
fuel tube installation (4JJ1 without DPD)
injector removal (4JJ1 without DPD)
injector installation (4JJ1 without DPD)
pre-fuel filter element removal (4JJ1 without DPD)
pre-fuel filter element installation (4JJ1 without DPD)
pre-fuel filter removal (4JJ1 without DPD)
pre-fuel filter installation (4JJ1 without DPD)
pressure limiter removal (4JJ1 without DPD)
pressure limiter installation (4JJ1 without DPD)
water sedimenter switch removal (4JJ1 without DPD)
water sedimenter switch inspection (4JJ1 without DPD)
water sedimenter switch installation (4JJ1 without DPD)
Supplementary Information (4JJ1 without DPD)

1C ENGINE FUEL SYSTEM RZ4E

fuel inspection (RZ4E-TC)
fuel air bleed (RZ4E-TC)
fuel drain water (RZ4E-TC)
common rail (fuel rail) removal (RZ4E-TC)
common rail (fuel rail) installation (RZ4E-TC)
filler neck removal (RZ4E-TC)
filler neck installation (RZ4E-TC)
FRP regulator removal (RZ4E-TC)
FRP regulator installation (RZ4E-TC)
fuel filler cap removal (RZ4E-TC)
fuel filler cap inspection (RZ4E-TC)
fuel filler cap installation (RZ4E-TC)
fuel filter element removal (RZ4E-TC)
fuel filter element installation (RZ4E-TC)
fuel filter removal (RZ4E-TC)
fuel filter inspection (RZ4E-TC)
fuel filter installation (RZ4E-TC)
fuel supply pump removal (RZ4E-TC)
fuel supply pump installation (RZ4E-TC)
fuel tank removal (RZ4E-TC)
fuel tank installation (RZ4E-TC)
fuel tank unit removal (RZ4E-TC)
fuel tank unit inspection (RZ4E-TC)
fuel tank unit installation (RZ4E-TC)
fuel tube removal (RZ4E-TC)
fuel tube inspection (RZ4E-TC)
fuel tube installation (RZ4E-TC)
injector removal (RZ4E-TC)
injector installation (RZ4E-TC)
pressure limiter removal (RZ4E-TC)
pressure limiter installation (RZ4E-TC)
water sedimenter switch removal (RZ4E-TC)
water sedimenter switch inspection (RZ4E-TC)
water sedimenter switch installation (RZ4E-TC)
Supplementary Information (RZ4E-TC)

1D ENGINE COOLING SYSTEM (4JJ1 WITHOUT DPD)

coolant inspection (4JJ1 without DPD)
coolant replacement (4JJ1 without DPD)
cooling fan belt removal (4JJ1 without DPD)
cooling fan belt inspection (4JJ1 without DPD)
cooling fan belt installation (4JJ1 without DPD)
cooling fan clutch removal (4JJ1 without DPD)
cooling fan clutch inspection (4JJ1 without DPD)
cooling fan clutch installation (4JJ1 without DPD)
radiator removal (4JJ1 without DPD)
radiator inspection (4JJ1 without DPD)
radiator installation (4JJ1 without DPD)
radiator reserve tank removal (4JJ1 without DPD)
radiator reserve tank installation (4JJ1 without DPD)
thermostat removal (4JJ1 without DPD)
thermostat inspection (4JJ1 without DPD)
thermostat installation (4JJ1 without DPD)
water pump removal (4JJ1 without DPD)
water pump inspection (4JJ1 without DPD)
water pump installation (4JJ1 without DPD)
Supplementary Information (4JJ1 without DPD)

1D ENGINE COOLING SYSTEM RZ4E

coolant inspection (RZ4E-TC)
coolant replacement (RZ4E-TC)
auto tensioner removal (RZ4E-TC)
auto tensioner inspection (RZ4E-TC)
auto tensioner installation (RZ4E-TC)
cooling fan belt removal (RZ4E-TC)
cooling fan belt inspection (RZ4E-TC)
cooling fan belt installation (RZ4E-TC)
cooling fan clutch removal (RZ4E-TC)
cooling fan clutch inspection (RZ4E-TC)
cooling fan clutch installation (RZ4E-TC)
radiator removal (RZ4E-TC)
radiator inspection (RZ4E-TC)
radiator installation (RZ4E-TC)
radiator reserve tank removal (RZ4E-TC)
radiator reserve tank installation (RZ4E-TC)
thermostat removal (RZ4E-TC)
thermostat inspection (RZ4E-TC)
thermostat installation (RZ4E-TC)
water pump removal (RZ4E-TC)
water pump inspection (RZ4E-TC)
water pump installation (RZ4E-TC)
Supplementary Information (RZ4E-TC)

1E ENGINE LUBRICATION SYSTEM (4JJ1 WITHOUT DPD)

engine oil inspection (4JJ1 without DPD)
engine oil replacement (4JJ1 without DPD)
oil cooler removal (4JJ1 without DPD)
oil cooler installation (4JJ1 without DPD)
oil filter element removal (4JJ1 without DPD)
oil filter element installation (4JJ1 without DPD)
oil filter removal (4JJ1 without DPD)
oil filter installation (4JJ1 without DPD)
oil pan removal (4JJ1 without DPD)
oil pan installation (4JJ1 without DPD)
oil pressure switch removal (4JJ1 without DPD)
oil pressure switch inspection (4JJ1 without DPD)
oil pressure switch installation (4JJ1 without DPD)
oil pump removal (4JJ1 without DPD)
oil pump inspection (4JJ1 without DPD)
oil pump installation (4JJ1 without DPD)
oil tray removal (4JJ1 without DPD)
oil tray installation (4JJ1 without DPD)
Supplementary Information (4JJ1 without DPD)

1E ENGINE LUBRICATION SYSTEM RZ4E

engine oil inspection (RZ4E-TC)
engine oil replacement (RZ4E-TC)
oil cooler removal (RZ4E-TC)
oil cooler installation (RZ4E-TC)
oil filter element removal (RZ4E-TC)
oil filter element installation (RZ4E-TC)
oil filter removal (RZ4E-TC)
oil filter installation (RZ4E-TC)
oil pan removal (RZ4E-TC)
oil pan installation (RZ4E-TC)
oil pressure switch removal (RZ4E-TC)
oil pressure switch inspection (RZ4E-TC)
oil pressure switch installation (RZ4E-TC)
oil pump removal (RZ4E-TC)
oil pump disassembly (RZ4E-TC)
oil pump reassembly (RZ4E-TC)
oil pump installation (RZ4E-TC)
Supplementary Information (RZ4E-TC)

1F ENGINE INDUCTION SYSTEM (4JJ1 WITHOUT DPD)

air cleaner element removal (4JJ1 without DPD)
air cleaner element inspection (4JJ1 without DPD)
air cleaner element installation (4JJ1 without DPD)
intercooler removal (4JJ1 without DPD)
intercooler inspection (4JJ1 without DPD)
intercooler installation (4JJ1 without DPD)
turbocharger control solenoid valve removal (4JJ1 without DPD)
turbocharger control solenoid valve inspection (4JJ1 without DPD)
turbocharger control solenoid valve installation (4JJ1 without DPD)
Turbocharger removal (4JJ1 without DPD)
Turbocharger inspection (4JJ1 without DPD)
Turbocharger installation (4JJ1 without DPD)
Supplementary Information (4JJ1 without DPD)

1F ENGINE INDUCTION SYSTEM RZ4E

air cleaner element removal (RZ4E-TC)
air cleaner element inspection (RZ4E-TC)
air cleaner element installation (RZ4E-TC)
intercooler removal (RZ4E-TC)
intercooler inspection (RZ4E-TC)
intercooler installation (RZ4E-TC)
turbocharger control solenoid valve removal (RZ4E-TC)
turbocharger control solenoid valve inspection (RZ4E-TC)
turbocharger control solenoid valve installation (RZ4E-TC)
Turbocharger removal (RZ4E-TC)
Turbocharger inspection (RZ4E-TC)
Turbocharger installation (RZ4E-TC)
Supplementary Information (RZ4E-TC)

1G ENGINE EXHAUST SYSTEM (4JJ1 WITHOUT DPD)

exhaust pipe removal (4JJ1 without DPD)
exhaust pipe inspection (4JJ1 without DPD)
exhaust pipe installation (4JJ1 without DPD)
catalytic converter removal (4JJ1 without DPD)
catalytic converter installation (4JJ1 without DPD)
Supplementary Information (4JJ1 without DPD)

1G ENGINE EXHAUST SYSTEM RZ4E

exhaust pipe removal (RZ4E-TC)
exhaust pipe inspection (RZ4E-TC)
exhaust pipe installation (RZ4E-TC)
catalytic converter removal (RZ4E-TC)
catalytic converter installation (RZ4E-TC)
Supplementary Information (RZ4E-TC)

1H ENGINE EMISSION CONTROL (4JJ1 WITHOUT DPD)

EGR cooler removal (4JJ1 without DPD)
EGR cooler inspection (4JJ1 without DPD)
EGR cooler installation (4JJ1 without DPD)
EGR pipe removal (4JJ1 without DPD)
EGR pipe inspection (4JJ1 without DPD)
EGR pipe installation (4JJ1 without DPD)
EGR valve removal (4JJ1 without DPD)
EGR valve inspection (4JJ1 without DPD)
EGR valve installation (4JJ1 without DPD)
Supplementary Information (4JJ1 without DPD)

1H ENGINE EMISSION CONTROL RZ4E

EGR removal (RZ4E-TC)
EGR inspection (RZ4E-TC)
EGR installation (RZ4E-TC)
Supplementary Information (RZ4E-TC)

1I ENGINE SPEED CONTROL SYSTEM (4JJ1 WITHOUT DPD)

accelerator pedal removal (4JJ1 without DPD)
accelerator pedal inspection (4JJ1 without DPD)
accelerator pedal installation (4JJ1 without DPD)

1I ENGINE SPEED CONTROL SYSTEM RZ4E

accelerator pedal removal (RZ4E-TC)
accelerator pedal inspection (RZ4E-TC)
accelerator pedal installation (RZ4E-TC)

1J ENGINE ELECTRICAL SYSTEM (4JJ1 WITHOUT DPD)

starter motor removal (4JJ1 without DPD)
starter motor disassembly (4JJ1 without DPD)
starter motor inspection (4JJ1 without DPD)
starter motor reassembly (4JJ1 without DPD)
starter motor installation (4JJ1 without DPD)
generator removal (4JJ1 without DPD)
generator inspection (4JJ1 without DPD)
generator installation (4JJ1 without DPD)
glow plug removal (4JJ1 without DPD)
glow plug inspection (4JJ1 without DPD)
glow plug installation (4JJ1 without DPD)
Supplementary Information (4JJ1 without DPD)

1J ENGINE ELECTRICAL SYSTEM RZ4E

starter motor removal (RZ4E-TC)
starter motor disassembly (RZ4E-TC)
starter motor inspection (RZ4E-TC)
starter motor reassembly (RZ4E-TC)
starter motor installation (RZ4E-TC)
battery sensor removal (RZ4E-TC)
battery sensor installation (RZ4E-TC)
generator removal (RZ4E-TC)
generator inspection (RZ4E-TC)
generator installation (RZ4E-TC)
glow plug removal (RZ4E-TC)
glow plug inspection (RZ4E-TC)
glow plug installation (RZ4E-TC)
Supplementary Information (RZ4E-TC)

1Z ENGINE ELECTRICAL CONTROL SYSTEM (4JJ1 WITHOUT DPD)

CMP sensor removal (4JJ1 without DPD)
CMP sensor inspection (4JJ1 without DPD)
CMP sensor installation (4JJ1 without DPD)
CKP sensor removal (4JJ1 without DPD)
CKP sensor inspection (4JJ1 without DPD)
CKP sensor installation (4JJ1 without DPD)
ECM removal (4JJ1 without DPD)
ECM installation (4JJ1 without DPD)
ECM setting (4JJ1 without DPD)
FRP sensor removal (4JJ1 without DPD)
FRP sensor inspection (4JJ1 without DPD)
FRP sensor installation (4JJ1 without DPD)
barometric pressure sensor removal (4JJ1 without DPD)
barometric pressure sensor inspection (4JJ1 without DPD)
barometric pressure sensor installation (4JJ1 without DPD)
boost pressure sensor removal (4JJ1 without DPD)
boost pressure sensor inspection (4JJ1 without DPD)
boost pressure sensor installation (4JJ1 without DPD)
engine coolant temperature sensor removal (4JJ1 without DPD)
engine coolant temperature sensor inspection (4JJ1 without DPD)
engine coolant temperature sensor installation (4JJ1 without DPD)
fuel temperature sensor removal (4JJ1 without DPD)
fuel temperature sensor inspection (4JJ1 without DPD)
fuel temperature sensor installation (4JJ1 without DPD)
MAF and IAT sensor removal (4JJ1 without DPD)
MAF and IAT sensor inspection (4JJ1 without DPD)
MAF and IAT sensor installation (4JJ1 without DPD)
Supplementary Information (4JJ1 without DPD)

1Z ENGINE ELECTRICAL CONTROL SYSTEM RZ4E

CMP sensor removal (RZ4E-TC)
CMP sensor inspection (RZ4E-TC)
CMP sensor installation (RZ4E-TC)
CKP sensor removal (RZ4E-TC)
CKP sensor inspection (RZ4E-TC)
CKP sensor installation (RZ4E-TC)
ECM removal (RZ4E-TC)
ECM installation (RZ4E-TC)
ECM setting (RZ4E-TC)
barometric pressure sensor removal (RZ4E-TC)
barometric pressure sensor inspection (RZ4E-TC)
barometric pressure sensor installation (RZ4E-TC)
boost pressure and CAC temperature sensor removal (RZ4E-TC)
boost pressure and CAC temperature sensor inspection (RZ4E-TC)
boost pressure and CAC temperature sensor installation (RZ4E-TC)
engine coolant temperature sensor removal (RZ4E-TC)
engine coolant temperature sensor inspection (RZ4E-TC)
engine coolant temperature sensor installation (RZ4E-TC)
FRP sensor removal (RZ4E-TC)
FRP sensor inspection (RZ4E-TC)
FRP sensor installation (RZ4E-TC)
fuel temperature sensor removal (RZ4E-TC)
fuel temperature sensor inspection (RZ4E-TC)
fuel temperature sensor installation (RZ4E-TC)
MAF and IAT sensor removal (RZ4E-TC)
MAF and IAT sensor inspection (RZ4E-TC)
MAF and IAT sensor installation (RZ4E-TC)
Supplementary Information (RZ4E-TC)

2B FRONT SUSPENSION

independent suspension removal
independent suspension disassembly
independent suspension inspection
independent suspension reassembly
independent suspension installation
Supplementary Information

2C REAR SUSPENSION

5-link suspension removal
5-link suspension disassembly
5-link suspension inspection
5-link suspension reassembly
5-link suspension installation
Supplementary Information

2D WHEEL AND TIRE SYSTEM

disc wheel and tire removal
disc wheel and tire inspection
disc wheel and tire installation
Supplementary Information

2Z SUSPENSION ELECTRICAL CONTROL

tire air pressure sensor removal
tire air pressure sensor installation
tire air pressure sensor setting
TPMS control unit removal
TPMS control unit installation
TPMS control unit setting
Supplementary Information

3B DIFFERENTIALS & FINAL DRIVE

differential oil inspection
differential oil replacement
Front final drive (φ194 mm (7.64 in) removal
Front final drive (φ194 mm (7.64 in) disassembly
Front final drive (φ194 mm (7.64 in) inspection
Front final drive (φ194 mm (7.64 in) reassembly
Front final drive (φ194 mm (7.64 in) installation
Rear final drive (φ220 mm, 8.66 in) (disc brake) removal
Rear final drive (φ220 mm, 8.66 in) (disc brake) disassembly
Rear final drive (φ220 mm, 8.66 in) (disc brake) inspection
Rear final drive (φ220 mm, 8.66 in) (disc brake) reassembly
Rear final drive (φ220 mm, 8.66 in) (disc brake) installation
Rear final drive (φ220 mm, 8.66 in) (drum brake) removal
Rear final drive (φ220 mm, 8.66 in) (drum brake) disassembly
Rear final drive (φ220 mm, 8.66 in) (drum brake) inspection
Rear final drive (φ220 mm, 8.66 in) (drum brake) reassembly
Rear final drive (φ220 mm, 8.66 in) (drum brake) installation
Rear final drive (φ220 mm, 8.66 in) (LSD) (disc brake) removal
Rear final drive (φ220 mm, 8.66 in) (LSD) (disc brake) disassembly
Rear final drive (φ220 mm, 8.66 in) (LSD) (disc brake) inspection
Rear final drive (φ220 mm, 8.66 in) (LSD) (disc brake) reassembly
Rear final drive (φ220 mm, 8.66 in) (LSD) (disc brake) installation
Rear final drive (φ220 mm, 8.66 in) (LSD) (drum brake) removal
Rear final drive (φ220 mm, 8.66 in) (LSD) (drum brake) disassembly
Rear final drive (φ220 mm, 8.66 in) (LSD) (drum brake) inspection
Rear final drive (φ220 mm, 8.66 in) (LSD) (drum brake) reassembly
Rear final drive (φ220 mm, 8.66 in) (LSD) (drum brake) installation
Supplementary Information

3C DRIVE SHAFT SYSTEM

front axle shaft removal
front axle shaft disassembly
front axle shaft inspection
front axle shaft reassembly
front axle shaft installation
front drive axle removal
front drive axle disassembly
front drive axle inspection
front drive axle reassembly
front drive axle installation
front hub removal
front hub disassembly
front hub inspection
front hub reassembly
front hub installation
front propeller shaft removal
front propeller shaft disassembly
front propeller shaft inspection
front propeller shaft reassembly
front propeller shaft installation
rear axle (disc brake) removal
rear axle (disc brake) disassembly
rear axle (disc brake) inspection
rear axle (disc brake) reassembly
rear axle (disc brake) installation
rear axle (drum brake) removal
rear axle (drum brake) disassembly
rear axle (drum brake) inspection
rear axle (drum brake) reassembly
rear axle (drum brake) installation
rear axle shaft (disc brake) removal
rear axle shaft (disc brake) disassembly
rear axle shaft (disc brake) inspection
rear axle shaft (disc brake) reassembly
rear axle shaft (disc brake) installation
rear axle shaft (drum brake) removal
rear axle shaft (drum brake) disassembly
rear axle shaft (drum brake) inspection
rear axle shaft (drum brake) reassembly
rear axle shaft (drum brake) installation
rear propeller shaft removal
rear propeller shaft disassembly
rear propeller shaft inspection
rear propeller shaft reassembly
rear propeller shaft installation
shift on the fly system removal
shift on the fly system disassembly
shift on the fly system inspection
shift on the fly system reassembly
shift on the fly system installation
shift on the fly system oil inspection
shift on the fly system oil replacement
knuckle removal
knuckle inspection
knuckle installation
oil catcher tank removal
oil catcher tank inspection
oil catcher tank installation
wheel alignment check
Supplementary Information

3D TRANSFER CASE

transfer removal
transfer disassembly
transfer inspection
transfer reassembly
transfer installation
front output shaft oil seal removal
front output shaft oil seal installation
rear output shaft oil seal removal
rear output shaft oil seal installation
transfer oil inspection
transfer oil replacement
Supplementary Information

3Z DRIVELINE-AXLE ELECTRICAL CONTROL

TCCM removal
TCCM installation

4B BRAKE SYSTEM

brake pedal removal
brake pedal inspection
brake pedal installation
blend proportioning valve removal
blend proportioning valve inspection
blend proportioning valve installation
brake booster removal
brake booster inspection
brake booster installation
brake fluid inspection
brake fluid replacement
brake master cylinder removal
brake master cylinder disassembly
brake master cylinder inspection
brake master cylinder reassembly
brake master cylinder installation
disc brake pad removal
disc brake pad inspection
disc brake pad installation
front disc brake removal
front disc brake disassembly
front disc brake inspection
front disc brake reassembly
front disc brake installation
rear disc brake removal
rear disc brake disassembly
rear disc brake inspection
rear disc brake reassembly
rear disc brake installation
rear drum brake removal
rear drum brake inspection
rear drum brake installation
rear wheel cylinder removal
rear wheel cylinder disassembly
rear wheel cylinder inspection
rear wheel cylinder reassembly
rear wheel cylinder installation
stoplight switch removal
stoplight switch inspection
stoplight switch installation
Supplementary Information

4C PARKING BRAKE SYSTEM

parking brake lever removal
parking brake lever installation
parking brake switch removal
parking brake switch inspection
parking brake switch installation
parking brake (rear disc brake) removal
parking brake (rear disc brake) inspection
parking brake (rear disc brake) installation
parking brake (rear drum brake) removal
parking brake (rear drum brake) inspection
parking brake (rear drum brake) installation
Supplementary Information

4D ANTI-LOCK BRAKE SYSTEM (ABS)

front exciter ring removal
front exciter ring inspection
front exciter ring installation
rear exciter ring removal
rear exciter ring inspection
rear exciter ring installation
Supplementary Information

4Z BRAKE ELECTRICAL CONTROL

front wheel speed sensor removal
front wheel speed sensor inspection
front wheel speed sensor installation
rear wheel speed sensor removal
rear wheel speed sensor inspection
rear wheel speed sensor installation
EHCU removal
EHCU installation
EHCU setting
Supplementary Information

5B AUTOMATIC TRANSMISSION (AWR6B45)

transmission removal (AWR6B45)
transmission disassembly (AWR6B45)
transmission inspection (AWR6B45)
transmission reassembly (AWR6B45)
transmission installation (AWR6B45)
ATF cooler pipe removal (AWR6B45)
ATF cooler pipe inspection (AWR6B45)
ATF cooler pipe installation (AWR6B45)
ATF inspection (AWR6B45)
ATF replacement (AWR6B45)
automatic transmission control cable removal (AWR6B45)
automatic transmission control cable installation (AWR6B45)
Brake piston No-1 disassembly (AWR6B45)
Brake piston No-1 reassembly (AWR6B45)
Brake piston No-2 disassembly (AWR6B45)
Brake piston No-2 reassembly (AWR6B45)
forward clutch assembly disassembly (AWR6B45)
forward clutch assembly inspection (AWR6B45)
forward clutch assembly reassembly (AWR6B45)
front planetary ring gear disassembly (AWR6B45)
front planetary ring gear inspection (AWR6B45)
front planetary ring gear reassembly (AWR6B45)
inhibitor switch removal (AWR6B45)
inhibitor switch inspection (AWR6B45)
inhibitor switch installation (AWR6B45)
middle planetary ring gear disassembly (AWR6B45)
middle planetary ring gear reassembly (AWR6B45)
oil pump disassembly (AWR6B45)
oil pump inspection (AWR6B45)
oil pump reassembly (AWR6B45)
rear planetary ring gear disassembly (AWR6B45)
rear planetary ring gear inspection (AWR6B45)
rear planetary ring gear reassembly (AWR6B45)
selector lever removal (AWR6B45)
selector lever disassembly (AWR6B45)
selector lever reassembly (AWR6B45)
selector lever installation (AWR6B45)
Supplementary Information (AWR6B45)

5B AUTOMATIC TRANSMISSION (TB-50LS)

transmission removal (TB-50LS)
transmission disassembly (TB-50LS)
transmission inspection (TB-50LS)
transmission reassembly (TB-50LS)
transmission installation (TB-50LS)
ATF cooler pipe removal (TB-50LS)
ATF cooler pipe inspection (TB-50LS)
ATF cooler pipe installation (TB-50LS)
ATF inspection (TB-50LS)
automatic transmission control cable removal (TB-50LS)
automatic transmission control cable installation (TB-50LS)
Brake piston No-1 disassembly (TB-50LS)
Brake piston No-1 reassembly (TB-50LS)
Brake piston No-2 disassembly (TB-50LS)
Brake piston No-2 reassembly (TB-50LS)
Brake piston No-3 disassembly (TB-50LS)
Brake piston No-3 inspection (TB-50LS)
Brake piston No-3 reassembly (TB-50LS)
forward clutch assembly disassembly (TB-50LS)
forward clutch assembly inspection (TB-50LS)
forward clutch assembly reassembly (TB-50LS)
front planetary ring gear disassembly (TB-50LS)
front planetary ring gear reassembly (TB-50LS)
inhibitor switch removal (TB-50LS)
inhibitor switch inspection (TB-50LS)
inhibitor switch installation (TB-50LS)
rear planetary ring gear disassembly (TB-50LS)
rear planetary ring gear inspection (TB-50LS)
rear planetary ring gear reassembly (TB-50LS)
selector lever removal (TB-50LS)
selector lever disassembly (TB-50LS)
selector lever reassembly (TB-50LS)
selector lever installation (TB-50LS)
valve body assembly disassembly (TB-50LS)
valve body assembly inspection (TB-50LS)
valve body assembly reassembly (TB-50LS)
Supplementary Information (TB-50LS)

5C MANUAL TRANSMISSION (MVL)

transmission removal (MVL)
transmission disassembly (MVL)
transmission inspection (MVL)
transmission reassembly (MVL)
transmission installation (MVL)
transmission oil inspection (MVL)
transmission oil replacement (MVL)
input shaft disassembly (MVL)
input shaft inspection (MVL)
input shaft reassembly (MVL)
main shaft disassembly (MVL)
main shaft inspection (MVL)
main shaft reassembly (MVL)
rear case disassembly (MVL)
rear case inspection (MVL)
rear case reassembly (MVL)
rear oil seal removal (MVL)
rear oil seal installation (MVL)
vehicle speed sensor removal (MVL)
vehicle speed sensor inspection (MVL)
vehicle speed sensor installation (MVL)
Supplementary Information (MVL)

5E CLUTCH SYSTEM (MVL)

Clutch removal (MVL)
Clutch inspection (MVL)
Clutch installation (MVL)
clutch control removal (MVL)
clutch control inspection (MVL)
clutch control installation (MVL)
clutch master cylinder disassembly (MVL)
clutch master cylinder reassembly (MVL)
clutch switch removal (MVL)
clutch switch installation (MVL)
shift fork removal (MVL)
shift fork inspection (MVL)
shift fork installation (MVL)
Slave cylinder disassembly (MVL)
Slave cylinder inspection (MVL)
Slave cylinder reassembly (MVL)
Supplementary Information (MVL)

5Z TRANSMISSION ELECTRICAL CONTROL (AWR6B45)

turbine speed sensor removal (AWR6B45)
turbine speed sensor inspection (AWR6B45)
turbine speed sensor installation (AWR6B45)
output speed sensor removal (AWR6B45)
output speed sensor inspection (AWR6B45)
output speed sensor installation (AWR6B45)
TCM removal (AWR6B45)
TCM installation (AWR6B45)
TCM setting (AWR6B45)

5Z TRANSMISSION ELECTRICAL CONTROL (TB-50LS)

turbine speed sensor removal (TB-50LS)
turbine speed sensor inspection (TB-50LS)
turbine speed sensor installation (TB-50LS)
output speed sensor removal (TB-50LS)
output speed sensor inspection (TB-50LS)
output speed sensor installation (TB-50LS)
TCM removal (TB-50LS)
TCM installation (TB-50LS)
TCM setting (TB-50LS)

6B POWER ASSISTED SYSTEM

power steering oil pump (4J series engine) removal
power steering oil pump (4J series engine) disassembly
power steering oil pump (4J series engine) inspection
power steering oil pump (4J series engine) reassembly
power steering oil pump (4J series engine) installation
power steering oil pump (RZ4E) removal
power steering oil pump (RZ4E) disassembly
power steering oil pump (RZ4E) inspection
power steering oil pump (RZ4E) reassembly
power steering oil pump (RZ4E) installation
power steering unit removal
power steering unit disassembly
power steering unit inspection
power steering unit reassembly
power steering unit installation
steering column removal
steering column inspection
steering column installation
power steering fluid replacement
Supplementary Information

6Z STEERING ELECTRICAL CONTROL

steering angle sensor removal
steering angle sensor installation
steering angle sensor setting
Supplementary Information

7B HEATER-VENTILATOR-AIR CONDITIONING

AC compressor (4JJ1 without DPD) removal
AC compressor (4JJ1 without DPD) installation
AC compressor (RZ4E) removal
AC compressor (RZ4E) installation
AC compressor drive belt (4JJ1 without DPD) removal
AC compressor drive belt (4JJ1 without DPD) inspection
AC compressor drive belt (4JJ1 without DPD) installation
AC compressor magnet clutch removal
AC compressor magnet clutch inspection
AC compressor magnet clutch installation
blower removal
blower installation
blower module removal
blower module inspection
blower module installation
blower motor removal
blower motor inspection
blower motor installation
blower resistor removal
blower resistor inspection
blower resistor installation
center ventilation grille removal
center ventilation grille installation
condenser removal
condenser installation
control panel and control lever removal
control panel and control lever inspection
control panel and control lever installation
evaporator core removal
evaporator core installation
heater core removal
heater core installation
heater evaporator unit removal
heater evaporator unit installation
intake actuator removal
intake actuator installation
intake door removal
intake door installation
mix actuator removal 1
mix actuator installation 1
mix actuator removal 2
mix actuator installation 2
mode actuator removal 1
mode actuator installation 1
mode actuator removal 2
mode actuator installation 2
pressure switch removal
pressure switch inspection
pressure switch installation
rear blower motor removal
rear blower motor inspection
rear blower motor installation
rear blower resistor removal
rear blower resistor inspection
rear blower resistor installation
rear cooler control switch removal
rear cooler control switch inspection
rear cooler control switch installation
rear cooler switch removal
rear cooler switch inspection
rear cooler switch installation
rear cooler unit removal
rear cooler unit installation
rear heater duct removal
rear heater duct installation
vent grille removal
vent grille installation
ventilation duct removal
ventilation duct installation
Supplementary Information

7Z HVAC CONTROL SYSTEM

inside air temperature sensor removal
inside air temperature sensor inspection
inside air temperature sensor installation
outside air temperature sensor removal
outside air temperature sensor inspection
outside air temperature sensor installation
sun sensor removal
sun sensor inspection
sun sensor installation

8B AIRBAG SYSTEM

driver airbag removal
driver airbag installation
driver airbag scrapping
passenger airbag removal
passenger airbag installation
passenger airbag scrapping
side airbag removal
side airbag installation
side airbag scrapping
curtain airbag removal
curtain airbag installation
curtain airbag scrapping
SRS coil removal
SRS coil installation
Supplementary Information

8C SEAT BELT SYSTEM

seat belt with pretensioner removal
seat belt with pretensioner installation
seat belt with pretensioner scrapping
buckle side 2ND seat belt (center) installation
buckle side 2ND seat belt (center) removal
buckle side 2ND seat belt removal
buckle side 2ND seat belt installation
buckle side 3RD seat belt removal
buckle side 3RD seat belt installation
buckle side driver seat belt removal
buckle side driver seat belt installation
buckle side passenger seat belt removal
buckle side passenger seat belt installation
tongue side 2ND seat belt removal
tongue side 2ND seat belt installation
tongue side 2ND seat belt with buckle (center) removal
tongue side 2ND seat belt with buckle (center) installation
tongue side 3RD seat belt removal
tongue side 3RD seat belt installation
Supplementary Information

8Z SEAT BELT & SRS AIRBAG ELECTRICAL CONTROL

SRS control unit removal
SRS control unit installation
door side airbag sensor removal
door side airbag sensor installation
front airbag sensor removal
front airbag sensor installation
side airbag sensor removal
side airbag sensor installation

9A LIGHTING SYSTEM

headlight removal
headlight inspection
headlight installation
backup light bulb removal
backup light bulb installation
combination switch removal
combination switch inspection
combination switch installation
door switch removal
door switch inspection
door switch installation
fog light removal
fog light installation
fog light bulb removal
fog light bulb installation
hazard warning flasher switch removal
hazard warning flasher switch inspection
hazard warning flasher switch installation
high mounted stoplight removal
high mounted stoplight installation
key reminder switch removal
key reminder switch inspection
key reminder switch installation
license plate light bulb removal
license plate light bulb installation
luggage dome light bulb removal
luggage dome light bulb installation
map light bulb removal
map light bulb installation
rear combination light removal
rear combination light installation
rear dome light bulb removal
rear dome light bulb installation
rear fog light bulb removal
rear fog light bulb installation
rear turn signal light bulb removal
rear turn signal light bulb installation
side turn signal light (door mirror integrated type) removal
side turn signal light (door mirror integrated type) installation
side turn signal light bulb removal
side turn signal light bulb installation
stoplight bulb removal
stoplight bulb installation
taillight removal
taillight installation

9B WIPER & WASHER SYSTEM

wiper arm removal
wiper arm installation
rear washer nozzle removal
rear washer nozzle installation
rear wiper arm removal
rear wiper arm installation
rear wiper blade removal
rear wiper blade installation
rear wiper motor removal
rear wiper motor installation
wiper blade rubber removal
wiper blade rubber installation
wiper linkage removal
wiper linkage installation
wiper motor removal
wiper motor inspection
wiper motor installation
washer motor removal
washer motor inspection
washer motor installation
washer nozzle removal
washer nozzle installation
Supplementary Information

9C ELECTRICAL CONTROL & ENTERTAINMENT

antenna removal
antenna installation
accessory socket removal
accessory socket installation
audio and navigation system removal
audio and navigation system installation
audio control steering wheel switch removal
audio control steering wheel switch inspection
audio control steering wheel switch installation
cigarette lighter removal
cigarette lighter installation
cruise control steering wheel switch removal
cruise control steering wheel switch inspection
cruise control steering wheel switch installation
display removal
display installation
Engine start-stop button removal
Engine start-stop button inspection
Engine start-stop button installation
ESC OFF switch removal
ESC OFF switch inspection
ESC OFF switch installation
front door speaker removal
front door speaker inspection
front door speaker installation
hill descent control switch removal
hill descent control switch inspection
hill descent control switch installation
4WD switch removal
4WD switch inspection
4WD switch installation
horn removal
horn inspection
horn installation
horn switch removal
horn switch inspection
horn switch installation
ignition switch removal
ignition switch inspection
ignition switch installation
rear door speaker removal
rear door speaker inspection
rear door speaker installation
roof speaker removal
roof speaker inspection
roof speaker installation
tailgate opener switch removal
tailgate opener switch inspection
tailgate opener switch installation
TPMS set switch removal
TPMS set switch inspection
TPMS set switch installation
tweeter removal
tweeter installation
USB charge port removal
USB charge port installation
USB-HDMI port removal
USB-HDMI port installation

9E INSTRUMENTATION & DRIVER INFO

instrument panel cluster diagnostics
instrument panel cluster removal
instrument panel cluster installation
instrument panel cluster setting
rearview camera removal
rearview camera installation

9G HOOD-FENDERS-DOORS

engine hood control cable removal
engine hood control cable installation
engine hood removal
engine hood installation
front door removal
front door disassembly
front door reassembly
front door installation
front fender panel removal
front fender panel installation
rear door removal
rear door disassembly
rear door reassembly
rear door installation
rear mudguard removal
rear mudguard installation
side step removal
side step installation
tail gate removal
tail gate disassembly
tail gate reassembly
tail gate installation
underguard removal
underguard installation
Supplementary Information

9H CAB STRUCTURE

front air dam removal
front air dam installation
front bumper removal
front bumper installation
radiator grille removal
radiator grille installation
rear bumper removal
rear bumper installation
roof rail removal
roof rail installation
Supplementary Information

9I SEAT SYSTEM

driver seat removal
driver seat disassembly
driver seat reassembly
driver seat installation
passenger seat removal
passenger seat disassembly
passenger seat reassembly
passenger seat installation
2ND seat removal
2ND seat disassembly
2ND seat reassembly
2ND seat installation
3RD seat removal
3RD seat disassembly
3RD seat reassembly
3RD seat installation
Supplementary Information

9J SECURITY & LOCKS SYSTEM

anti theft horn removal
anti theft horn installation
anti theft indicator light removal
anti theft indicator light installation
center in-vehicle antenna removal
center in-vehicle antenna installation
Electronic key disassembly
Electronic key reassembly
Electronic key setting
external antenna removal
external antenna installation
External buzzer removal
External buzzer installation
front door lock removal
front door lock inspection
front door lock installation
fuel filler lid cable removal
fuel filler lid cable installation
glove box key lock removal
glove box key lock installation
keyless entry receiver removal
keyless entry receiver installation
rear door lock removal
rear door lock inspection
rear door lock installation
rear in-vehicle antenna removal
rear in-vehicle antenna installation
remote controller key disassembly
remote controller key reassembly
remote controller key setting
steering lock removal
steering lock installation
steering lock setting
tail gate lock removal
tail gate lock inspection
tail gate lock installation

9L EXTERIOR & INTERIOR TRIM

center pillar upper trim cover removal
center pillar upper trim cover installation
console box removal
console box installation
front pillar trim cover removal
front pillar trim cover installation
head lining removal
head lining installation
instrument panel removal
instrument panel installation
quarter upper trim cover removal
quarter upper trim cover installation
reinforcement removal
reinforcement installation
Supplementary Information

9M CAB MOUNTING

9T GLASS, WINDOWS & MIRRORS SYSTEM

front door power window switch removal
front door power window switch inspection
front door power window switch installation
front door power window switch setting
front windshield glass removal
front windshield glass installation
outside rearview mirror removal
outside rearview mirror installation
quarter window glass removal
quarter window glass installation
rear door power window switch removal
rear door power window switch inspection
rear door power window switch installation
remote control mirror switch removal
remote control mirror switch inspection
remote control mirror switch installation
tail gate glass removal
tail gate glass installation
Supplementary Information

9Z BODY, CAB, ACCESSORIES ELECTRICAL CONTROL

BCM removal
BCM installation
BCM setting
DRM removal
DRM installation
ICU removal
ICU installation
ICU setting
headlight auto leveling control unit removal
headlight auto leveling control unit installation
headlight auto leveling control unit setting
headlight leveling sensor removal
headlight leveling sensor installation
passive entry and start system receiver removal
passive entry and start system receiver installation
passive entry and start system control unit removal
passive entry and start system control unit installation
passive entry and start system control unit setting

BODY CONTROL (BCM WITH KEYLESS ENTRY-PASSIVE ENTRY-START SYSTEM)

36B MAINTENANCE INFORMATION

introduction to the trouble diagnosis of body control (BCM with Keyless Entry)
maintenance precautions of body control (BCM with Keyless Entry)
function, structure, operation of body control (BCM with Keyless Entry)

36D SYMPTOM TROUBLESHOOTING

all doors neither lock nor unlock (BCM with Keyless Entry)
all of the doors do not lock or unlock (BCM with Keyless Entry)
auto door lock works, but does not work with remote controller key, or operation range is narrow (BCM with Keyless Entry)
door at the driver side does not lock or unlock (BCM with Keyless Entry)
door at the passenger side does not lock or unlock (BCM with Keyless Entry)
door lock at the driver side does not work (BCM with Keyless Entry)
door lock works with remote controller key, but does not answer back, or room light does not illuminate (BCM with Keyless Entry)
ID Code not yet programmed or no remote key programmed (BCM with Keyless Entry)
intermittent conditions of body control system (BCM with Keyless Entry)
rear left door does not lock or unlock (BCM with Keyless Entry)
rear right door does not lock or unlock (BCM with Keyless Entry)
rear washer motor does not operate (BCM with Keyless Entry)
rear wiper does not operate (BCM with Keyless Entry)
wiper motor does not stop (BCM with Keyless Entry)

BODY, CAB, ACCESSORIES

23B MAINTENANCE INFORMATION

primary specifications of body, cab, accessories
function, structure, operation of body, cab, accessories
maintenance precautions of body, cab, accessories
introduction to the trouble diagnosis of body, cab, accessories

23C FUNCTIONAL INSPECTION

speedometer accuracy check inspection
tachometer accuracy check inspection

23D SYMPTOM TROUBLESHOOTING

brake system warning light does not light up even when the brake fluid in the tank decreases
brake system warning light lights even when brake fluid is filled to specified level
driving information is not displayed
engine oil pressure warning light does not turn off even when the engine is running
indicated error of the speedometer is significantly large
indicated error of the tachometer is significantly large
none of the windows operate
operation abnormality of the backup light function
operation abnormality of the clearance light function
operation abnormality of the dome light function
operation abnormality of the headlight function
operation abnormality of the instrument panel cluster illumination function
operation abnormality of the license plate light function
Operation abnormality of the taillight-stoplight function
operation abnormality of the turn signal light function
Parking brake warning light does not light up even when the parking brake lever is engaged
Parking brake warning light does not turn off even when the parking brake lever is fully released
reading of the engine coolant temperature gauge is lower (higher) than reality
rear left side window does not operate
segment display of the fuel gauge does not change
speedometer and odometer do not operate
water separator warning light does not light even when water exceeds water separator drain line
water separator warning light lights even when water level is low in water separator
wiper does not operate at the _HI_ position
wiper does not operate at the _INT_ position
wiper does not operate at the _LO_ position
wiper does not operate regardless of the switch position
wiper motor does not stop

BRAKES

18B MAINTENANCE INFORMATION

primary specifications of brake
function, structure, operation of brake
introduction to the trouble diagnosis of brake
maintenance precautions of brake

18D SYMPTOM TROUBLESHOOTING

ABS works frequently but the brake is not effective or TCS operates frequently
brake abnormal noise
brake does not work efficiently
brake operation sounds are heard from the hydraulic unit even though the brake is not applied
brake pedal feeling is abnormal
brake pedal pulsates
defective straight driving
dragging brakes
ESC does not work efficiently
intermittent conditions of brake
one wheel locks
stepping power of the brake pedal is large
stroke of the brake pedal is abnormal
uneven braking occurs while ABS works
wheels lock when braking

CONNECTOR LOCATION DIAGRAMS-RELAY-FUSE

LHD Connector Location Diagram Door and Floor 1
LHD Connector Location Diagram Door and Floor 2
LHD Connector Location Diagram Door and Floor 3
LHD Connector Location Diagram Door and Floor 4
LHD Connector Location Diagram Engine Compartment 1
LHD Connector Location Diagram Engine Compartment 2
LHD Connector Location Diagram Engine Compartment 3
LHD Connector Location Diagram Frame and Roof
LHD Connector Location Diagram Fuse and Relay Box (Engine Compartment) 1
LHD Connector Location Diagram Fuse and Relay Box (Engine Compartment) 2
LHD Connector Location Diagram Fuse and Relay Box (Instrument Panel)
LHD Connector Location Diagram Headlight
LHD Connector Location Diagram Instrument Panel 1
LHD Connector Location Diagram Instrument Panel 2
LHD Connector Location Diagram Instrument Panel 3
LHD Connector Location Diagram Instrument Panel 4
LHD Connector Location Diagram Transmission 1
LHD Connector Location Diagram Transmission 2
LHD Connector Location Diagram Transmission 3
LHD Connector Location Diagram Transmission 4
LHD Connector Location Diagram Transmission 5
LHD Fuse and Relay Box Internal Circuit Engine Compartment
LHD Fuse and Relay Box Internal Circuit Instrument Panel 1
LHD Fuse and Relay Box Internal Circuit Instrument Panel 2
LHD Fuse Location Diagram Fuse and Relay Box (Engine Compartment) 1
LHD Fuse Location Diagram Fuse and Relay Box (Engine Compartment) 2
LHD Fuse Location Diagram Fuse and Relay Box (Instrument Panel) 1
LHD Fuse Location Diagram Fuse and Relay Box (Instrument Panel) 2
LHD Ground Location Diagram Engine Compartment 1
LHD Ground Location Diagram Engine Compartment 2
LHD Ground Location Diagram Floor
LHD Ground Location Diagram Instrument Panel
LHD Relay Location Diagram Fuse and Relay Box (Engine Compartment)
LHD Relay Location Diagram Fuse and Relay Box (Instrument Panel)
LHD Relay Location Diagram Relay Block
LHD Unit Location Diagram Engine Compartment
LHD Unit Location Diagram Instrument Panel
RHD Connector Location Diagram Door and Floor 1
RHD Connector Location Diagram Door and Floor 2
RHD Connector Location Diagram Door and Floor 3
RHD Connector Location Diagram Door and Floor 4
RHD Connector Location Diagram Engine Compartment 1
RHD Connector Location Diagram Engine Compartment 2
RHD Connector Location Diagram Engine Compartment 3
RHD Connector Location Diagram Frame and Roof
RHD Connector Location Diagram Fuse and Relay Box (Engine Compartment) 1
RHD Connector Location Diagram Fuse and Relay Box (Engine Compartment) 2
RHD Connector Location Diagram Fuse and Relay Box (Instrument Panel)
RHD Connector Location Diagram Headlight
RHD Connector Location Diagram Instrument Panel 1
RHD Connector Location Diagram Instrument Panel 2
RHD Connector Location Diagram Instrument Panel 3
RHD Connector Location Diagram Instrument Panel 4
RHD Connector Location Diagram Transmission 1
RHD Connector Location Diagram Transmission 2
RHD Connector Location Diagram Transmission 3
RHD Connector Location Diagram Transmission 4
RHD Connector Location Diagram Transmission 5
RHD Connector Location Diagram Transmission 6
RHD Fuse and Relay Box Internal Circuit Engine Compartment
RHD Fuse and Relay Box Internal Circuit Instrument Panel 1
RHD Fuse and Relay Box Internal Circuit Instrument Panel 2
RHD Fuse Location Diagram Fuse and Relay Box (Engine Compartment) 1
RHD Fuse Location Diagram Fuse and Relay Box (Engine Compartment) 2
RHD Fuse Location Diagram Fuse and Relay Box (Instrument Panel) 1
RHD Fuse Location Diagram Fuse and Relay Box (Instrument Panel) 2
RHD Ground Location Diagram Engine Compartment 1
RHD Ground Location Diagram Engine Compartment 2
RHD Ground Location Diagram Floor
RHD Ground Location Diagram Instrument Panel
RHD Relay Location Diagram Fuse and Relay Box (Engine Compartment)
RHD Relay Location Diagram Fuse and Relay Box (Instrument Panel)
RHD Relay Location Diagram Relay Block
RHD Unit Location Diagram Engine Compartment
RHD Unit Location Diagram Instrument Panel

DRIVELINE & AXLE

17B MAINTENANCE INFORMATION

primary specifications of driveline, axle
function, structure, operation of driveline, axle
introduction to the trouble diagnosis of driveline, axle
maintenance precautions of driveline, axle

17C FUNCTIONAL INSPECTION
17D SYMPTOM TROUBLESHOOTING

abnormal noise and vibration from front axle
abnormal noise and vibration from propeller shaft
abnormal noise and vibration from rear axle
abnormal sound or noise from the transfer
gear does not engage when switching from HIGH to LOW
gear does not engage when switching to front drive
intermittent conditions of transfer case control system
oil leakage from front drive axle
oil leakage from rear axle
oil leakage from transfer
power not being transmitted to the wheels

ELECTRICAL WIRING DIAGRAMS

RHD 4WD
RHD Anti-lock Brake
RHD Audio and Navigation System (Except Premium)
RHD Audio and Navigation System (Premium)
RHD Automatic Transmission (AWR6B45 Except Passive Entry and Start System)
RHD Automatic Transmission (AWR6B45, Passive Entry and Start System)
RHD Automatic Transmission (TB-50LS Except Passive Entry and Start System)
RHD Automatic Transmission (TB-50LS, Passive Entry and Start System)
RHD Backup Light
RHD Battery Sensor (Except Passive Entry and Start System)
RHD Battery Sensor (Passive Entry and Start System)
RHD Body Control
RHD Cigarette Lighter
RHD Combination Meter
RHD Controller Area Network (Except Passive Entry and Start System)
RHD Controller Area Network (Passive Entry and Start System)
RHD Data Recording
RHD Daytime Running Light
RHD DLC
RHD Dome Light
RHD Electronic Stability Control
RHD Engine Control
RHD Fog Light (Front Fog Light)
RHD Fog Light (Rear Fog Light)
RHD Fuse Load
RHD Ground Distribution
RHD Headlight
RHD Horn
RHD HVAC (Auto Cooler, Automatic Air Conditioner)
RHD HVAC (Manual Cooler, Manual Air Conditioner)
RHD HVAC (Rear Cooler)
RHD Immobilizer
RHD Outside Mirror
RHD Passive Entry and Start System
RHD Power Distribution (Except Passive Entry and Start System)
RHD Power Distribution (Passive Entry and Start System)
RHD Power Door Locks (Anti Theft)
RHD Power Door Locks (Except Anti Theft)
RHD Power Windows
RHD Seats
RHD SRS airbag (Except Side Airbag and Curtain Airbag)
RHD SRS airbag (Side Airbag and Curtain Airbag)
RHD Starter and Charging (Except Passive Entry and Start System)
RHD Starter and Charging (Passive Entry and Start System)
RHD Stoplight
RHD Taillight
RHD Turn Signal Light
RHD Windshield Wiper and Washer (Front Wiper Except Passive Entry and Start System)
RHD Windshield Wiper and Washer (Front Wiper, Passive Entry and Start System)
RHD Windshield Wiper and Washer (Rear Wiper)
LHD 4WD
LHD Anti-lock Brake
LHD Audio and Navigation System (Except Premium)
LHD Audio and Navigation System (Premium)
LHD Automatic Transmission (AWR6B45 Except Passive Entry and Start System)
LHD Automatic Transmission (AWR6B45, Passive Entry and Start System)
LHD Automatic Transmission (TB-50LS Except Passive Entry and Start System)
LHD Automatic Transmission (TB-50LS, Passive Entry and Start System)
LHD Backup Light
LHD Battery Sensor (Except Passive Entry and Start System)
LHD Battery Sensor (Passive Entry and Start System)
LHD Body Control
LHD Cigarette Lighter
LHD Combination Meter
LHD Controller Area Network (Except Passive Entry and Start System)
LHD Controller Area Network (Passive Entry and Start System)
LHD Data Recording
LHD Daytime Running Light
LHD DLC
LHD Dome Light
LHD Electronic Stability Control
LHD Engine Control
LHD Fog Light (Front Fog Light)
LHD Fog Light (Rear Fog Light)
LHD Fuse Load
LHD Ground Distribution
LHD Headlight
LHD Horn
LHD HVAC (Auto Cooler, Automatic Air Conditioner)
LHD HVAC (Manual Cooler, Manual Air Conditioner)
LHD HVAC (Rear Cooler)
LHD Immobilizer
LHD Outside Mirror
LHD Passive Entry and Start System
LHD Power Distribution (Except Passive Entry and Start System)
LHD Power Distribution (Passive Entry and Start System)
LHD Power Door Locks (Anti Theft)
LHD Power Door Locks (Except Anti Theft)
LHD Power Windows
LHD Seats
LHD SRS airbag (Except Side Airbag and Curtain Airbag)
LHD SRS airbag (Side Airbag and Curtain Airbag)
LHD Starter and Charging (Except Passive Entry and Start System)
LHD Starter and Charging (Passive Entry and Start System)
LHD Stoplight
LHD Taillight
LHD Tire Pressure Monitoring System
LHD Trailer Socket
LHD Turn Signal Light
LHD Windshield Wiper and Washer (Front Wiper Except Passive Entry and Start System)
LHD Windshield Wiper and Washer (Front Wiper, Passive Entry and Start System)
LHD Windshield Wiper and Washer (Rear Wiper)

ENGINE (4JJ1 WITHOUT DPD)

15B MAINTENANCE INFORMATION

maintenance precautions of engine (4JJ1 without DPD)
function, structure, operation of engine (4JJ1 without DPD)
primary specifications of engine (4JJ1 without DPD)
introduction to the trouble diagnosis of engine (4JJ1 without DPD)

15C FUNCTIONAL INSPECTION

charging system check (4JJ1 without DPD)
engine compression pressure inspection (4JJ1 without DPD)
fuel supply pump functional inspection (4JJ1 without DPD)
lubricating system inspection (4JJ1 without DPD)

15D SYMPTOM TROUBLESHOOTING

abnormal combustion noise (4JJ1 without DPD)
Abnormal sound in generator (4JJ1 without DPD)
Black smoke (4JJ1 without DPD)
cuts out (4JJ1 without DPD)
defect of charging system (4JJ1 without DPD)
defect of turbocharger (4JJ1 without DPD)
engine does not stop (4JJ1 without DPD)
engine does not turn over (4JJ1 without DPD)
engine has overcooled (4JJ1 without DPD)
engine has overheated (4JJ1 without DPD)
engine slow to warm up (4JJ1 without DPD)
exhaust gas leak, noise (4JJ1 without DPD)
Hard start (4JJ1 without DPD)
hesitation, sag or stumble (4JJ1 without DPD)
High idle speed (4JJ1 without DPD)
intermittent conditions of engine (4JJ1 without DPD)
lack of power, sluggishness or sponginess (4JJ1 without DPD)
poor fuel economy (4JJ1 without DPD)
preheating does not operate (4JJ1 without DPD)
preheating time is too long (4JJ1 without DPD)
preheating time is too short (4JJ1 without DPD)
rough, unstable (4JJ1 without DPD)
Starter overrun (4JJ1 without DPD)
surges (4JJ1 without DPD)
vibrations and rattling sounds from the exhaust system (4JJ1 without DPD)
White smoke (4JJ1 without DPD)

ENGINE (IBS (RZ4E-TC))

15B MAINTENANCE INFORMATION

maintenance precautions of IBS (IBS (RZ4E-TC))
function, structure, operation of IBS (IBS (RZ4E-TC))
introduction to the trouble diagnosis of IBS (IBS (RZ4E-TC))

15D SYMPTOM TROUBLESHOOTING

ENGINE (RZ4E-TC)

15B MAINTENANCE INFORMATION

maintenance precautions of engine (RZ4E-TC)
function, structure, operation of engine (RZ4E-TC)
primary specifications of engine (RZ4E-TC)
introduction to the trouble diagnosis of engine (RZ4E-TC)

15C FUNCTIONAL INSPECTION

charging system check (RZ4E-TC)
engine compression pressure inspection (RZ4E-TC)
fuel supply pump functional inspection (RZ4E-TC)
lubricating system inspection (RZ4E-TC)

15D SYMPTOM TROUBLESHOOTING

abnormal combustion noise (RZ4E-TC)
Abnormal sound in generator (RZ4E-TC)
Black smoke (RZ4E-TC)
cuts out (RZ4E-TC)
defect of charging system (RZ4E-TC)
defect of turbocharger (RZ4E-TC)
engine does not stop (RZ4E-TC)
engine does not turn over (RZ4E-TC)
engine has overcooled (RZ4E-TC)
engine has overheated (RZ4E-TC)
engine slow to warm up (RZ4E-TC)
exhaust gas leak, noise (RZ4E-TC)
Hard start (RZ4E-TC)
hesitation, sag or stumble (RZ4E-TC)
High idle speed (RZ4E-TC)
intermittent conditions of engine (RZ4E-TC)
lack of power, sluggishness or sponginess (RZ4E-TC)
poor fuel economy (RZ4E-TC)
preheating does not operate (RZ4E-TC)
preheating time is too long (RZ4E-TC)
preheating time is too short (RZ4E-TC)
rough, unstable (RZ4E-TC)
Starter overrun (RZ4E-TC)
surges (RZ4E-TC)
vibrations and rattling sounds from the exhaust system (RZ4E-TC)
White smoke (RZ4E-TC)

FRAME, FRAME ACCESSORIES

HVAC

21B MAINTENANCE INFORMATION

maintenance precautions of heating, ventilation air conditioning
function, structure, operation of heating, ventilation air conditioning
primary specifications of heating, ventilation air conditioning
introduction to the trouble diagnosis of heating, ventilation air conditioning

21C FUNCTIONAL INSPECTION

air conditioning system check
automatic air conditioning control unit power circuit inspection
checking the air conditioning system using the manifold gauge

21D SYMPTOM TROUBLESHOOTING

blower motor does not function at the _HI_ position
blower motor does not function at the _LOW_ position
blower motor does not function at the _MEDIUM HI_ position
blower motor does not function at the _MEDIUM LOW_ position
blower motor does not operate regardless of the switch position
blower motor does not stop operating
code 22 shows on the control panel display
code 24 shows on the control panel display
code 25 shows on the control panel display
code 31 shows on the control panel display
code 32 shows on the control panel display
code 33 shows on the control panel display
code 34 shows on the control panel display
code 35 shows on the control panel display
code 37 shows on the control panel display
code 38 shows on the control panel display
code 39 shows on the control panel display
cooling system is not functioning or is weak
insufficient air flow from the cooling system
intake actuator does not work
magnetic clutch is not functioning
mode door cannot be set to a specified mode

LIGHTING CONTROL (HEADLIGHT AUTOMATIC LEVELING)

37B MAINTENANCE INFORMATION

maintenance precautions of lighting control (Headlight Automatic Leveling Control)
function, structure, operation of lighting control (Headlight Automatic Leveling Control)
introduction to the trouble diagnosis of lighting control (Headlight Automatic Leveling Control)

37D SYMPTOM TROUBLESHOOTING

RESTRAINTS

22B MAINTENANCE INFORMATION

maintenance precautions of restraint
function, structure, operation of restraint
introduction to the trouble diagnosis of restraint

22D SYMPTOM TROUBLESHOOTING

SECURITY & LOCKS CONTROL (PASSIVE ENTRY & START SYSTEM)

42B MAINTENANCE INFORMATION

maintenance precautions of security and locks control (Passive Entry and Start System)
function, structure, operation of security and locks control (Passive Entry and Start System)
introduction to the trouble diagnosis of security and locks control (Passive Entry and Start System)

42D SYMPTOM TROUBLESHOOTING

answer back buzzer (external buzzer) does not work (Passive Entry and Start System)
doors do not lock even when operating the door lock button on the driver side (Passive Entry and Start System)
doors do not lock even when tail gate lock button is operated (Passive Entry and Start System)
doors do not lock or unlock with electronic key button operation (Passive Entry and Start System)
doors do not unlock even when gripping the driver side door handle (Passive Entry and Start System)
doors do not unlock even when opener switch is operated (Passive Entry and Start System)
intermittent conditions of passive entry and start system (Passive Entry and Start System)
the power mode does not change (Passive Entry and Start System)

STEERING

20B MAINTENANCE INFORMATION

primary specifications of steering
function, structure, operation of steering

20C FUNCTIONAL INSPECTION

inspection of steering free play
measurement of the power steering operating pressure

20D SYMPTOM TROUBLESHOOTING

abnormal kickback of the steering wheel
abnormal noises of power steering
excessive play of the steering
improper return of the steering wheel to the center position
key cannot be pull out at the
large force required to operate the steering
lock does not lock
lock does not unlock
rattling of the steering wheel
steering malfunction when the brake is applied
steering operation is heavy, or power assist does not work
steering wheel is difficult to control
surging of power steering
unstable steering
vibration of the steering wheel

SUSPENSION

16B MAINTENANCE INFORMATION

function, structure, operation of suspension
primary specifications of suspension

16D SYMPTOM TROUBLESHOOTING

abnormal noises from suspension
abnormal wear of the tire
spring breakage
suspension hits the bottom
tilting of the body
trim height is uneven
uncomfortable ride
unevenness during wheel rotation

TIRE PRESSURE MONITORING SYSTEM

45B MAINTENANCE INFORMATION

maintenance precautions of tire pressure monitoring system
function, structure, operation of tire pressure monitoring system
introduction to the trouble diagnosis of tire pressure monitoring system

45D SYMPTOM TROUBLESHOOTING

TRANSMISSION, TRANSAXLE (AWR6B45)

19B MAINTENANCE INFORMATION

maintenance precautions of transmission, transaxle (AWR6B45)
function, structure, operation of transmission, transaxle (AWR6B45)
primary specifications of transmission, transaxle (AWR6B45)
introduction to the trouble diagnosis of transmission, transaxle (AWR6B45)

19C FUNCTIONAL INSPECTION

measurement of the automatic transmission operating pressure (AWR6B45)
time lag test (AWR6B45)

19D SYMPTOM TROUBLESHOOTING

abnormal noise or vibration of the vehicle with automatic transmission (AWR6B45)
acceleration failure of the vehicle with automatic transmission (AWR6B45)
ATF leakage (AWR6B45)
automatic transmission cannot shift (AWR6B45)
automatic transmission slips (AWR6B45)
engine cannot be started when shifted to N or P (AWR6B45)
engine of the vehicle with automatic transmission stalls (AWR6B45)
erratic shifting of the automatic transmission (AWR6B45)
harsh shocks during automatic transmission shifting (AWR6B45)
Intermittent conditions of automatic transmission (AWR6B45)
kickdown does not occur (AWR6B45)
mode select does not work (AWR6B45)
selector lever movement is stiff or loose (AWR6B45)
shift time lag of automatic transmission (AWR6B45)
Vehicle with automatic transmission does not move (AWR6B45)

TRANSMISSION, TRANSAXLE (MVL)

19B MAINTENANCE INFORMATION

function, structure, operation of transmission, transaxle (MVL)
primary specifications of transmission, transaxle (MVL)

19D SYMPTOM TROUBLESHOOTING

abnormal noises from the clutch (MVL)
abnormal noises from transmission (MVL)
clutch fluid leakage (MVL)
clutch judder (MVL)
clutch slipping (MVL)
difficulty in shifting (MVL)
falling out of gears (MVL)
oil leakage from transmission (MVL)
release failure in the clutch (MVL)

TRANSMISSION, TRANSAXLE (TB-50LS)

19B MAINTENANCE INFORMATION

maintenance precautions of transmission, transaxle (TB-50LS)
function, structure, operation of transmission, transaxle (TB-50LS)
primary specifications of transmission, transaxle (TB-50LS)
introduction to the trouble diagnosis of transmission, transaxle (TB-50LS)

19C FUNCTIONAL INSPECTION

measurement of the automatic transmission operating pressure (TB-50LS)
time lag test (TB-50LS)

19D SYMPTOM TROUBLESHOOTING

abnormal sounds from power train or exhaust system with automatic transmission (TB-50LS)
acceleration failure of the vehicle with automatic transmission (TB-50LS)
ATF leakage (TB-50LS)
automatic transmission cannot shift (TB-50LS)
automatic transmission slips (TB-50LS)
engine cannot be started when shifted to N or P (TB-50LS)
engine of the vehicle with automatic transmission stalls (TB-50LS)
erratic shifting of the automatic transmission (TB-50LS)
harsh shocks during automatic transmission shifting (TB-50LS)
Intermittent conditions of automatic transmission (TB-50LS)
kickdown does not occur (TB-50LS)
mode select does not work (TB-50LS)
poor fuel efficiency of the vehicle with automatic transmission (TB-50LS)
selector lever movement is stiff or loose (TB-50LS)
shift time lag of automatic transmission (TB-50LS)
Vehicle with automatic transmission does not move (TB-50LS)
vibrations of the vehicle with automatic transmission (TB-50LS)