Manual PDF Isuzu MU-X UCR UCS Series model 2025 Mechanical Repair Procedures UCHTML-WEN-2531

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Isuzu MU-X UCR UCS Series model 2025 Mechanical Repair Procedures UCHTML-WEN-2531
Size: 274 MB
Format: PDF
Language: English
Brand: Isuzu
Type of Machine: Automotive - SUV-Car
Type of Manual: Workshop Manual - Diagnostics Service Information, Troubleshooting(DTC)
Model: Isuzu MU-X UCR Series ; UCS Series 21 Cab model SUV-Car
Date: 2025
Engine: Isuzu 4JJ3 Euro2 ; 4JJ3 Euro4 ; 4JJ3 Euro5 ; RZ4E-TC Euro2 ; RZ4E-TC Euro4 ; RZ4E-TC Euro5 Engine
Except Thailand
Parts Number: UCHTML-WEN-2531
Number of Pages: 6511 Pages

Contents:
1.1. Engine (4JJ3 (Euro2 and Euro4 specification))

1B. Mechanical​

Camshaft - inspection​

Camshaft - installation​

Camshaft - removal​

Crankcase - disassembly​

Crankcase - inspection​

Crankcase - installation​

Crankcase - reassembly​

Crankcase - removal​

Crankshaft - disassembly​

Crankshaft - inspection​

Crankshaft - installation​

Crankshaft - reassembly​

Crankshaft - removal​

Crankshaft front oil seal - installation​

Crankshaft front oil seal - removal​

Crankshaft pulley - installation​

Crankshaft pulley - removal​

Crankshaft rear oil seal - installation​

Crankshaft rear oil seal - removal​

Cylinder block - inspection​

Cylinder block - installation​

Cylinder block - removal​

Cylinder head - disassembly​

Cylinder head - inspection​

Cylinder head - installation​

Cylinder head - reassembly​

Cylinder head - removal​

Cylinder head cover - installation​

Cylinder head cover - removal​

Engine - installation​

Engine - removal​

Engine mounting - installation​

Engine mounting - removal​

Exhaust manifold - inspection​

Exhaust manifold - installation​

Exhaust manifold - removal​

Flywheel - disassembly​

Flywheel - inspection​

Flywheel - installation​

Flywheel - reassembly​

Flywheel - removal​

Idle gear - disassembly​

Idle gear - inspection​

Idle gear - installation​

Idle gear - reassembly​

Idle gear - removal​

Inlet manifold - installation​

Inlet manifold - removal​

Intake throttle valve - installation​

Intake throttle valve - removal​

Piston - disassembly​

Piston - inspection​

Piston - installation​

Piston - reassembly​

Piston - removal​

Rear plate - installation​

Rear plate - removal​

Rocker arm shaft - installation​

Rocker arm shaft - removal​

Supplementary Information​

Swirl control solenoid valve - installation​

Swirl control solenoid valve - removal​

Timing chain - installation​

Timing chain - removal​

Timing gear case - installation​

Timing gear case - removal​

1C. Fuel System​

Common rail (fuel rail) - installation​

Common rail (fuel rail) - removal​

Filler neck - installation​

Filler neck - removal​

Fuel - air bleed​

Fuel - drain water​

Fuel - inspection​

Fuel filler cap - inspection​

Fuel filler cap - installation​

Fuel filler cap - removal​

Fuel filter - inspection​

Fuel filter - installation​

Fuel filter - removal​

Fuel filter element - installation​

Fuel filter element - removal​

Fuel supply pump - installation​

Fuel supply pump - removal​

Fuel tank - installation​

Fuel tank - removal​

Fuel tank unit - inspection​

Fuel tank unit - installation​

Fuel tank unit - removal​

Fuel tube - inspection​

Fuel tube - installation​

Fuel tube - removal​

Injector - installation​

Injector - removal​

Supplementary Information​

Water sedimenter switch - inspection​

Water sedimenter switch - installation​

Water sedimenter switch - removal​

1D. Cooling​

Coolant - inspection​

Coolant - replacement​

Cooling fan belt - inspection​

Cooling fan belt - installation​

Cooling fan belt - removal​

Cooling fan clutch - inspection​

Cooling fan clutch - installation​

Cooling fan clutch - removal​

Radiator - inspection​

Radiator - installation​

Radiator - removal​

Radiator reserve tank - installation​

Radiator reserve tank - removal​

Supplementary Information​

Thermostat - inspection​

Thermostat - installation​

Thermostat - removal​

Water pump - inspection​

Water pump - installation​

Water pump - removal​

1E. Lubrication​

Engine oil - inspection​

Engine oil - replacement​

Oil cooler - installation​

Oil cooler - removal​

Oil filter - installation​

Oil filter - removal​

Oil filter element - installation​

Oil filter element - removal​

Oil pan - installation​

Oil pan - removal​

Oil pressure switch - inspection​

Oil pressure switch - installation​

Oil pressure switch - removal​

Oil pump - inspection​

Oil pump - installation​

Oil pump - removal​

Oil tray - installation​

Oil tray - removal​

Supplementary Information​

1F. Induction​

Air cleaner element - inspection​

Air cleaner element - installation​

Air cleaner element - removal​

Intercooler - inspection​

Intercooler - installation​

Intercooler - removal​

Supplementary Information​

Turbocharger - inspection​

Turbocharger - installation​

Turbocharger - removal​

1G. Exhaust​

Catalytic converter - installation​

Catalytic converter - removal​

Exhaust pipe - inspection​

Exhaust pipe - installation​

Exhaust pipe - removal​

Supplementary Information​

1H. Aux. Emission Control Devices​

EGR cooler - inspection​

EGR cooler - installation​

EGR cooler - removal​

EGR valve - inspection​

EGR valve - installation​

EGR valve - removal​

Supplementary Information​

1I. Speed Control Systems​

Accelerator pedal - inspection​

Accelerator pedal - installation​

Accelerator pedal - removal​

1J. Electrical​

Battery sensor - installation​

Battery sensor - removal​

Generator - inspection​

Generator - installation​

Generator - removal​

Glow plug - inspection​

Glow plug - installation​

Glow plug - removal​

ICR relay - inspection​

ICR relay - installation​

ICR relay - removal​

Starter motor - disassembly​

Starter motor - inspection​

Starter motor - installation​

Starter motor - reassembly​

Starter motor - removal​

Supplementary Information​

1Z. Engine Electrical Control​

Boost pressure sensor - inspection​

Boost pressure sensor - installation​

Boost pressure sensor - removal​

CKP sensor - inspection​

CKP sensor - installation​

CKP sensor - removal​

CMP sensor - inspection​

CMP sensor - installation​

CMP sensor - removal​

ECM - inspection​

ECM - installation​

ECM - removal​

ECM - setting​

Engine coolant temperature sensor - inspection​

Engine coolant temperature sensor - installation​

Engine coolant temperature sensor - removal​

Fuel temperature sensor - inspection​

Fuel temperature sensor - installation​

Fuel temperature sensor - removal​

MAF and IAT sensor - inspection​

MAF and IAT sensor - installation​

MAF and IAT sensor - removal​

1.2. Engine (4JJ3 (Euro5 specification))

1B. Mechanical​

Camshaft - inspection​

Camshaft - installation​

Camshaft - removal​

Crankcase - disassembly​

Crankcase - inspection​

Crankcase - installation​

Crankcase - reassembly​

Crankcase - removal​

Crankshaft - disassembly​

Crankshaft - inspection​

Crankshaft - installation​

Crankshaft - reassembly​

Crankshaft - removal​

Crankshaft front oil seal - installation​

Crankshaft front oil seal - removal​

Crankshaft pulley - installation​

Crankshaft pulley - removal​

Crankshaft rear oil seal - installation​

Crankshaft rear oil seal - removal​

Cylinder block - inspection​

Cylinder block - installation​

Cylinder block - removal​

Cylinder head - disassembly​

Cylinder head - inspection​

Cylinder head - installation​

Cylinder head - reassembly​

Cylinder head - removal​

Cylinder head cover - installation​

Cylinder head cover - removal​

Engine - installation​

Engine - removal​

Engine mounting - installation​

Engine mounting - removal​

Exhaust manifold - inspection​

Exhaust manifold - installation​

Exhaust manifold - removal​

Flywheel - disassembly​

Flywheel - inspection​

Flywheel - installation​

Flywheel - reassembly​

Flywheel - removal​

Idle gear - disassembly​

Idle gear - inspection​

Idle gear - installation​

Idle gear - reassembly​

Idle gear - removal​

Inlet manifold - installation​

Inlet manifold - removal​

Intake throttle valve - installation​

Intake throttle valve - removal​

Piston - disassembly​

Piston - inspection​

Piston - installation​

Piston - reassembly​

Piston - removal​

Rear plate - installation​

Rear plate - removal​

Rocker arm shaft - installation​

Rocker arm shaft - removal​

Supplementary Information​

Swirl control solenoid valve - installation​

Swirl control solenoid valve - removal​

Timing chain - installation​

Timing chain - removal​

Timing gear case - installation​

Timing gear case - removal​

1C. Fuel System​

Common rail (fuel rail) - installation​

Common rail (fuel rail) - removal​

Filler neck - installation​

Filler neck - removal​

Fuel - air bleed​

Fuel - drain water​

Fuel - inspection​

Fuel filler cap - inspection​

Fuel filler cap - installation​

Fuel filler cap - removal​

Fuel filter - inspection​

Fuel filter - installation​

Fuel filter - removal​

Fuel filter element - installation​

Fuel filter element - removal​

Fuel supply pump - installation​

Fuel supply pump - removal​

Fuel tank - installation​

Fuel tank - removal​

Fuel tank unit - inspection​

Fuel tank unit - installation​

Fuel tank unit - removal​

Fuel tube - inspection​

Fuel tube - installation​

Fuel tube - removal​

Injector - installation​

Injector - removal​

Supplementary Information​

Water sedimenter switch - inspection​

Water sedimenter switch - installation​

Water sedimenter switch - removal​

1D. Cooling​

Coolant - inspection​

Coolant - replacement​

Cooling fan belt - inspection​

Cooling fan belt - installation​

Cooling fan belt - removal​

Cooling fan clutch - inspection​

Cooling fan clutch - installation​

Cooling fan clutch - removal​

Radiator - inspection​

Radiator - installation​

Radiator - removal​

Radiator reserve tank - installation​

Radiator reserve tank - removal​

Supplementary Information​

Thermostat - inspection​

Thermostat - installation​

Thermostat - removal​

Water pump - inspection​

Water pump - installation​

Water pump - removal​

1E. Lubrication​

Engine oil - inspection​

Engine oil - replacement​

Oil cooler - installation​

Oil cooler - removal​

Oil filter - installation​

Oil filter - removal​

Oil filter element - installation​

Oil filter element - removal​

Oil pan - installation​

Oil pan - removal​

Oil pressure switch - inspection​

Oil pressure switch - installation​

Oil pressure switch - removal​

Oil pump - inspection​

Oil pump - installation​

Oil pump - removal​

Oil tray - installation​

Oil tray - removal​

Supplementary Information​

1F. Induction​

Air cleaner element - inspection​

Air cleaner element - installation​

Air cleaner element - removal​

Intercooler - inspection​

Intercooler - installation​

Intercooler - removal​

Supplementary Information​

Turbocharger - inspection​

Turbocharger - installation​

Turbocharger - removal​

1G. Exhaust​

DPD - inspection​

DPD - installation​

DPD - removal​

Exhaust pipe - inspection​

Exhaust pipe - installation​

Exhaust pipe - removal​

Supplementary Information​

1H. Aux. Emission Control Devices​

EGR cooler - inspection​

EGR cooler - installation​

EGR cooler - removal​

EGR cooler bypass control solenoid valve - installation​

EGR cooler bypass control solenoid valve - removal​

EGR cooler bypass valve - inspection​

EGR cooler bypass valve - installation​

EGR cooler bypass valve - removal​

EGR valve - inspection​

EGR valve - installation​

EGR valve - removal​

Supplementary Information​

1I. Speed Control Systems​

Accelerator pedal - inspection​

Accelerator pedal - installation​

Accelerator pedal - removal​

1J. Electrical​

Battery sensor - installation​

Battery sensor - removal​

Generator - inspection​

Generator - installation​

Generator - removal​

Glow control unit - installation​

Glow control unit - removal​

Glow plug - inspection​

Glow plug - installation​

Glow plug - removal​

Starter motor - disassembly​

Starter motor - inspection​

Starter motor - installation​

Starter motor - reassembly​

Starter motor - removal​

Supplementary Information​

1Z. Engine Electrical Control​

Boost pressure sensor - inspection​

Boost pressure sensor - installation​

Boost pressure sensor - removal​

Charge air cooler temperature sensor 1 - inspection​

Charge air cooler temperature sensor 1 - installation​

Charge air cooler temperature sensor 1 - removal​

Charge air cooler temperature sensor - inspection​

Charge air cooler temperature sensor - installation​

Charge air cooler temperature sensor - removal​

CKP sensor - inspection​

CKP sensor - installation​

CKP sensor - removal​

CMP sensor - inspection​

CMP sensor - installation​

CMP sensor - removal​

ECM - inspection​

ECM - installation​

ECM - removal​

ECM - setting​

EGR gas pressure sensor - inspection​

EGR gas pressure sensor - installation​

EGR gas pressure sensor - removal​

EGR gas temperature sensor 1 (exhaust manifold side) - inspection​

EGR gas temperature sensor 1 (exhaust manifold side) - installation​

EGR gas temperature sensor 1 (exhaust manifold side) - removal​

EGR gas temperature sensor 2 (EGR valve side) - inspection​

EGR gas temperature sensor 2 (EGR valve side) - installation​

EGR gas temperature sensor 2 (EGR valve side) - removal​

Engine coolant temperature sensor - inspection​

Engine coolant temperature sensor - installation​

Engine coolant temperature sensor - removal​

Exhaust differential pressure sensor - inspection​

Exhaust differential pressure sensor - installation​

Exhaust differential pressure sensor - removal​

Exhaust gas temperature sensor 1 (Front of DPD filter) - inspection​

Exhaust gas temperature sensor 1 (Front of DPD filter) - installation​

Exhaust gas temperature sensor 1 (Front of DPD filter) - removal​

Exhaust gas temperature sensor 2 (Front of LNT catalyst) - inspection​

Exhaust gas temperature sensor 2 (Front of LNT catalyst) - installation​

Exhaust gas temperature sensor 2 (Front of LNT catalyst) - removal​

Fuel temperature sensor - inspection​

Fuel temperature sensor - installation​

Fuel temperature sensor - removal​

Heated oxygen sensor 1 - installation​

Heated oxygen sensor 1 - removal​

Heated oxygen sensor 2 - installation​

Heated oxygen sensor 2 - removal​

Idling stop system control unit - installation​

Idling stop system control unit - removal​

Idling stop system control unit - setting​

MAF and IAT sensor - inspection​

MAF and IAT sensor - installation​

MAF and IAT sensor - removal​

Oil level sensor - inspection​

Oil level sensor - installation​

Oil level sensor - removal​

PM sensor - installation​

PM sensor - removal​

1.3. Engine (RZ4E-TC (Euro2 and less specification))

1B. Mechanical​

Camshaft - disassembly​

Camshaft - inspection​

Camshaft - installation​

Camshaft - reassembly​

Camshaft - removal​

Crankcase - inspection​

Crankcase - installation​

Crankcase - removal​

Crankshaft - disassembly​

Crankshaft - inspection​

Crankshaft - installation​

Crankshaft - reassembly​

Crankshaft - removal​

Crankshaft front oil seal - installation​

Crankshaft front oil seal - removal​

Crankshaft pulley - installation​

Crankshaft pulley - removal​

Crankshaft rear oil seal - installation​

Crankshaft rear oil seal - removal​

Cylinder block - inspection​

Cylinder block - installation​

Cylinder block - removal​

Cylinder head - disassembly​

Cylinder head - inspection​

Cylinder head - installation​

Cylinder head - reassembly​

Cylinder head - removal​

Cylinder head cover - installation​

Cylinder head cover - removal​

Engine - installation​

Engine - removal​

Engine mounting - installation​

Engine mounting - removal​

Exhaust manifold - inspection​

Exhaust manifold - installation​

Exhaust manifold - removal​

Flywheel - disassembly​

Flywheel - inspection​

Flywheel - installation​

Flywheel - reassembly​

Flywheel - removal​

Flywheel housing - installation​

Flywheel housing - removal​

Front cover - installation​

Front cover - removal​

Idle gear - inspection​

Idle gear - installation​

Idle gear - removal​

Inlet cover - installation​

Inlet cover - removal​

Intake throttle valve - installation​

Intake throttle valve - removal​

Piston - disassembly​

Piston - inspection​

Piston - installation​

Piston - reassembly​

Piston - removal​

Supplementary Information​

Timing chain - installation​

Timing chain - removal​

1C. Fuel System​

Common rail (fuel rail) - installation​

Common rail (fuel rail) - removal​

Filler neck - installation​

Filler neck - removal​

FRP regulator - installation​

FRP regulator - removal​

Fuel - air bleed​

Fuel - drain water​

Fuel - inspection​

Fuel filler cap - inspection​

Fuel filler cap - installation​

Fuel filler cap - removal​

Fuel filter - inspection​

Fuel filter - installation​

Fuel filter - removal​

Fuel filter element - installation​

Fuel filter element - removal​

Fuel supply pump - installation​

Fuel supply pump - removal​

Fuel tank - installation​

Fuel tank - removal​

Fuel tank unit - inspection​

Fuel tank unit - installation​

Fuel tank unit - removal​

Fuel tube - inspection​

Fuel tube - installation​

Fuel tube - removal​

Injector - installation​

Injector - removal​

Pre-fuel filter - installation​

Pre-fuel filter - removal​

Pre-fuel filter element - installation​

Pre-fuel filter element - removal​

Pressure limiter - installation​

Pressure limiter - removal​

Supplementary Information​

Water sedimenter switch - inspection​

Water sedimenter switch - installation​

Water sedimenter switch - removal​

1D. Cooling​

Auto tensioner - inspection​

Auto tensioner - installation​

Auto tensioner - removal​

Coolant - inspection​

Coolant - replacement​

Cooling fan belt - inspection​

Cooling fan belt - installation​

Cooling fan belt - removal​

Cooling fan clutch - inspection​

Cooling fan clutch - installation​

Cooling fan clutch - removal​

Radiator - inspection​

Radiator - installation​

Radiator - removal​

Radiator reserve tank - installation​

Radiator reserve tank - removal​

Supplementary Information​

Thermostat - inspection​

Thermostat - installation​

Thermostat - removal​

Water pump - inspection​

Water pump - installation​

Water pump - removal​

1E. Lubrication​

Engine oil - inspection​

Engine oil - replacement​

Oil cooler - installation​

Oil cooler - removal​

Oil filter - installation​

Oil filter - removal​

Oil filter element - installation​

Oil filter element - removal​

Oil pan - installation​

Oil pan - removal​

Oil pressure switch - inspection​

Oil pressure switch - installation​

Oil pressure switch - removal​

Oil pump - disassembly​

Oil pump - installation​

Oil pump - reassembly​

Oil pump - removal​

Supplementary Information​

1F. Induction​

Air cleaner element - inspection​

Air cleaner element - installation​

Air cleaner element - removal​

Intercooler - inspection​

Intercooler - installation​

Intercooler - removal​

Relief valve - installation​

Relief valve - removal​

Relief valve control solenoid valve - installation​

Relief valve control solenoid valve - removal​

Supplementary Information​

Turbocharger - inspection​

Turbocharger - installation​

Turbocharger - removal​

Turbocharger control solenoid valve - inspection​

Turbocharger control solenoid valve - installation​

Turbocharger control solenoid valve - removal​

1G. Exhaust​

Exhaust pipe - inspection​

Exhaust pipe - installation​

Exhaust pipe - removal​

Supplementary Information​

1H. Aux. Emission Control Devices​

EGR - inspection​

EGR - installation​

EGR - removal​

EGR control solenoid valve - installation​

EGR control solenoid valve - removal​

Supplementary Information​

1I. Speed Control Systems​

Accelerator pedal - inspection​

Accelerator pedal - installation​

Accelerator pedal - removal​

1J. Electrical​

Battery sensor - installation​

Battery sensor - removal​

Generator - inspection​

Generator - installation​

Generator - removal​

Glow plug - inspection​

Glow plug - installation​

Glow plug - removal​

ICR relay - inspection​

ICR relay - installation​

ICR relay - removal​

Starter motor - disassembly​

Starter motor - inspection​

Starter motor - installation​

Starter motor - reassembly​

Starter motor - removal​

Supplementary Information​

1Z. Engine Electrical Control​

Barometric pressure sensor - inspection​

Barometric pressure sensor - installation​

Barometric pressure sensor - removal​

Boost pressure and CAC temperature sensor - inspection​

Boost pressure and CAC temperature sensor - installation​

Boost pressure and CAC temperature sensor - removal​

CKP sensor - inspection​

CKP sensor - installation​

CKP sensor - removal​

CMP sensor - inspection​

CMP sensor - installation​

CMP sensor - removal​

ECM - installation​

ECM - removal​

ECM - setting​

Engine coolant temperature sensor - inspection​

Engine coolant temperature sensor - installation​

Engine coolant temperature sensor - removal​

FRP sensor - inspection​

FRP sensor - installation​

FRP sensor - removal​

Fuel temperature sensor - inspection​

Fuel temperature sensor - installation​

Fuel temperature sensor - removal​

MAF and IAT sensor - inspection​

MAF and IAT sensor - installation​

MAF and IAT sensor - removal​

Supplementary Information​

1.4. Engine (RZ4E-TC (Euro4 specification))

1B. Mechanical​

Camshaft - disassembly​

Camshaft - inspection​

Camshaft - installation​

Camshaft - reassembly​

Camshaft - removal​

Crankcase - inspection​

Crankcase - installation​

Crankcase - removal​

Crankshaft - disassembly​

Crankshaft - inspection​

Crankshaft - installation​

Crankshaft - reassembly​

Crankshaft - removal​

Crankshaft front oil seal - installation​

Crankshaft front oil seal - removal​

Crankshaft pulley - installation​

Crankshaft pulley - removal​

Crankshaft rear oil seal - installation​

Crankshaft rear oil seal - removal​

Cylinder block - inspection​

Cylinder block - installation​

Cylinder block - removal​

Cylinder head - disassembly​

Cylinder head - inspection​

Cylinder head - installation​

Cylinder head - reassembly​

Cylinder head - removal​

Cylinder head cover - installation​

Cylinder head cover - removal​

Engine - installation​

Engine - removal​

Engine mounting - installation​

Engine mounting - removal​

Exhaust manifold - inspection​

Exhaust manifold - installation​

Exhaust manifold - removal​

Flywheel - disassembly​

Flywheel - inspection​

Flywheel - installation​

Flywheel - reassembly​

Flywheel - removal​

Flywheel housing - installation​

Flywheel housing - removal​

Front cover - installation​

Front cover - removal​

Idle gear - inspection​

Idle gear - installation​

Idle gear - removal​

Inlet cover - installation​

Inlet cover - removal​

Intake throttle valve - installation​

Intake throttle valve - removal​

Piston - disassembly​

Piston - inspection​

Piston - installation​

Piston - reassembly​

Piston - removal​

Supplementary Information​

Timing chain - installation​

Timing chain - removal​

1C. Fuel System​

Common rail (fuel rail) - installation​

Common rail (fuel rail) - removal​

Filler neck - installation​

Filler neck - removal​

Fuel - air bleed​

Fuel - drain water​

Fuel - inspection​

Fuel filler cap - inspection​

Fuel filler cap - installation​

Fuel filler cap - removal​

Fuel filter - inspection​

Fuel filter - installation​

Fuel filter - removal​

Fuel filter element - installation​

Fuel filter element - removal​

Fuel supply pump - installation​

Fuel supply pump - removal​

Fuel tank - installation​

Fuel tank - removal​

Fuel tank unit - inspection​

Fuel tank unit - installation​

Fuel tank unit - removal​

Fuel tube - inspection​

Fuel tube - installation​

Fuel tube - removal​

Injector - installation​

Injector - removal​

Pressure limiter - installation​

Pressure limiter - removal​

Supplementary Information​

Water sedimenter switch - inspection​

Water sedimenter switch - installation​

Water sedimenter switch - removal​

1D. Cooling​

Auto tensioner - inspection​

Auto tensioner - installation​

Auto tensioner - removal​

Coolant - inspection​

Coolant - replacement​

Cooling fan belt - inspection​

Cooling fan belt - installation​

Cooling fan belt - removal​

Cooling fan clutch - inspection​

Cooling fan clutch - installation​

Cooling fan clutch - removal​

Radiator - inspection​

Radiator - installation​

Radiator - removal​

Radiator reserve tank - installation​

Radiator reserve tank - removal​

Supplementary Information​

Thermostat - inspection​

Thermostat - installation​

Thermostat - removal​

Water pump - inspection​

Water pump - installation​

Water pump - removal​

1E. Lubrication​

Engine oil - inspection​

Engine oil - replacement​

Oil cooler - installation​

Oil cooler - removal​

Oil filter - installation​

Oil filter - removal​

Oil filter element - installation​

Oil filter element - removal​

Oil pan - installation​

Oil pan - removal​

Oil pressure switch - inspection​

Oil pressure switch - installation​

Oil pressure switch - removal​

Oil pump - disassembly​

Oil pump - installation​

Oil pump - reassembly​

Oil pump - removal​

Supplementary Information​

1F. Induction​

Air cleaner element - inspection​

Air cleaner element - installation​

Air cleaner element - removal​

Intercooler - inspection​

Intercooler - installation​

Intercooler - removal​

Supplementary Information​

Turbocharger - inspection​

Turbocharger - installation​

Turbocharger - removal​

1G. Exhaust​

Catalytic converter - installation​

Catalytic converter - removal​

Exhaust pipe - inspection​

Exhaust pipe - installation​

Exhaust pipe - removal​

Supplementary Information​

1H. Aux. Emission Control Devices​

EGR - inspection​

EGR - installation​

EGR - removal​

EGR control solenoid valve - installation​

EGR control solenoid valve - removal​

Supplementary Information​

1I. Speed Control Systems​

Accelerator pedal - inspection​

Accelerator pedal - installation​

Accelerator pedal - removal​

1J. Electrical​

Battery sensor - installation​

Battery sensor - removal​

Generator - inspection​

Generator - installation​

Generator - removal​

Glow plug - inspection​

Glow plug - installation​

Glow plug - removal​

ICR relay - inspection​

ICR relay - installation​

ICR relay - removal​

Starter motor - disassembly​

Starter motor - inspection​

Starter motor - installation​

Starter motor - reassembly​

Starter motor - removal​

Supplementary Information​

1Z. Engine Electrical Control​

Barometric pressure sensor - inspection​

Barometric pressure sensor - installation​

Barometric pressure sensor - removal​

Boost pressure and CAC temperature sensor - inspection​

Boost pressure and CAC temperature sensor - installation​

Boost pressure and CAC temperature sensor - removal​

CKP sensor - inspection​

CKP sensor - installation​

CKP sensor - removal​

CMP sensor - inspection​

CMP sensor - installation​

CMP sensor - removal​

ECM - inspection​

ECM - installation​

ECM - removal​

ECM - setting​

Engine coolant temperature sensor - inspection​

Engine coolant temperature sensor - installation​

Engine coolant temperature sensor - removal​

Engine oil temperature sensor - inspection​

Engine oil temperature sensor - installation​

Engine oil temperature sensor - removal​

FRP sensor - inspection​

FRP sensor - installation​

FRP sensor - removal​

MAF and IAT sensor - inspection​

MAF and IAT sensor - installation​

MAF and IAT sensor - removal​

Supplementary Information​

1.5. Engine (RZ4E-TC (Euro5 specification))

1B. Mechanical​

Camshaft - disassembly​

Camshaft - inspection​

Camshaft - installation​

Camshaft - reassembly​

Camshaft - removal​

Crankcase - inspection​

Crankcase - installation​

Crankcase - removal​

Crankshaft - disassembly​

Crankshaft - inspection​

Crankshaft - installation​

Crankshaft - reassembly​

Crankshaft - removal​

Crankshaft front oil seal - installation​

Crankshaft front oil seal - removal​

Crankshaft pulley - installation​

Crankshaft pulley - removal​

Crankshaft rear oil seal - installation​

Crankshaft rear oil seal - removal​

Cylinder block - inspection​

Cylinder block - installation​

Cylinder block - removal​

Cylinder head - disassembly​

Cylinder head - inspection​

Cylinder head - installation​

Cylinder head - reassembly​

Cylinder head - removal​

Cylinder head cover - installation​

Cylinder head cover - removal​

Engine - installation​

Engine - removal​

Engine mounting - installation​

Engine mounting - removal​

Exhaust manifold - inspection​

Exhaust manifold - installation​

Exhaust manifold - removal​

Flywheel - disassembly​

Flywheel - inspection​

Flywheel - installation​

Flywheel - reassembly​

Flywheel - removal​

Flywheel housing - installation​

Flywheel housing - removal​

Front cover - installation​

Front cover - removal​

Idle gear - inspection​

Idle gear - installation​

Idle gear - removal​

Inlet manifold - installation​

Inlet manifold - removal​

Intake throttle valve - installation​

Intake throttle valve - removal​

Piston - disassembly​

Piston - inspection​

Piston - installation​

Piston - reassembly​

Piston - removal​

Supplementary Information​

Swirl control solenoid valve - installation​

Swirl control solenoid valve - removal​

Timing chain - installation​

Timing chain - removal​

1C. Fuel System​

Common rail (fuel rail) - installation​

Common rail (fuel rail) - removal​

Filler neck - installation​

Filler neck - removal​

Fuel - air bleed​

Fuel - drain water​

Fuel - inspection​

Fuel filler cap - inspection​

Fuel filler cap - installation​

Fuel filler cap - removal​

Fuel filter - inspection​

Fuel filter - installation​

Fuel filter - removal​

Fuel filter element - installation​

Fuel filter element - removal​

Fuel supply pump - installation​

Fuel supply pump - removal​

Fuel tank - installation​

Fuel tank - removal​

Fuel tank unit - inspection​

Fuel tank unit - installation​

Fuel tank unit - removal​

Fuel tube - inspection​

Fuel tube - installation​

Fuel tube - removal​

Injector - installation​

Injector - removal​

Pressure limiter - installation​

Pressure limiter - removal​

Supplementary Information​

Water sedimenter switch - inspection​

Water sedimenter switch - installation​

Water sedimenter switch - removal​

1D. Cooling​

Auto tensioner - inspection​

Auto tensioner - installation​

Auto tensioner - removal​

Coolant - inspection​

Coolant - replacement​

Cooling fan belt - inspection​

Cooling fan belt - installation​

Cooling fan belt - removal​

Cooling fan clutch - inspection​

Cooling fan clutch - installation​

Cooling fan clutch - removal​

Radiator - inspection​

Radiator - installation​

Radiator - removal​

Radiator reserve tank - installation​

Radiator reserve tank - removal​

Supplementary Information​

Thermostat - inspection​

Thermostat - installation​

Thermostat - removal​

Water pump - inspection​

Water pump - installation​

Water pump - removal​

1E. Lubrication​

Engine oil - inspection​

Engine oil - replacement​

Oil cooler - installation​

Oil cooler - removal​

Oil filter - installation​

Oil filter - removal​

Oil filter element - installation​

Oil filter element - removal​

Oil pan - installation​

Oil pan - removal​

Oil pressure switch - inspection​

Oil pressure switch - installation​

Oil pressure switch - removal​

Oil pump - disassembly​

Oil pump - installation​

Oil pump - reassembly​

Oil pump - removal​

Supplementary Information​

1F. Induction​

Air cleaner element - inspection​

Air cleaner element - installation​

Air cleaner element - removal​

Intercooler - inspection​

Intercooler - installation​

Intercooler - removal​

Supplementary Information​

Turbocharger - inspection​

Turbocharger - installation​

Turbocharger - removal​

1G. Exhaust​

DPD - inspection​

DPD - installation​

DPD - removal​

Exhaust pipe - inspection​

Exhaust pipe - installation​

Exhaust pipe - removal​

Supplementary Information​

1H. Aux. Emission Control Devices​

EGR - inspection​

EGR - installation​

EGR - removal​

EGR control solenoid valve - installation​

EGR control solenoid valve - removal​

Supplementary Information​

1I. Speed Control Systems​

Accelerator pedal - inspection​

Accelerator pedal - installation​

Accelerator pedal - removal​

1J. Electrical​

Battery sensor - installation​

Battery sensor - removal​

Generator - inspection​

Generator - installation​

Generator - removal​

Glow control unit - installation​

Glow control unit - removal​

Glow plug - inspection​

Glow plug - installation​

Glow plug - removal​

ICR relay - inspection​

ICR relay - installation​

ICR relay - removal​

Starter motor - disassembly​

Starter motor - inspection​

Starter motor - installation​

Starter motor - reassembly​

Starter motor - removal​

Supplementary Information​

1Z. Engine Electrical Control​

Boost pressure sensor - inspection​

Boost pressure sensor - installation​

Boost pressure sensor - removal​

Charge air cooler temperature sensor - inspection​

Charge air cooler temperature sensor - installation​

Charge air cooler temperature sensor - removal​

CKP sensor - inspection​

CKP sensor - installation​

CKP sensor - removal​

CMP sensor - inspection​

CMP sensor - installation​

CMP sensor - removal​

ECM - inspection​

ECM - installation​

ECM - removal​

ECM - setting​

EGR gas pressure sensor - inspection​

EGR gas pressure sensor - installation​

EGR gas pressure sensor - removal​

EGR gas temperature sensor - inspection​

EGR gas temperature sensor - installation​

EGR gas temperature sensor - removal​

Engine coolant temperature sensor - inspection​

Engine coolant temperature sensor - installation​

Engine coolant temperature sensor - removal​

Engine oil temperature sensor - inspection​

Engine oil temperature sensor - installation​

Engine oil temperature sensor - removal​

Exhaust differential pressure sensor - inspection​

Exhaust differential pressure sensor - installation​

Exhaust differential pressure sensor - removal​

Exhaust gas temperature sensor 1 (Front of DPD filter) - inspection​

Exhaust gas temperature sensor 1 (Front of DPD filter) - installation​

Exhaust gas temperature sensor 1 (Front of DPD filter) - removal​

Exhaust gas temperature sensor 2 (Front of oxidation catalyst) - inspection​

Exhaust gas temperature sensor 2 (Front of oxidation catalyst) - installation​

Exhaust gas temperature sensor 2 (Front of oxidation catalyst) - removal​

FRP sensor - inspection​

FRP sensor - installation​

FRP sensor - removal​

Heated oxygen sensor - installation​

Heated oxygen sensor - removal​

MAF and IAT sensor - inspection​

MAF and IAT sensor - installation​

MAF and IAT sensor - removal​

Supplementary Information​

1.6. Engine (RZ4F-TC)

1B. Mechanical​

Camshaft - disassembly​

Camshaft - inspection​

Camshaft - installation​

Camshaft - reassembly​

Camshaft - removal​

Crankcase - inspection​

Crankcase - installation​

Crankcase - removal​

Crankshaft - disassembly​

Crankshaft - inspection​

Crankshaft - installation​

Crankshaft - reassembly​

Crankshaft - removal​

Crankshaft front oil seal - installation​

Crankshaft front oil seal - removal​

Crankshaft pulley - installation​

Crankshaft pulley - removal​

Crankshaft rear oil seal - installation​

Crankshaft rear oil seal - removal​

Cylinder block - inspection​

Cylinder block - installation​

Cylinder block - removal​

Cylinder head - disassembly​

Cylinder head - inspection​

Cylinder head - installation​

Cylinder head - reassembly​

Cylinder head - removal​

Cylinder head cover - installation​

Cylinder head cover - removal​

Engine - installation​

Engine - removal​

Engine mounting - installation​

Engine mounting - removal​

Exhaust manifold - inspection​

Exhaust manifold - installation​

Exhaust manifold - removal​

Flywheel - disassembly​

Flywheel - inspection​

Flywheel - installation​

Flywheel - reassembly​

Flywheel - removal​

Flywheel housing - installation​

Flywheel housing - removal​

Front cover - installation​

Front cover - removal​

Idle gear - inspection​

Idle gear - installation​

Idle gear - removal​

Inlet manifold - installation​

Inlet manifold - removal​

Intake throttle valve - installation​

Intake throttle valve - removal​

Piston - disassembly​

Piston - inspection​

Piston - installation​

Piston - reassembly​

Piston - removal​

Supplementary Information​

Timing chain - installation​

Timing chain - removal​

1C. Fuel System​

Common rail (fuel rail) - installation​

Common rail (fuel rail) - removal​

Filler neck - installation​

Filler neck - removal​

Fuel - air bleed​

Fuel - drain water​

Fuel - inspection​

Fuel filler cap - inspection​

Fuel filler cap - installation​

Fuel filler cap - removal​

Fuel filter - inspection​

Fuel filter - installation​

Fuel filter - removal​

Fuel filter element - installation​

Fuel filter element - removal​

Fuel supply pump - installation​

Fuel supply pump - removal​

Fuel tank - installation​

Fuel tank - removal​

Fuel tank unit - inspection​

Fuel tank unit - installation​

Fuel tank unit - removal​

Fuel tube - inspection​

Fuel tube - installation​

Fuel tube - removal​

Injector - installation​

Injector - removal​

Pressure limiter - installation​

Pressure limiter - removal​

Supplementary Information​

Water sedimenter switch - inspection​

Water sedimenter switch - installation​

Water sedimenter switch - removal​

1D. Cooling​

Auto tensioner - inspection​

Auto tensioner - installation​

Auto tensioner - removal​

Coolant - inspection​

Coolant - replacement​

Cooling fan belt - inspection​

Cooling fan belt - installation​

Cooling fan belt - removal​

Cooling fan clutch - inspection​

Cooling fan clutch - installation​

Cooling fan clutch - removal​

Radiator - inspection​

Radiator - installation​

Radiator - removal​

Radiator reserve tank - installation​

Radiator reserve tank - removal​

Supplementary Information​

Thermostat - inspection​

Thermostat - installation​

Thermostat - removal​

Water pump - inspection​

Water pump - installation​

Water pump - removal​

1E. Lubrication​

Engine oil - inspection​

Engine oil - replacement​

Oil cooler - installation​

Oil cooler - removal​

Oil filter - installation​

Oil filter - removal​

Oil filter element - installation​

Oil filter element - removal​

Oil pan - installation​

Oil pan - removal​

Oil pressure switch - inspection​

Oil pressure switch - installation​

Oil pressure switch - removal​

Oil pump - disassembly​

Oil pump - installation​

Oil pump - reassembly​

Oil pump - removal​

Supplementary Information​

1F. Induction​

Air cleaner element - inspection​

Air cleaner element - installation​

Air cleaner element - removal​

Intercooler - inspection​

Intercooler - installation​

Intercooler - removal​

Supplementary Information​

Turbocharger - inspection​

Turbocharger - installation​

Turbocharger - removal​

1G. Exhaust​

DPD - inspection​

DPD - installation​

DPD - removal​

Exhaust pipe - inspection​

Exhaust pipe - installation​

Exhaust pipe - removal​

Supplementary Information​

1H. Aux. Emission Control Devices​

EGR - inspection​

EGR - installation​

EGR - removal​

EGR cooler bypass control solenoid valve - installation​

EGR cooler bypass control solenoid valve - removal​

Supplementary Information​

1I. Speed Control Systems​

Accelerator pedal - inspection​

Accelerator pedal - installation​

Accelerator pedal - removal​

1J. Electrical​

Battery sensor - installation​

Battery sensor - removal​

Generator - inspection​

Generator - installation​

Generator - removal​

Glow plug - inspection​

Glow plug - installation​

Glow plug - removal​

ICR relay - inspection​

ICR relay - installation​

ICR relay - removal​

Starter motor - disassembly​

Starter motor - inspection​

Starter motor - installation​

Starter motor - reassembly​

Starter motor - removal​

Supplementary Information​

1Z. Engine Electrical Control​

Boost pressure sensor - inspection​

Boost pressure sensor - installation​

Boost pressure sensor - removal​

Charge air cooler temperature sensor - inspection​

Charge air cooler temperature sensor - installation​

Charge air cooler temperature sensor - removal​

CKP sensor - inspection​

CKP sensor - installation​

CKP sensor - removal​

CMP sensor - inspection​

CMP sensor - installation​

CMP sensor - removal​

ECM - inspection​

ECM - installation​

ECM - removal​

ECM - setting​

EGR gas temperature sensor - inspection​

EGR gas temperature sensor - installation​

EGR gas temperature sensor - removal​

Engine coolant temperature sensor - inspection​

Engine coolant temperature sensor - installation​

Engine coolant temperature sensor - removal​

Engine oil temperature sensor - inspection​

Engine oil temperature sensor - installation​

Engine oil temperature sensor - removal​

Exhaust differential pressure sensor - inspection​

Exhaust differential pressure sensor - installation​

Exhaust differential pressure sensor - removal​

Exhaust gas temperature sensor 1 (Front of DPD filter) - inspection​

Exhaust gas temperature sensor 1 (Front of DPD filter) - installation​

Exhaust gas temperature sensor 1 (Front of DPD filter) - removal​

Exhaust gas temperature sensor 2 (Front of oxidation catalyst) - inspection​

Exhaust gas temperature sensor 2 (Front of oxidation catalyst) - installation​

Exhaust gas temperature sensor 2 (Front of oxidation catalyst) - removal​

FRP sensor - inspection​

FRP sensor - installation​

FRP sensor - removal​

Idling stop system control unit - installation​

Idling stop system control unit - removal​

Idling stop system control unit - setting​

MAF and IAT sensor - inspection​

MAF and IAT sensor - installation​

MAF and IAT sensor - removal​

Supplementary Information​

2. Suspension

2B. Front Suspension​

Independent suspension - disassembly​

Independent suspension - inspection​

Independent suspension - installation​

Independent suspension - reassembly​

Independent suspension - removal​

Supplementary Information​

2C. Rear Suspension​

5-link suspension - disassembly​

5-link suspension - inspection​

5-link suspension - installation​

5-link suspension - reassembly​

5-link suspension - removal​

Supplementary Information​

2D. Wheel, Tire System​

Disc wheel and tire - inspection​

Disc wheel and tire - installation​

Disc wheel and tire - removal​

Supplementary Information​

Tire air pressure sensor - installation​

Tire air pressure sensor - removal​

Tire air pressure sensor - setting​

3. Driveline, Axle

3B. Differentials​

Differential oil - inspection​

Differential oil - replacement​

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 }) - installation​

Front final drive (φ194 mm { 7.64 in }) - reassembly​

Front final drive (φ194 mm { 7.64 in }) - removal​

Rear final drive (φ220 mm { 8.66 in }) - disassembly​

Rear final drive (φ220 mm { 8.66 in }) - inspection​

Rear final drive (φ220 mm { 8.66 in }) - installation​

Rear final drive (φ220 mm { 8.66 in }) - reassembly​

Rear final drive (φ220 mm { 8.66 in }) - removal​

Rear final drive (φ220 mm { 8.66 in })(differential lock) - disassembly​

Rear final drive (φ220 mm { 8.66 in })(differential lock) - inspection​

Rear final drive (φ220 mm { 8.66 in })(differential lock) - installation​

Rear final drive (φ220 mm { 8.66 in })(differential lock) - reassembly​

Rear final drive (φ220 mm { 8.66 in })(differential lock) - removal​

Supplementary Information​

3C. Drive Shaft System​

Front axle shaft - disassembly​

Front axle shaft - inspection​

Front axle shaft - installation​

Front axle shaft - reassembly​

Front axle shaft - removal​

Front drive axle - disassembly​

Front drive axle - inspection​

Front drive axle - installation​

Front drive axle - reassembly​

Front drive axle - removal​

Front hub - disassembly​

Front hub - inspection​

Front hub - installation​

Front hub - reassembly​

Front hub - removal​

Front propeller shaft - disassembly​

Front propeller shaft - inspection​

Front propeller shaft - installation​

Front propeller shaft - reassembly​

Front propeller shaft - removal​

Knuckle - inspection​

Knuckle - installation​

Knuckle - removal​

Rear axle - disassembly​

Rear axle - inspection​

Rear axle - installation​

Rear axle - reassembly​

Rear axle - removal​

Rear axle shaft - disassembly​

Rear axle shaft - inspection​

Rear axle shaft - installation​

Rear axle shaft - reassembly​

Rear axle shaft - removal​

Rear propeller shaft - disassembly​

Rear propeller shaft - inspection​

Rear propeller shaft - installation​

Rear propeller shaft - reassembly​

Rear propeller shaft - removal​

Shift on the fly system - disassembly​

Shift on the fly system - inspection​

Shift on the fly system - installation​

Shift on the fly system - reassembly​

Shift on the fly system - removal​

Shift on the fly system oil - inspection​

Shift on the fly system oil - replacement​

Supplementary Information​

Wheel alignment check​

3D. Transfer Case​

Front output shaft oil seal - installation​

Front output shaft oil seal - removal​

Rear output shaft oil seal - installation​

Rear output shaft oil seal - removal​

Supplementary Information​

Transfer - disassembly​

Transfer - inspection​

Transfer - installation​

Transfer - reassembly​

Transfer - removal​

Transfer oil - inspection​

Transfer oil - replacement​

3Z. Driveline, Axle Electrical Control​

Rear differential lock control unit - installation​

Rear differential lock control unit - removal​

Rear differential lock control unit - setting​

TCCM - installation​

TCCM - removal​

TCCM - setting​

4. Brakes

4B. Brake System​

Brake booster - inspection​

Brake booster - installation​

Brake booster - removal​

Brake fluid - inspection​

Brake fluid - replacement​

Brake master cylinder - disassembly​

Brake master cylinder - inspection​

Brake master cylinder - installation​

Brake master cylinder - reassembly​

Brake master cylinder - removal​

Brake pedal - inspection​

Brake pedal - installation​

Brake pedal - removal​

Disc brake pad - inspection​

Disc brake pad - installation​

Disc brake pad - removal​

Front disc brake - disassembly​

Front disc brake - inspection​

Front disc brake - installation​

Front disc brake - reassembly​

Front disc brake - removal​

Rear disc brake - inspection​

Rear disc brake - installation​

Rear disc brake - removal​

Stoplight switch - inspection​

Stoplight switch - installation​

Stoplight switch - removal​

Supplementary Information​

Vacuum switch - inspection​

Vacuum switch - installation​

Vacuum switch - removal​

4C. Parking Brake System​

Electric parking brake switch - inspection​

Electric parking brake switch - installation​

Electric parking brake switch - removal​

Parking brake - inspection​

Parking brake - installation​

Parking brake - removal​

Supplementary Information​

4D. ABS​

Front exciter ring - installation​

Front exciter ring - removal​

Rear exciter ring - inspection​

Rear exciter ring - installation​

Rear exciter ring - removal​

Supplementary Information​

4Z. Brake Electrical Control​

EHCU - installation​

EHCU - removal​

EHCU - setting​

Front wheel speed sensor - inspection​

Front wheel speed sensor - installation​

Front wheel speed sensor - removal​

Rear wheel speed sensor - inspection​

Rear wheel speed sensor - installation​

Rear wheel speed sensor - removal​

Supplementary Information​

5.1. Transmission, Transaxle (AWR6B45)

5B. Automatic​

ATF - inspection​

ATF - replacement​

ATF cooler_warmer - installation​

ATF cooler_warmer - removal​

Automatic transmission control cable - installation​

Automatic transmission control cable - removal​

Brake piston No.1 - disassembly​

Brake piston No.1 - reassembly​

Brake piston No.2 - disassembly​

Brake piston No.2 - reassembly​

Breather hose clip - disassembly​

Breather hose clip - reassembly​

Forward clutch assembly - disassembly​

Forward clutch assembly - inspection​

Forward clutch assembly - reassembly​

Front planetary ring gear - disassembly​

Front planetary ring gear - inspection​

Front planetary ring gear - reassembly​

Inhibitor switch - inspection​

Inhibitor switch - installation​

Inhibitor switch - removal​

Middle planetary ring gear - disassembly​

Middle planetary ring gear - reassembly​

Oil pump - disassembly​

Oil pump - inspection​

Oil pump - reassembly​

Rear planetary ring gear - disassembly​

Rear planetary ring gear - inspection​

Rear planetary ring gear - reassembly​

Selector lever - disassembly​

Selector lever - installation​

Selector lever - reassembly​

Selector lever - removal​

Supplementary Information​

Transmission - disassembly​

Transmission - inspection​

Transmission - installation​

Transmission - reassembly​

Transmission - removal​

5Z. Transmission Electrical Control​

Output speed sensor - inspection​

Output speed sensor - installation​

Output speed sensor - removal​

TCM - installation​

TCM - removal​

TCM - setting​

Turbine speed sensor - inspection​

Turbine speed sensor - installation​

Turbine speed sensor - removal​

5.2. Transmission, Transaxle (L-B500)

5B. Automatic​

ATF - inspection​

ATF - replacement​

ATF cooler_warmer - installation​

ATF cooler_warmer - removal​

Automatic transmission control cable - installation​

Automatic transmission control cable - removal​

Brake cylinder assembly - disassembly​

Brake cylinder assembly - inspection​

Brake cylinder assembly - reassembly​

Breather hose clip - disassembly​

Breather hose clip - reassembly​

Clutch No.1 assembly - disassembly​

Clutch No.1 assembly - inspection​

Clutch No.1 assembly - reassembly​

Clutch No.2 assembly - disassembly​

Clutch No.2 assembly - inspection​

Clutch No.2 assembly - reassembly​

Clutch No.3 assembly - disassembly​

Clutch No.3 assembly - inspection​

Clutch No.3 assembly - reassembly​

Clutch No.4 assembly - disassembly​

Clutch No.4 assembly - inspection​

Clutch No.4 assembly - reassembly​

Front planetary ring gear - disassembly​

Front planetary ring gear - reassembly​

Inhibitor switch - inspection​

Inhibitor switch - installation​

Inhibitor switch - removal​

Oil pump - disassembly​

Oil pump - inspection​

Oil pump - reassembly​

Selector lever - disassembly​

Selector lever - installation​

Selector lever - reassembly​

Selector lever - removal​

Supplementary Information​

Transmission - disassembly​

Transmission - inspection​

Transmission - installation​

Transmission - reassembly​

Transmission - removal​

5Z. Transmission Electrical Control​

Output speed sensor - inspection​

Output speed sensor - installation​

Output speed sensor - removal​

TCM - installation​

TCM - removal​

TCM - setting​

Turbine speed sensor - inspection​

Turbine speed sensor - installation​

Turbine speed sensor - removal​

5.3. Transmission, Transaxle (MVL)

5C. Manual​

Input shaft - disassembly​

Input shaft - inspection​

Input shaft - reassembly​

Main shaft - disassembly​

Main shaft - inspection​

Main shaft - reassembly​

Rear case - disassembly​

Rear case - inspection​

Rear case - reassembly​

Rear oil seal - installation​

Rear oil seal - removal​

Supplementary Information​

Transmission - disassembly​

Transmission - inspection​

Transmission - installation​

Transmission - reassembly​

Transmission - removal​

Transmission oil - inspection​

Transmission oil - replacement​

5E. Clutch System​

Clutch - inspection​

Clutch - installation​

Clutch - removal​

Clutch control - inspection​

Clutch control - installation​

Clutch control - removal​

Clutch master cylinder - inspection​

Clutch master cylinder - installation​

Clutch master cylinder - removal​

Clutch switch - installation​

Clutch switch - removal​

Shift fork - inspection​

Shift fork - installation​

Shift fork - removal​

Slave cylinder - disassembly​

Slave cylinder - inspection​

Slave cylinder - reassembly​

Supplementary Information​

6. Steering

6B. Power Assisted System​

Power steering fluid - replacement​

Power steering oil pump (4JJ3) - disassembly​

Power steering oil pump (4JJ3) - inspection​

Power steering oil pump (4JJ3) - installation​

Power steering oil pump (4JJ3) - reassembly​

Power steering oil pump (4JJ3) - removal​

Power steering oil pump (RZ4E) - disassembly​

Power steering oil pump (RZ4E) - inspection​

Power steering oil pump (RZ4E) - installation​

Power steering oil pump (RZ4E) - reassembly​

Power steering oil pump (RZ4E) - removal​

Power steering unit - disassembly​

Power steering unit - inspection​

Power steering unit - installation​

Power steering unit - reassembly​

Power steering unit - removal​

Power steering unit - setting​

Steering column - inspection​

Steering column - installation​

Steering column - removal​

Supplementary Information​

6Z. Steering Electrical Control​

Steering angle sensor - installation​

Steering angle sensor - removal​

Steering angle sensor - setting​

7. HVAC

7B. Heater Ventilator Airconditioner​

A_C compressor (4JJ3) - installation​

A_C compressor (4JJ3) - removal​

A_C compressor (RZ4E) - installation​

A_C compressor (RZ4E) - removal​

A_C compressor (RZ4F) - installation​

A_C compressor (RZ4F) - removal​

A_C compressor drive belt(4JJ3) - inspection​

A_C compressor drive belt(4JJ3) - installation​

A_C compressor drive belt(4JJ3) - removal​

A_C compressor magnet clutch - inspection​

A_C compressor magnet clutch - installation​

A_C compressor magnet clutch - removal​

Actuator - installation​

Actuator - removal​

Blower - installation​

Blower - removal​

Blower module - inspection​

Blower module - installation​

Blower module - removal​

Blower motor - inspection​

Blower motor - installation​

Blower motor - removal​

Blower resistor - inspection​

Blower resistor - installation​

Blower resistor - removal​

Condenser - installation​

Condenser - removal​

Control panel and control lever - inspection​

Control panel and control lever - installation​

Control panel and control lever - removal​

Control panel and control lever - setting​

Evaporator core - installation​

Evaporator core - removal​

Heater core - installation​

Heater core - removal​

Heater evaporator unit - installation​

Heater evaporator unit - removal​

Intake door - installation​

Intake door - removal​

Pressure switch - inspection​

Pressure switch - installation​

Pressure switch - removal​

Rear blower motor - inspection​

Rear blower motor - installation​

Rear blower motor - removal​

Rear blower resistor - inspection​

Rear blower resistor - installation​

Rear blower resistor - removal​

Rear cooler control switch - inspection​

Rear cooler control switch - installation​

Rear cooler control switch - removal​

Rear cooler unit - installation​

Rear cooler unit - removal​

Rear evaporator core - installation​

Rear evaporator core - removal​

Rear heater duct - installation​

Rear heater duct - removal​

Supplementary Information​

Vent grille - installation​

Vent grille - removal​

7Z. HVAC Control​

Inside air temperature sensor - inspection​

Inside air temperature sensor - installation​

Inside air temperature sensor - removal​

Outside air temperature sensor - inspection​

Outside air temperature sensor - installation​

Outside air temperature sensor - removal​

Sun sensor - inspection​

Sun sensor - installation​

Sun sensor - removal​

8. Restraints

8B. Airbag Systems​

Curtain airbag - installation​

Curtain airbag - removal​

Curtain airbag - scrapping​

Driver airbag - installation​

Driver airbag - removal​

Driver airbag - scrapping​

Far side air bag - installation​

Far side air bag - removal​

Far side air bag - scrapping​

Knee air bag - installation​

Knee air bag - removal​

Knee air bag - scrapping​

Passenger airbag - installation​

Passenger airbag - removal​

Passenger airbag - scrapping​

Side airbag - installation​

Side airbag - removal​

Side airbag - scrapping​

SRS coil - installation​

SRS coil - removal​

8C. Seat Belt Systems​

Buckle side 2ND seat belt - installation​

Buckle side 2ND seat belt - removal​

Buckle side 3RD seat belt - installation​

Buckle side 3RD seat belt - removal​

Front buckle side seat belt - installation​

Front buckle side seat belt - removal​

Front tongue side seat belt (with pretensioner) - installation​

Front tongue side seat belt (with pretensioner) - removal​

Front tongue side seat belt (with pretensioner) - scrapping​

Supplementary Information​

Tongue side 2ND seat belt (with pretensioner) - installation​

Tongue side 2ND seat belt (with pretensioner) - removal​

Tongue side 2ND seat belt (with pretensioner) - scrapping​

Tongue side 2ND seat belt (without pretensioner) - installation​

Tongue side 2ND seat belt (without pretensioner) - removal​

Tongue side 2ND seat belt with buckle (center) - installation​

Tongue side 2ND seat belt with buckle (center) - removal​

Tongue side 3RD seat belt - installation​

Tongue side 3RD seat belt - removal​

8Z. Seat Belt and SRS Airbag Electrical Control​

Door side airbag sensor - installation​

Door side airbag sensor - removal​

Floor side airbag sensor - installation​

Floor side airbag sensor - removal​

Front airbag sensor - installation​

Front airbag sensor - removal​

Rear side airbag sensor - installation​

Rear side airbag sensor - removal​

SRS control unit - installation​

SRS control unit - removal​

SRS control unit - setting​

Supplementary Information​

9. Body, Cab, Accessories

9A. Lighting Systems​

Ambient light (front door) - installation​

Ambient light (front door) - removal​

Ambient light (passenger side instrument panel) - installation​

Ambient light (passenger side instrument panel) - removal​

Ambient light (rear door) - installation​

Ambient light (rear door) - removal​

Ambient light (roof) - installation​

Ambient light (roof) - removal​

Backup light bulb - installation​

Backup light bulb - removal​

Combination switch - inspection​

Combination switch - installation​

Combination switch - removal​

Dome light bulb - installation​

Dome light bulb - removal​

Fog light - installation​

Fog light - removal​

Foot lamp (driver side) - installation​

Foot lamp (driver side) - removal​

Foot lamp (passenger side) - installation​

Foot lamp (passenger side) - removal​

Hazard warning flasher switch - inspection​

Hazard warning flasher switch - installation​

Hazard warning flasher switch - removal​

Headlight - inspection​

Headlight - installation​

Headlight - removal​

Headlight leveling switch - inspection​

Headlight leveling switch - installation​

Headlight leveling switch - removal​

High mounted stoplight - installation​

High mounted stoplight - removal​

Key reminder switch - inspection​

Key reminder switch - installation​

Key reminder switch - removal​

License plate light bulb - installation​

License plate light bulb - removal​

Luggage dome light bulb - installation​

Luggage dome light bulb - removal​

Map light bulb - installation​

Map light bulb - removal​

Rear combination light - installation​

Rear combination light - removal​

Side turn signal light (door mirror integrated type) - installation​

Side turn signal light (door mirror integrated type) - removal​

Side turn signal light bulb - installation​

Side turn signal light bulb - removal​

9B. Wiper, Washer Systems​

Rear washer nozzle - installation​

Rear washer nozzle - removal​

Rear wiper arm - installation​

Rear wiper arm - removal​

Rear wiper blade - installation​

Rear wiper blade - removal​

Rear wiper motor - inspection​

Rear wiper motor - installation​

Rear wiper motor - removal​

Supplementary Information​

Washer motor - inspection​

Washer motor - installation​

Washer motor - removal​

Washer nozzle - installation​

Washer nozzle - removal​

Washer tank - installation​

Washer tank - removal​

Wiper arm - installation​

Wiper arm - removal​

Wiper blade rubber - installation​

Wiper blade rubber - removal​

Wiper linkage - installation​

Wiper linkage - removal​

Wiper motor - inspection​

Wiper motor - installation​

Wiper motor - removal​

9C. Electrical Control, Entertainment​

4WD switch - inspection​

4WD switch - installation​

4WD switch - removal​

Antenna - installation​

Antenna - removal​

Audio and navigation system - installation​

Audio and navigation system - removal​

Audio and navigation system - setting​

Audio control steering wheel switch - inspection​

Audio control steering wheel switch - installation​

Audio control steering wheel switch - removal​

Center accessory socket - installation​

Center accessory socket - removal​

Cruise control steering wheel switch - inspection​

Cruise control steering wheel switch - installation​

Cruise control steering wheel switch - removal​

DC-DC converter (rearview mirror base USB charge) - installation​

DC-DC converter (rearview mirror base USB charge) - removal​

Differential lock switch (instrument panel side) - inspection​

Differential lock switch (instrument panel side) - installation​

Differential lock switch (instrument panel side) - removal​

Differential lock switch (shift console side) - inspection​

Differential lock switch (shift console side) - installation​

Differential lock switch (shift console side) - removal​

Electrical socket - installation​

Electrical socket - removal​

Engine start_stop button - inspection​

Engine start_stop button - installation​

Engine start_stop button - removal​

ESC OFF switch - inspection​

ESC OFF switch - installation​

ESC OFF switch - removal​

Film antenna - installation​

Film antenna - removal​

Front accessory socket - installation​

Front accessory socket - removal​

Front door speaker - inspection​

Front door speaker - installation​

Front door speaker - removal​

Hands-free function OFF switch - inspection​

Hands-free function OFF switch - installation​

Hands-free function OFF switch - removal​

Hill descent control switch - inspection​

Hill descent control switch - installation​

Hill descent control switch - removal​

Horn - inspection​

Horn - installation​

Horn - removal​

Horn switch - inspection​

Horn switch - installation​

Horn switch - removal​

Idling stop system OFF switch - inspection​

Idling stop system OFF switch - installation​

Idling stop system OFF switch - removal​

Ignition switch - inspection​

Ignition switch - installation​

Ignition switch - removal​

Illumination control switch - installation​

Illumination control switch - removal​

Inverter - installation​

Inverter - removal​

Paddle shifter switch - inspection​

Paddle shifter switch - installation​

Paddle shifter switch - removal​

Parking aid system OFF switch - inspection​

Parking aid system OFF switch - installation​

Parking aid system OFF switch - removal​

Passenger airbag cut off switch - inspection​

Passenger airbag cut off switch - installation​

Passenger airbag cut off switch - removal​

Power tailgate switch - inspection​

Power tailgate switch - installation​

Power tailgate switch - removal​

Rear accessory socket - installation​

Rear accessory socket - removal​

Rear cooler switch - inspection​

Rear cooler switch - installation​

Rear cooler switch - removal​

Rear door speaker - inspection​

Rear door speaker - installation​

Rear door speaker - removal​

Rear door tweeter - installation​

Rear door tweeter - removal​

Rearview mirror base USB charge - installation​

Rearview mirror base USB charge - removal​

Rough terrain mode switch - inspection​

Rough terrain mode switch - installation​

Rough terrain mode switch - removal​

SOS button - inspection​

SOS button - installation​

SOS button - removal​

Tweeter - installation​

Tweeter - removal​

USB power outlet - installation​

USB power outlet - removal​

USB_AUX terminal - installation​

USB_AUX terminal - removal​

9E. Instrumentation, Driver Info​

Antenna - installation​

Antenna - removal​

DC-DC converter （idling stop system） - installation​

DC-DC converter （idling stop system） - removal​

Forward collision warning light - installation​

Forward collision warning light - removal​

Front camera - installation​

Front camera - removal​

Instrument panel cluster - diagnostics​

Instrument panel cluster - installation​

Instrument panel cluster - removal​

Instrument panel cluster - setting​

Microphone - installation​

Microphone - removal​

Passenger airbag indicator - installation​

Passenger airbag indicator - removal​

Pillar microphone - installation​

Pillar microphone - removal​

Radar sensor (Type 1) - installation​

Radar sensor (Type 1) - removal​

Radar sensor (Type 1) - setting​

Radar sensor (Type 2) - installation​

Radar sensor (Type 2) - removal​

Radar sensor (Type 2) - setting​

Rearview camera - installation​

Rearview camera - removal​

Side camera - installation​

Side camera - removal​

Sonar sensor - installation​

Sonar sensor - removal​

Speaker microphone - installation​

Speaker microphone - removal​

Stereo camera - cleaning​

Stereo camera - installation​

Stereo camera - removal​

Stereo camera - setting​

Stereo camera - writing​

9G. Hood, Fenders, Doors​

Engine hood - installation​

Engine hood - removal​

Engine hood control cable - installation​

Engine hood control cable - removal​

Engine hood lock - installation​

Engine hood lock - removal​

Front door - disassembly​

Front door - installation​

Front door - reassembly​

Front door - removal​

Front fender panel - installation​

Front fender panel - removal​

Hands-free function sensor - installation​

Hands-free function sensor - removal​

Power tailgate buzzer - installation​

Power tailgate buzzer - removal​

Power tailgate module - installation​

Power tailgate module - removal​

Power tailgate module - setting​

Power tailgate spindle unit - installation​

Power tailgate spindle unit - removal​

Power tailgate touch sensor - inspection​

Power tailgate touch sensor - installation​

Power tailgate touch sensor - removal​

Rear door - disassembly​

Rear door - installation​

Rear door - reassembly​

Rear door - removal​

Rear mudguard - installation​

Rear mudguard - removal​

Side spoiler - installation​

Side spoiler - removal​

Supplementary Information​

Tailgate - disassembly​

Tailgate - installation​

Tailgate - reassembly​

Tailgate - removal​

Tailgate - setting​

Tailgate close switch - inspection​

Tailgate close switch - installation​

Tailgate close switch - removal​

Tailgate open switch - inspection​

Tailgate open switch - installation​

Tailgate open switch - removal​

Transmission air deflector - installation​

Transmission air deflector - removal​

Underguard - installation​

Underguard - removal​

9H. Cab Structure​

Air outlet valve - installation​

Air outlet valve - removal​

Front bumper - disassembly​

Front bumper - installation​

Front bumper - reassembly​

Front bumper - removal​

Radiator grille - installation​

Radiator grille - removal​

Rear bumper - disassembly​

Rear bumper - installation​

Rear bumper - reassembly​

Rear bumper - removal​

Roof rail - installation​

Roof rail - removal​

Side step - installation​

Side step - removal​

Supplementary Information​

9I. Seats​

2ND seat - disassembly​

2ND seat - installation​

2ND seat - reassembly​

2ND seat - removal​

3RD seat - disassembly​

3RD seat - installation​

3RD seat - reassembly​

3RD seat - removal​

Driver seat - disassembly​

Driver seat - installation​

Driver seat - reassembly​

Driver seat - removal​

Passenger seat - disassembly​

Passenger seat - installation​

Passenger seat - reassembly​

Passenger seat - removal​

Supplementary Information​

9J. Security and Locks​

Anti theft horn - installation​

Anti theft horn - removal​

Center in-vehicle antenna - installation​

Center in-vehicle antenna - removal​

Electronic key - disassembly​

Electronic key - reassembly​

Electronic key - setting​

External antenna - installation​

External antenna - removal​

External buzzer - installation​

External buzzer - removal​

Front door lock - inspection​

Front door lock - installation​

Front door lock - removal​

Immobilizer coil - installation​

Immobilizer coil - removal​

Key cylinder - installation​

Key cylinder - removal​

Keyless entry key - disassembly​

Keyless entry key - reassembly​

Keyless entry key - setting​

Rear door lock - inspection​

Rear door lock - installation​

Rear door lock - removal​

Rear in-vehicle antenna - installation​

Rear in-vehicle antenna - removal​

Steering lock - installation​

Steering lock - removal​

Steering lock - setting​

Steering lock barrel - installation​

Steering lock barrel - removal​

Tailgate lock - inspection​

Tailgate lock - installation​

Tailgate lock - removal​

Transponder key - setting​

9L. Exterior, Interior Trim​

Center pillar upper trim cover - installation​

Center pillar upper trim cover - removal​

Console box - installation​

Console box - removal​

Front pillar trim cover - installation​

Front pillar trim cover - removal​

Head lining - installation​

Head lining - removal​

Instrument panel - installation​

Instrument panel - removal​

Quarter upper trim cover - installation​

Quarter upper trim cover - removal​

Reinforcement - installation​

Reinforcement - removal​

Supplementary Information​

9M. Cab Mounting​

Body mounting - installation​

Body mounting - removal​

Supplementary Information​

9T. Glass, Windows, Mirrors​

Front door power window switch - inspection​

Front door power window switch - installation​

Front door power window switch - removal​

Front door power window switch - setting​

Front windshield glass - installation​

Front windshield glass - removal​

Outside rearview mirror - disassembly​

Outside rearview mirror - installation​

Outside rearview mirror - reassembly​

Outside rearview mirror - removal​

Quarter window glass - installation​

Quarter window glass - removal​

Rear door power window switch - inspection​

Rear door power window switch - installation​

Rear door power window switch - removal​

Remote control mirror switch - inspection​

Remote control mirror switch - installation​

Remote control mirror switch - removal​

Supplementary Information​

Tailgate glass - installation​

Tailgate glass - removal​

9Z. Body, Cab, Accessories Electrical Control​

BCM - installation​

BCM - removal​

BCM - setting​

Central gateway control unit - installation​

Central gateway control unit - removal​

Central gateway control unit - setting​

DRM - installation​

DRM - removal​

Headlight auto leveling control unit - installation​

Headlight auto leveling control unit - removal​

Headlight auto leveling control unit - setting​

Information module - installation​

Information module - removal​

Information module - setting​

Parking aid system control unit - installation​

Parking aid system control unit - removal​

Parking aid system control unit - setting​

Rain and light sensor - installation​

Rain and light sensor - removal​

Surround view control unit - installation​

Surround view control unit - removal​

Surround view control unit - setting​

Surround view control unit - writing​

Wireless access module - installation​

Wireless access module - removal​

Wireless access module - setting (with passive entry and start system)​

Wireless access module - setting (without passive entry and start system)​