SECTION 0A - GENERAL INFORMATION

1. PRECAUTIONS

1.1 SUPPLEMENTAL RESTRAINT SYSTEM

PRECAUTIONS

Diagnosis

Servicing and Handling

1.2 GENERAL PRECAUTIONS

1.3 PRECAUTIONS FOR CATALYTIC

CONVERTER

1.4 PRECAUTIONS FOR INSTALLING

MOBILE COMMUNICATION

EQUIPMENT

1.5 PRECAUTION IN SERVICING FULL-TIME

4WD VEHICLES

1.6 PRECAUTIONS FOR ELECTRICAL

CIRCUIT SERVICE

1.7 ELECTRICA L CIRCUIT INSPECTION

PROCEDURE

Open Circuit Check

Continuity Check

Voltage Check

Short Circuit Check (Wire Harness

to Ground)

Intermittents and Poor Connections

2. IDENTIFICATION INFORMATION &

PLATES

2.1 VEHICLE IDENTIFICATION NUMBER

2.2 ENGINE IDENTIFICATION NUMBER

2.3 TRANSMISSION IDENTIFICATION

NUMBER

2.4 SAFETY COMPLIANCE PLATE

2.5 BODY & OPTION IDENTIFICATION

PLATE

2.6 TA G PLATE

3. WARNING, CAUTION AND INFORMATION

LABELS

4. LIFTING POINTS

Using a Hoist

Using a Floor Jack

5. ABBREVIATIONS AND SYMBOLS USED IN

THIS MANUAL

Abbreviations

Symbols

Wire Colour Symbols

6. FASTENER INFORMATION

6.1 METRIC FASTENERS

6.2 FASTENER STRENGTH

IDENTIFICATION

6.3 STANDARD TIGHTENING TORQUE

Tightening Torque Chart

7. CONSOLIDATED TOOL LIST

Consolidated Tool List Table

Techline

1. PRECAUTIONS

1.1 SUPPLEMENTAL RESTRAINT SYSTEM PRECAUTIONS

WARNING:

• The configuration of airbag system parts are as shown in the figure. When it is necessary to ser-

vice (remove, reinstall and inspect) these parts, follow the procedures described in Section 10B.

Failure to follow proper procedures could result in possible airbag system activation, personal

injury, damage to parts or the airbag system being unable to activate when necessary.

• If the airbag system and another system within the vehicle both need repair, the airbag system

should be repaired first to avoid unintended airbag system activation.

• Do not modify the steering wheel, dashboard, or any other airbag system components.

Modifications can adversely affect airbag system performance and lead to injury.

• If the vehicle will be exposed to temperatures over 93°C (for example, during a paint baking

process), remove the airbag system components beforehand to avoid component damage or

unintended airbag system activation.

Legend

DIAGNOSIS

• When troubleshooting the airbag system, refer to

Section 10B, 2. DIAGNOSIS. Bypassing these

procedures may result in extended diagnostic time,

incorrect diagnosis, and incorrect parts replacement.

• Never use electrical test equipment other than that

specified.

WARNING: Never measu re the resistance of the ai rbag

(inflato r) modules (d river and passenger) an d seat belt

pretensioners (driver and passenger), as the electric

current from the tester may deploy the airbag or

activate the pretensioner.

1. Airbag wire harness 4. Seat belt pretensioner

2. Passenger airbag (inflator) module 5. Contact coil

3. SDM 6. Driver airbag (inflator) module

SERVICING AND HANDLING

WARNING – DRIVER AND PASSENGER AIRBAG MODULES:

Many service procedures require disconnection of the AIRBAG fuse and all airbag (inflator) modules

from the initiator circuit to avoid an accidental deployment.

• For the handling and storage of a live airbag (inflator) module, select a place where the ambient

temperature is below 65°C, with low humidity and away from electric noise.

• When carrying a live airbag (inflator) module, make sure the airbag opening is pointed away from

you (A). In case of an accidental deployment, the airbag will then deploy with minimal chance of

injury.

• Never carry the airbag (inflator) module by the wires or connector on the underside of the module.

• When placing a live airbag (inflator) module on a bench or other surface, always face the airbag

up, away from the surface (B). As the live passenger airbag (inflator) module must be placed with

its bag (trim cover) facing up, place it on the workbench with a slit or use the workbench vise (2) to

hold it securely at its lower mounting bracket (3). This is necessary so that a free space is

provided to allow the airbag to expand in the unlikely event of accidental deployment. Otherwise,

personal injury may result.

• Never dispose of live (undeployed) airbag (inflator) modules. If disposal is necessary, deploy them

according to the deployment procedures described in Section 10B before disposal.

• The airbag (inflator) module is very hot immediately after deployment. Wait for at least half an hour

for it to cool before proceeding the work.

• After an airbag (inflator) module has been deployed, the surface of the airbag may contain a

powdery residue. This powder consists primarily of cornstarch, used to lubricate the bag as it

inflates, and by-products of the chemical reaction. As with many service procedures, gloves and

safety glasses should be worn.

WARNING – SENSING AND DIAGNOSTIC MODULE (SDM):

• For handling and storage of a SDM, select a place where the ambient temperature is below 65°C,

with low humidity and away from electric noise.

• During service procedures, be very careful when handling a SDM. Never strike or jar the SDM.

• Never power-up the airbag system when the SDM is not rigidly attached to the vehicle. All SDM

and mounting bracket fasteners must be carefully torqued and the arro w must be pointing toward

the front of the vehicle to ensure proper operation of the airbag system. The SDM could be

activated when powered while not rigidly attached to the vehicle, which could cause deployment

and result in personal injury.

WARNING – DRIVER AND PASSENGER SEAT BELT PRETENSIONERS:

• For handling and storage of a live seat belt pretensioner, select a place where the ambient

temperature is below 65°C, with low humidity and away from electric noise.

• Never carry seat belt pretensioner by the wire or connector of the pretensioner.

• When placing a live seat belt pretensioner on a workbench or similar, do not place anything

else on top of it.

• Never dispose of a live (unactivated) seat belt pretensioner. If disposal is necessary, activate

the pretensioner according to activation procedures described in Section 10B before disposal.

• The seat belt pretensioner is very hot immediately after activation. Wait for at least half an hour

for it to cool before proceeding work.

• As with many service procedures, gloves and safety glasses should be worn to prevent any

possible irritation of the skin or eyes.

WARNING:

• If a collision was light enough not to cause airbags to activate, inspect system parts and other

related parts according to instructions under 3.2 REPAIR AND INSPECTION REQUIRED AFTER AN

ACCIDENT in Section 10B.

• When servicing parts other than airbag system, if shocks may be applied to airbag system

component parts, remove those parts beforehand.

• When handling the airbag (inflator) modules, seat belt pretensioners or SDM, be careful not to

drop or apply an impact to it. If an excessive impact was applied, never attempt disassembly or

repair but replace it with a new one.

• If grease, cleaning agent, oil, water, etc. gets onto an airbag (inflator) module or seat belt

pretensioner, wipe it off immediately with a dry cloth.

• The airbag wire harness can be identified easily as it is covered with a yellow protection tube. Be

very careful when handling it.

• When an open in airbag wire harness, damaged wire harness, connector or terminal is found,

replace the wire harness, connectors and terminals as an assembly.

• Do not apply power to the airbag system unless all components are connected or a diagnostic

chart requests it, as this will set a diagnostic trouble code.

• Never use airbag system components from another vehicle.

• When electric welding, temporarily disable the airbag system, refer to

3.1 SERVICE PRECAUTIONS in Section 10B.

• Never expose the airbag system component parts directly to hot air (drying or baking the vehicle

after painting) or flames.

• WARNING/CAUTION labels are attached on each part of airbag system components. Follow the

instructions.

• After the vehicle is completely repaired, perform 2.4 AIRBAG DIAGNOSTIC SYSTEM CHECK in

Section 10B.

1.2 GENERAL PRECAUTIONS

The warnings and cautions below describe some of the general precautions that you should observe when

servicing a vehicle. These general precautions apply to many of the service procedures described in this

service information and will not necessarily be repeated with each procedure to which they apply.

WARNING:

• Whenever raising a vehicle for service, follow the instructions under 4. VEHICLE LIFTING POINTS

in this Section.

• When service work is required while the engine running, ensure the park ing brake is fully ON and

the transmission is in Neutral (manual transmission) or Park (automatic transmission). Keep

hands, hair, clothing, tools, etc. away from the fan and belts when the engine is running.

• When it is necessary to run the engine indoors, make sure that the exhaust gas is forced

outdoors.

• Do not perf orm service w ork in area s wh e re comb ust ible mat er ials can co me in contact wi th a hot

exhaust system.

• When working with toxic or flammable materials (such as gasoline and refrigerant), make sure that

the area the work is well-ventilated.

• To avoid burns, keep away from hot metal parts such as the radiator, exhaust manifold, tail pipe,

muffler, etc.

• New and used engine oil can be hazardous. Do not swallow oil or allow continuous contact with

the skin. Continuous contact with used engine oil has been found to cause [skin] cancer in

laborato ry animals. Brief contact with used oil may irr itate skin. To minimise your exposure, wear

a long-sleeve shirt and moisture-proof gloves when changing engine oil. If engine oil contacts

your skin, wash thoroughly with soap and water. Launder any clothing or rags if wet with oil.

• Keep oil filters away from children and pets. Recycle or properly dispose of used oil and filters

• Make sure the bonnet is fully closed and latched before driving. If it is not, it can open

unexpectedly during driving, obstructing your view and resulting in a collision.

• Before beginning any service work, cover the fenders,

seats and any other parts that are likely to get

scratched or stained during servicing. Also be aware

that what you wear (e.g. buttons) may cause damage

to the vehicle’s finish.

• When performing service of electrical parts that does

not require use of battery power, disconnect the

negative cable of the battery.

IMPORTANT: Whenever the battery is disconnected,

the audio unit is disabled and will require a personal

identification number (PIN) code to be entered for the

audio unit to be reinstated, refer to Section 8B,

2.1 AUDIO UNIT PIN CODE.

• When removing the battery, disconnect the negative

cable first and then the positive cable. When

reconnecting the battery, connect the positive cable

first and then the negative cable, and replace the

terminal cover.

• When removi ng parts that are to be re used, ke ep the m

arranged in an orderly manner so that they may be

reinstalled in the proper order and position.

• Whenever you use oil seals, gaskets, packing, O-rings,

locking washers, split pins, self-locking nuts, and

certain other parts as specified, replace with new ones.

Also, before installing new gaskets, packing, etc.,

remove any residual material from the mating surfaces.

• Make sure that all parts used in reassembly are

perfectly clean.

When use of a certain type of lubricant, bond or sealant

is specified, be sure to use the specified type,

e.g. (A ): Seala nt Three Bond No . 1207C

• Be sure to use special tools when instructed,

e.g. special tool (A) 09917-98221 (A) and

(B) 09916-58210 (B).

• When disconnecting vacuum hoses, attach a tag

describing the correct installation positions so that the

hoses can be reinstalled correctly.

• After servicing fuel, oil, coolant, vacuum, exhaust or

brake systems, check all lines related to the system for

leaks.

• For vehicles equipped with fuel injection systems,

never disconnect the fuel line between the fuel pump

and inje ctor witho ut firs t relea sing the f uel p ressure, or

fuel can be sprayed out under pressure.

• When performing a work that produces a heat

exceeding 80°C in the vicinity of the electrical parts,

remove the heat sensitive electrical part(s) beforehand.

• Use care no t to expose c onnec tors and el ectric al parts

to water.

• Always be carefu l not to handle elec tr ical parts (ECMs ,

relays, etc.) in a rough manner or drop them.

1.3 PRECAUTIONS FOR CATALYTIC CONVERTER

Use only unleaded fuel and ensure unburned fuel does not enter the catalytic converter as it can be damaged.

• Conduct a spark jump test only when necessary, make it as short as possible, and do not open the

throttle.

• Conduct engine compression checks within the shortest possible time.

• Avoid situations which can result in engine misfire (e.g. starting the engine when the fuel tank is nearly

empty.)

1.4 PRECAUTIONS FOR INSTALLING MOBILE COMMUNICATION EQUIPMENT

When in stalling mobi le com munication equipme nt s uch as C B radi o or cellula r-te lep hon e, ob ser v e the foll ow-

ing precautions. Failure to follow cautions may adversely affect electronic control system.

• Keep the antenna as far away as possible from the vehicle’s electronic control module (ECM).

• Keep the antenna feeder more than 20 cm away from the electronic control module and its wire har-

nesses.

• Do not run the antenna feeder parallel with other wire harnesses.

• Confirm that the antenna and feeder are correctly adjusted.

1.5 PRECAUTION IN SERVICING FULL-TIME 4WD VEHICLES

This full-time 4WD vehicle can not be converted to 2WD.

Observe the following cautions when servicing otherwise drivetrain damage and personal injury may result.

• Never perform any of the following types of service

work:

[A]: Testing with 2-wheel chassis dynamometer, speed-

ometer tester or brake tester.

[B]: Driving front wheels which are jacked up.

[C]: Towing under the condition where either front or

rear wheels can not rotate.

• If testing with 2-wheel chassis dynamometer, speed-

ometer tester or brake tester is required, make the

vehicle front wheel drive by removing the propeller

shaft.

• When using on-vehicle type wheel balancing equip-

ment (1), jack up all four wheels off the ground com-

pletely and support vehicle with safety stands (2).

Be careful of the other wheels, which will rotate at the

same time.

• This vehicle must only be towed under one of the fol-

lowing conditions:

•With all wheels on a flatbed truck, or

•With the front or rear wheels lifted and a dolly under

the other wheels.

1.6 PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICE

• When replacing a fuse, only use a fuse of the specified

capacity. Use of a fuse with a larger capacity will cause

a damage to the electrical parts and a fire.

• When disconnecting and connecting connectors, turn

ignition switch OFF or electronic parts may get dam-

aged.

• When disconnecting connectors, never pull the wiring

harness. Unlock the connector lock first and then pull

them apart by holding the connectors themselves.

• When connecting connectors, also hold connectors

and push them together until they lock securely (a click

is heard).

• When installing the wiring harness, fix it with clamps so

that no slack is left.

• When in stalling vehic le parts, take care not to int erfere

with wiring harness or any other part.

• To avoid damage to the harness, protect it from contact

against a part forming a sharp angle by winding tape or

the like aroun d it.

• Do not touch the electrica l termi nals of parts whic h use

microcomp uters (e.g. E CM, PCM, P/S controller, etc .).

The static electricity from your body can damage these

parts.

• Never connect a tester (voltmeter, ohmmeter, etc.) to

an electroni c contro l module whe n its connector i s dis-

connected as it may cause damage.

• Never con nect an ohmme ter to ele ctronic contr ol mod-

ule with its connec tor connecte d as it may caus e dam-

age to the electronic control module and sensors.

• Only use a spe cifie d voltme ter/oh mmeter to te st cir cuit

otherwise accurate measurements may not be

obtained or personal i njury may r esult. If no t specifie d,

use a voltmeter with high impedance (M Ω/V minimum)

or a digital type voltmeter.

• When taking measurements at electrical connectors

using a te ster probe, insert th e probe (2) fr om the wire

harness side (backside) of the connector (1).

• When con necting a me ter probe ( 2) from term inal side

of connector (1) because it can’t be connected from

harness side, use e xtra care not to bend the m ale ter-

minal or force its female terminal open.

In case of such connector as shown, connect the probe

as shown to avoid opening female terminal.

• When checking connection of terminals, check its male

half for bends and the female half for excessive open-

ing and both for locking (looseness), corrosion, dust,

etc.

• Before measuring voltage at each terminal, check to

make sure that battery voltage is 11 V or higher. Such

terminal voltage check at low battery voltage will lead

to erroneous diagnosis.

1.7 ELEC TRICAL CIRCUIT INSPECTION PROCEDURE

While there are various electrical circuit inspection meth-

ods, de scribed here i s a general metho d to check for ope n

and short circuit by using an ohmmeter and a voltmeter.

OPEN CIRCUIT CHECK

Possible causes for an open circuit are as follows. As the

cause is in the connector or terminal in many cases, they

need to be checked carefully.

• Loose co nne ction of conn ec tor.

• Poor contact of terminal (due to dirt, corrosion, poor

contact tension, entry of foreign object etc.).

• Wire harness being open.

When checking system circuits, including an electronic

control module such as the ECM, TCM, ABS con trol mod-

ule, etc., start with items which are easier to check.

1. Disconnect negative (–) cable from battery

2. Check ea ch co nne cto r at both en ds of the ci rcui t b ein g

checked for loose connection. Also check lock

conditio n of th e co nnector if equ ip ped wi th a con nec tor

lock.

3. Using a male tes t termina l (1), chec k both t erminal s of

the circuit being checked for contact tension of its

female terminal.

Check eac h termina l visual ly for poo r contact (p ossibly

caused by dirt, corrosion, entry of foreign object, etc.).

At the same time, check to make sure that each

terminal is locked in the connector fully.

4. Using continuity check or voltage check as described

in the following procedure, check the wire harness for

looseness of crimping (1), open circuit (2), thin

(broken) strands of wire (3) and poor connection with

its terminals. Locate abnormality, if any.

CONTINUITY CHECK

1. Measure the resistance between connector terminals

at both end s of the c ircui t be in g c hec ked (b etwe en A- 1

and C-1 a s sh own). If no c ont inu ity i s ind icate d ( infi nity

or over limit) , the cir cuit is op en betwee n termina ls A-1

and C-1.

2. Disconnect the connector included in the circuit (con-

nector-B) and measure resistance between terminals

A-1 and B-1.

If no cont inu ity is ind icate d, the ci rcui t is ope n b etwee n

terminals A-1 and B-1. If continuity is indicated, there is

an open circuit between terminals B-1 and C-1 or an

abnormality in connector B.

VOLTAGE CHECK

If voltage is sup pl ied to the ci rcui t bei ng chec k ed, a vo ltage

check can be used as a circuit check.

1. With all connectors connected and voltage applied to

the circuit being checked, measure the voltage

between each terminal and body ground.

a. If measurements were taken as shown and the

results were as listed below, the circuit is open

between terminals B-1 and A-1.

Voltage between

C-1 and body ground: Approx. 5 V

B-1 and body ground: Approx. 5 V

A-1 and body ground: 0 V

b. If the mea sured values were as listed below, there

is a resistance (abnormality) of such a level which

corresponds to the voltage drop in the circuit

between terminals A-1 and B-1.

Voltage between

C-1 and body ground: Approx. 5 V

B-1 and body ground: Approx. 5 V

A-1 and body ground: Approx. 3 V

SHORT CIRCUIT CHECK (WIRE HARNESS TO

GROUND)

1. Disconnect negative (–) cable at battery.

2. Disconnect the connectors at both ends of the circuit to

be checked.

NOTE: If the circuit to be checked is connected to other

parts (1), disconnect all connectors of those parts.

Otherwise, diagnosis will be miss-led.

3. Measure the resistance between the terminal at one

end of circuit (A-1 terminal) and body ground. If conti-

nuity is indicated, there is a short to ground between

terminals A-1 and C-1 of the circuit.

4. Disconnect the connector included in the circuit (con-

nector B) and measure resistance between A-1 and

body ground.

If continuity is indicated, the circuit is shorted to the

ground between terminals A-1 and B-1.

INTERMITTENTS AND POOR CONNECTIONS

Most intermittents are caused by faulty electrical connec-

tions or wiring, although a sticking relay or solenoid can

occas ionally be at fault. Whe n ch ecking for prope r connec-

tion, perform careful checks of suspect circuits for:

• Poor ma ting of conn ector halves, o r terminals no t fully

seated in the connector body (backed out).

• Dirt or corrosion on the terminals. The terminals must

be clean and free of any foreign material which could

impede proper terminal contact. Cleaning the terminal

with a sand paper or the like is prohibited.

• Damaged connector body, exposing the terminals to

moisture a nd dirt as we ll a s not ma inta ining pr op er te r-

minal orientation with the component or mating con-

nector.

• Improperly formed or damaged terminals.

Check each connector terminal in problem circuits

carefully to ensure good contact tension (1) by using

the correspo ndi ng mati ng termi nal .

If contact tension is not enough, reform it to increase

contact tension or replace.

Also check for bent terminals and poor alignment (2).

• Poor t erminal-to-wire connection.

Check each wire harness in problem circuits for

poor connection by shaking it by hand lightly. If any

abnormal condition is found, repair or replace.

• Wire insulation which is rubbed through can cause an

intermit tent sh ort as the bare ar ea touc he s othe r wirin g

or parts of the vehicle.

• Wiring broken inside the insulation could cause conti-

nuity check to show a good circuit, but if only 1 or 2

strands o f a m u lt i-s tra nd-ty pe wi r e a re i ntact, the re sis-

tance could be far too high.

If any abnormality is found, repair or replace.

2. IDENTIFICATION INFORMATION & PLATES

2.1 VEHICLE IDEN TIFICATION NUMBER

The vehicle identification number is stamped on the front

dash panel in the engine compartment.

2.2 ENGINE IDENTIFICATION NUMBER

The engine number is stamped on the cylinder block.

2.3 TRANSMISSION IDENTIFICATION NUMBER

The automatic transmission identification number is located

on transmission case.

Techline

2.4 SAFETY COMPLIA NCE PLATE

The s afety com pliance pl ate is a ffixed to th e left-hand side

of the dash panel in the engine compartment with rivets

and is stamped with the following information:

• Compliance plate approval number,

• Vehicle category code,

• Name appearing on compliance plate approval,

• Make and model,

• Seating capacity,

• Date of manufactur e,

• Vehicle identification number (VIN).

2.5 BODY & OPTION IDENTIFICATION PLATE

The body and option identification plate is affixed to the

right-hand side of the dash panel in the engine compart-

ment with riv ets and is stamped with the followin g informa-

tion:

• Body Type,

• Vehicle identification number (VIN),

• Engine model,

• Paint / Trim number,

• Date of manufactur e.

2.6 TAG PLATE

The tag plate is affixed to the left-hand inner fender panel in

the engine compartment with rivets and is stamped with

vehicle body information.

3. WARNING, CAUTION AND INFORMATION LABELS

The figure below shows the main labels that are attached to vehicle component parts.

When servicing and handling parts, refer to W ARNING/CAUTION instructions printed on labels.

If any WARNING/CAUTION label is found stained or damaged, clean or replace it as necessary.

Legend

1. Airbag label on back side of engine hood 4. Engine cooling fan label

2. Airbag label on sun visor 5. Steering shaft joint cover label

3. Radiator cap label

1. Airbag label on driver airbag (inflator) module 4. Airbag label on SDM

2. Airbag label on combination switch and contact coil 5. Pretensioner label on seat belt retractor

3. Airbag label on passenger airbag (inflator) module 6. Child seat label

4. VEHICLE LIFTING POINTS

USING A HOIST

WARNING:

• Before hoisting the vehicle, consider the vehicle balance during the service operations being

performaed. The balance while on the hoist may change depending on the parts to be removed.

• Before lifting the vehicle, check that each end of the hoist arms are not in contact with brake

pipes, fuel pipes, brackets or any other part.

• Locate the hoist pads as shown. Lift up the vehicle until the tyres are slightly off the ground and

make sure that the vehicle will not fall by moving vehicle body both ways. Work can be started

only after this confirmation.

• Make absolutely sure to lock the hoist after vehicle is raised.

Legend

1. Veh icle fr ont 3. Floo r jack positio n

2. Support position for hoist pads and safety stand 4. Embossed-mark

USING A FLOOR JACK

WARNING: If the vehicle is to be jacked-up only at the

front or rea r end, block the wheels on grou nd to ensure

safety.

Aft er the v ehicle is jacked-up, suppor t it on stands. It is

extremely dangerous to do any work on the vehicle

raised on a jack alone.

CAUTION: Never place the jack against suspension

parts (i.e. stabiliser, etc.) or vehicle floor.

When ra ising fron t or rear o f the vehicl e off the floor with a

jack, loc at e the jac k agains t the fr ont ja ck in g bra cket ( 1), or

the rear axle housing (2).

When per forming serv ice with the vehic le jacked up, pl ace

safety stands (1) under the vehicle body at [A] the front or

[B] the r ear at the embo ss ed mar k ( 2), so tha t it is s ec urely

suppor ted. Check t o ensur e that the vehicle does not slide

on the safety stands and the vehicle is held stable.

5. ABBREVIATIONS AND SYMBOL S USED IN THIS MANUAL

ABBREVIATIONS

ABS Anti-lock Brake System

EFE Heater Early Fuel Evaporation Heater

(Positive T emperature Coefficient,

PTC Heater)

ATDC After Top Dead Centre

API American Petroleum Institute

ATF Automatic Transmission Fluid EPS Electronic Power Steering

ALR Automatic Locking Retractor EVAP Evaporative Emission

AC Alternating Current EVAP Canister Evaporative Emission Canister

(Charcoal Canister)

A/T Automatic Transmission

4WD 4 Wheel Drive

A/C Air Conditioni ng

GEN Generator

ABDC After Bottom Dead Centre GND Ground

A/F Air Fuel Mixture Ratio

HC Hydrocarbons

A-ELR Automatic-Emergency Locking

Retractor HO2S Heated Oxygen Sensor

IAC Valve Idle Air Control Valve (Idle Speed

Control Solenoid Valve ISC

Solenoid Valve)

B+ Battery Positive Voltage

BTDC Before Top Dead Centre

BBDC Before Bottom Dead Centre IAT Sensor Intake Air Temperature Sensor

(Air temperature Sensor, ATS)

CKT Circuit

CKP sensor Crankshaft Position Sensor ICM Immobiliser Control Module

CMP sensor Camshaft Position Sensor IG Ignition

CO Carbon Monoxide ISC Actuator Idle Speed Control Actuator

CPP switch Clutch Pedal Position Switch

(Clutch Switch, Clutch Start

Switch)

LH Left Hand

LSPV Load Sen sing Prop or tio nin g

Valve

CPU Central Processing Unit

MAF Sensor Mass Air Flow Sensor (Air Flow

Sensor, AFS, Air Flow Meter,

AFM)

CRS Child Res traint System

DC Direct Current

DLC Data Link Connector (Assembly

Line Diag. Link, ALDL, Serial Data

Link, SDL)

MAP Sensor Manifold Absolute Pressure

Sensor (Pressure Sensor, PS)

Max Maximum

DOHC Double Over Head Camshaft MFI Multiport Fuel Injection

(Multipoi nt Fu el Injec tio n)

DOJ Double Offset Joint

DRL Daytime Running Light MIN Minimum

DTC Diagnostic Trouble Code MIL Malfunction Indicator Lamp

EBCM Electronic Brake Control Module,

ABS Control Module M/T Manual Transmis si on

EBD Electronic Brake Force

Distribution

NG No Good

ECM Engine Control Module NOx Nitrogen Oxides

ECT sensor Engine Coolant Temperature

Sensor (Water Temp. Sensor,

WTS)

OBD On-Board Diagnostic System

(Self-Diagnosis Function)

O/D Overdrive

EGR Exhaust Gas Recirculation OHC Over Head Camshaft

EGRT sensor EGR Temperature Sensor

(Recirculated Exhaust Gas Temp.

Sensor, REGTS)

O2S Oxygen Sensor

PNP Park/Neutral Position

P/S Power Steering

PSP Switch Power Steering Pressure Switch

(P/S Pres su re Switc h)

PCM P owe rt rain Cont ro l Modu le

PCV Positive Crankcase Ventilation

RH Right Hand

SAE Society of Automotive Engineers

SDM S en si ng and Diag nos ti c Mod ule

(Airbag control module)

SFI Sequential Multiport Fuel Injection

SOHC Single over Head Camshaft

TBI Throttle Body Fuel Injection

(Single-Point Fuel Injection, SPI)

TCC Torque Converter Clutch

TCM Tran sm ission Control Modu le

(A/T Control Module)

TP Sensor Throttle Position Sensor

TVV Thermal Vacuum Valve (Thermal

Vacuum Switching Valve, TVSV,

Bimetal Vacuum Switching Valve,

BVSV)

TWC Three Way Catalytic Converter

(Three Way Catalyst)

2WD 2 Wheel Drive

VIN Vehicle Identification Number

VSS Vehicle Speed Sensor

WU-OC Warm Up Oxidation Catalytic

Converter

WU-TWC Warm Up Three Way Catalytic

Converter

SYMBOLS

WIRE COLOUR SYMBOLS

There are two type of coloured wire used in this vehicle.

One is single-coloured wire and the other is dual-coloured

(traced) wire.

The si ngle-colour ed wire uses only on e colour symb ol (i.e.

GRN).

The dual-coloured wire uses two colour symbols (i.e. GRN/

YEL). The first symbol represents the base colour of the

wire (GRN in the figure) and the sec on d symbo l repr es ents

the colour of the trace (YEL in the figure).

SYMBOL DEFINITION SYMBOL DEFINITION

Tightening torque Apply Three Bond No. 1207C

Apply oil (engine, transmission,

transfer, differential) Apply Three Bond No. 1216B

Apply fluid (brake, power steering or

automatic transmission fluid) Apply Sealing Compound 366E

Lithium Grease Apply THREAD LOCK 1322

Lithium Grease Apply THREAD LOCK 1333B

Lithium Grease Apply THREAD LOCK 1342

Lithium Grease

Lithium Grease Do not reuse

Apply Three Bond No. 1215 Note on reassembly

Symbol Wire Colour Symbol Wire Colour

B BLK Black O, Or ORN Orange

BlBLUBlue RREDRed

Br BRN Brown W WHT White

GGRN Green Y YEL Yellow

Gr GRY Gray P PNK Pink

Lbl LT BLU Light blue V PPL Violet

Lg LT GRN Light green

6. FASTENER INFORMATION

6.1 METR IC FASTENERS

Most of th e fasten ers u sed for thi s vehic le are metri c. Whe n replac ing any fastener s, it is most impo rtant that

replacement fasteners be the correct diameter, thread pitch and strength.

6.2 FASTENER STRENGTH IDENTIFICATION

Most co mmonly us ed metric fas tener streng th property c lasses are 4T, 6.8, 7T, 8.8 and rad ial line. The cl ass

identification is embossed on the head of each bolt. Some metric nuts will be marked with punched with a 6 or

8 strength identification mark on the nut face (1). The figure shows the different strength markings.

When replacing metric fasteners, be careful to use bolts and nuts of the same strength or greater than the

original fasteners (the same number marking or higher). It is also important to select replacement fasteners of

the correct diameter and thread pitch.

6.3 STANDARD TIGHTENING TORQUE

Each fas tener should be tightened to the tor que specifi ed in each Secti on of this manua l. If no description or

specification is provided, refer to the following tightening torque chart for the applicable torque for each fas-

tener. When a fastener of greater strength than the original one is used, use the torque specified for the origi-

nal fastener.

NOTE:

• For the flanged bolt, flanged nut and self-lock nut of 4T and 7T strength, add 10% to the tightening torque

given in the chart below.

• The chart below is applicable only where the fastened parts are made of steel or light alloy.

TIGHTENING TORQUE CHART

Thread Diameter (Nominal Diameter) (mm)

4 5 6 8 10 12 14 16 18

Strength

Equivalent of 4T fastener (Nm)

1.5 3.0 5.5 13 29 45 65 105 160

Equivalent of 6.8 fastener without

flange (Nm)

2.4 4.7 8.4 20 42 80 125 193 280

Equivalent of 6.8 fastener with flange

(Nm)

2.4 4.9 8.8 21 44 84 133 203 298

Equivalent of 7T fastener (Nm)

2.3 4.5 10 23 50 85 135 210 240

Equivalent of 8.8 fastener without

flange (Nm)

3.1 6.3 11 27 56 105 168 258 373

Equivalent of 8.8 fastener with flange

(Nm)

3.2 6.5 12 29 59 113 175 270 395

7. CONSOLIDATED TOOL LIST

The following consolidated tool list table lists the special service tools required for use on the Holden Cruze

(YGM) vehicle. The tools are listed in numerical order and include the SPX equivalent part number (if avail-

able), an illustrated reference and the tools classification (category).

The tools are classified in the following Categories:

Mandatory

Desirable

Available

Unique

CONSOLIDATED TOOL LIST TABLE

Tool No. Spx

Tool No. Description Illustration Section

Number /usage Category

09900-00411 HEXAGON

WRENCH

SOCKET

3D - FRONT

SUSPENSION

• Strut nut loosening/

removal/installation

Available

09900-00414 HEXAGON

WRENCH BIT 6

3D - FRONT

SUSPENSION

• Strut nut loosening/

removal/installation

Unique

09900-06106 SNAP RING

REMOVER 5 – BRAKES

• Mast er cylinder sleeve

cup removal

Available

09900-06107

SNAP RING

PLIERS

(OPEN

TYPE)

1B - AIR CONDITIONING

• Compressor clutch

circlips removal/

installation

Available

4A – FRONT DRIVE

SHAFT

• Cage circlip removal/

installation

7A - MANUAL

TRANSAXLE

• Fifth gear circlip

removal/installation

09900-20605 DIAL CALIPER

GAUGE 7B - AUTOMATIC

TRANSAXLE

• Oil pump stator shaft

bush bore measurement

• Oil pump stator body

bush bore measurement

• Transaxle rear cover

bush bore measurement

Available

09900-20607 DIAL GAUGE 5 – BRAKES

• Front disc deflection

measurement

Available

7A - MANUAL

TRANSAXLE

• Differential gear thrust

play measurement

7B - AUTOMAT IC

TRANSAXLE

• Differential gear thrust

play measurement

•1

and reverse brake

piston stroke

measurement

• Input shaft thrust play

• Direct clutch piston

stroke measurement

• Reverse clutch piston

stroke measurement

• Forward clutch piston

stroke measurement

7F - REAR

DIFFERENTIAL

• Differential gear thrust

play measurement

• Drive bevel gear

backlash mea surem ent

09900-20701 MAGNETIC

STAND 5 – BRAKES

• Front disc deflection

measurement

Available

7A - MANUAL

TRANSAXLE

• Differential gear thrust

play measurement

7B - AUTOMAT IC

TRANSAXLE

• Differential gear thrust

play measurement

•1

and reverse brake

piston stroke

measurement

• Input shaft thrust play

• Direct clutch piston

stroke measurement

• Reverse clutch piston

stroke measurement

• Forward clutch piston

stroke measurement

7F - REAR

DIFFERENTIAL

Diff erential gear thrust pl ay

measurement

Drive bevel gear backlash

measurement

09911-97720 OIL SEAL GUIDE 6A1 - ENGINE

MECHANICAL (M15)

• Rear oil seal housing

bolts installation

Unique

09911-97820 OIL SEAL

INSTALLER 6A1 - ENGINE MECHANI-

CAL (M15)

• Rear oil seal installation

Unique

Tool No. Spx

Tool No. Description Illustration Section

Number /usage Category

09912-57610 CHECKING TOOL

PLATE 6 - ENGINE GENERAL

INFORMATION &

DIAGNOSIS

• Diagnosis

Desirable

6E1 - ENGINE AND EMIS-

SION CONTROL SYSTEM

• Fuel injector diagnosis

09912-58421 CHECKING TOOL

SET 6 - ENGINE GENERAL

INFORMATION &

DIAGNOSIS

• Diagnosis

Desirable

6E1 - ENGINE AND EMIS-

SION CONTROL SYSTEM

• Fuel injector diagnosis

09912-58431 As an

alternative

use hose

SD28057

(released for

‘V’ and ‘W’

car) w i th the

quick connect

release tools

removed

PRESSURE HOSE 6 - ENGINE GENERAL

INFORMATION &

DIAGNOSIS

• Fuel press ure test

Mandatory

6E1 - ENGINE AND EMIS-

SION CONTROL SYSTEM

• Fuel press ure inspection

09912-58441 As an

alternative

use AU338 or

SD 28018

PRESSURE

GAUGE 6 - ENGINE GENERAL

INFORMATION &

DIAGNOSIS

• Fuel press ure test

Mandatory

6E1 - ENGINE AND EMIS-

SION CONTROL SYSTEM

• Fuel press ure inspection

09912-58490 Refer to

09912-58431 3-WAY JOINT &

HOSE 6 - ENGINE GENE RAL

INFORMATION &

DIAGNOSIS

• Fuel press ure test

Mandatory

6E1 - ENGINE AND EMIS-

SION CONTROL SYSTEM

• Fuel press ure inspection

09913-50121 OIL SEAL

REMOVER 3B - MANUAL RACK AND

PINION

• Pinion bearing plug oil

seal removal

Unique

3E - REAR SUSPENSION

• Rear axle shaft oil seal

removal

7B - AUTOMAT IC

TRANSAXLE

• Oil pump body oil seal

removal

7D – TRANSFER

• Pinion shaft oil seal

removal

7F - REAR

DIFFERENTIAL

• Differential carrier oil

seal removal

Tool No. Spx

Tool No. Description Illustration Section

Number /usage Category

09913-60910 E2M49 OR

21M16 BEARING/GEAR

PULLER 7A - MANUAL

TRANSAXLE

• Differential assembly

right/left bearing removal

Unique

7D – TRANSFER

• Flange removal

7F - REAR

DIFFERENTIAL

• Differential side bearings

removal

09913-61510 E21M16 BEARING PULLER 7B - AUTOMATIC

TRANSAXLE

• Countershaft RH

bearing removal

Unique

09913-65135 BEARING PULLER 7D – TRANSFER

• Left side driven gear

bearing removal

• Driven gear assem bly

bevel gear removal

Unique

7F - REAR

DIFFERENTIAL

• Companion flange drive

bevel pinion removal

09913-65210 7310 OR

7311 TIE-ROD END

REMOVER 3B - MANUAL RACK AND

PINION

• Tie rod end removal

Desirable

3D - FRONT

SUSPENSION

• Front tie rod end

removal

4A - FRONT DRI VE

SHAFT

• Front tie rod end

removal

09913-65810 BEARING PULLER 3D - FRONT

SUSPENSION

• Front wheel bearing

outside inner race

removal

Unique

09913-70123 BEARING

INSTALLER 7B - AUTOMATIC

TRANSAXLE

• Differential left/right side

bearing installation

Unique

09913-75510 BEARING

INSTALLER 3D - FRONT

SUSPENSION

• Front wheel bearing

installation

Unique

Tool No. Spx

Tool No. Description Illustration Section

Number /usage Category

09913-75510 BEARING

INSTALLER 7A - MANUAL

TRANSAXLE

• Differential side oil seal

installation

• Differential sensor rotor

installation

Unique

09913-75520 BEARING

INSTALLER 3D - FRONT

SUSPENSION

• Front wheel bearing

removal/installation

Unique

6A1 - ENGINE

MECHANICAL (M15)

• Timing chain cover oil

seal

7B - AUTOMAT IC

TRANSAXLE

• Countershaft right hand

bearing cup installation

09913-75810 BEARING

INSTALLER 3D - FRONT

SUSPENSION

• Front wheel bearing

outside inner race

removal/installation

Unique

7D – TRANSFER

• Pinion shaft bearing

installation

7F - REAR

DIFFERENTIAL

Differential carrier oil seal

installation

09913-75821 BEARING

INSTALL ER

HANDLE

7B - AUTOMAT IC

TRANSAXLE

• Countershaft left hand

bearing cup and shim

installation

Unique

7D – TRANSFER

• Reduct ion drive gear oil

seals removal/

installation

• Pinion shaft bearing

outer races (front and

rear) installation

09913-80113 BEAR ING

INSTALLER 7A - MANUAL

TRANSAXLE

• Input drive shaft bearing

installation

•3

gear and spacer

installation

Unique

09913-84510 BEARING

INSTALLER 7A - MANUAL

TRANSAXLE

• High speed sleeve and

hub installation

•5

gear countershaft

bearing cup installation

Unique

7B - AUTOMAT IC

TRANSAXLE

• Planetary ring gear

subassembly

• Countershaft reduction

driven gear installation

• Countershaft left hand

bearing installation

Tool No. Spx

Tool No. Description Illustration Section

Number /usage Category

09913-85210 BEARING

INSTALLER 7B - AUTOMATIC

TRANSAXLE

• Oil pump body seal

installation

Unique

09915-64510-

001 COMPRESSION

GAUGE 6A1 - ENGINE

MECHANICAL (M15)

• Engine compression

check

Available

09915-64510-

002 CONNECTOR 6A1 - ENGINE

MECHANICAL (M15)

• Engine compression

check

Available

09915-64530 HOSE 6A1 - ENGINE

MECHANICAL (M15)

• Engine compression

check

Available

09915-67010 ATTA CHME NT 6A1 - ENGINE

MECHANICAL (M15)

• Engine compression

check

Available

09915-67310 J23738-A VACUUM GAUGE 6A1 - ENGINE

MECHANICAL (M15)

• Engine vacuum check

Available

09915-77310 OIL PRESSURE

GAUGE 6A1 - ENGINE

MECHANICAL (M15)

• Oil pressure check

Available

09915-78211 OIL PRESSURE

GAUGE

ATTACHMENT

6A1 - ENGINE

MECHANICAL (M15)

• Oil pressure check

Desirable

Tool No. Spx

Tool No. Description Illustration Section

Number /usage Category

09916-14510 VALV E LIFT ER 6A1 - ENGINE

MECHANICAL (M15)

• Valve spring

compression

Available

09916-14910 VALV E LIFTER

ATTACHMENT 6A1 - ENGINE

MECHANICAL (M15)

• Valve spring

compression

Available

09916-34542 REAMER HANDL E 6A1 - ENGINE

MECHANICAL (M15)

• Valve guide reaming

Unique

09916-34550 REAMER (5.5 mm ) 6A1 - ENGINE

MECHANICAL (M15)

• Valve guide bore

reaming

Unique

09916-37320 REAMER

(10.5mm) 6A1 - ENGINE

MECHANICAL (M15)

• Valve guide reaming

Unique

09916-44910 VALV E GU IDE

REMOVER 6A1 - ENGINE

MECHANICAL (M15)

• Valve guide removal

Unique

09916-56011 VALVE GUIDE

INSTALLER 6A1 - ENGINE

MECHANICAL (M15)

• Valve guide installation

Unique

Tool No. Spx

Tool No. Description Illustration Section

Number /usage Category

09916-58210 VALV E GU IDE

INSTALL ER

HANDLE

6A1 - ENGINE

MECHANICAL (M15)

• Valve guide installation

• Valve stem seal

installation

Unique

09916-67020 As alternative

use

J42689AUS

previously

released by

IGM for Light

Commercial

vehicle use

TAPPET HOLDER 6A1 - ENGINE

MECHANICAL (M15)

• Tappet retainer

Desirable

09916-77310 E 191 P ISTON RING

COMPRESSOR 6A1 - ENGINE

MECHANICAL (M15)

• Piston ring installation

Available

09916-84511 FORCEPS 6A1 - ENGINE

MECHANICAL (M15)

• Valve cotter removal

Available

09917-47010 J23738-A VACUUM PUMP

GAUGE 6 - ENGINE GENERAL

INFORMATION &

DIAGNOSIS

• Diagnosis

Mandatory -

previously

released

6C - ENGINE F UEL

09917-68221 CAMSHAFT LOCK

HOLDER 6A1 - ENGINE

MECHANICAL (M15)

• Crankshaft pulley

removal/installation

Desirable

09917-98221 VALVE STEM

SEAL INSTALLER 6A1 - ENGINE

MECHANICAL (M15)

• Valve stem seal

installation

Desirable

09919-47020 7370 OR

7371 QUICK JOINT

REMOVER 6C – ENGINE FUEL

• Fuel line joint

disconnection

Mandatory

Tool No. Spx

Tool No. Description Illustration Section

Number /usage Category

09921-20200 PINION BEARING

REMOVER 3B - MANUAL RACK AND

PINION

• Gear case pinion

bearing removal

Unique

09921-26020 BEARING

REMOVER 7C – CLUTCH

• Input shaf t bearing

removal

Unique

09921-57810 BEARING

REMOVER 3E – REAR SUS PE N SI ON

• Rear brake back plate

and wheel bearing

spacer

Unique

09922-46010 BUSH REMOVE R 7C – CLUTCH

• Clutch release sys tem

No. 2 bush removal/

installation

Unique

09922-76120 DUMMY SHAFT 7F - REAR

DIFFERENTIAL

• Differential carrier and

drive bevel pinion

adjustment

Unique

09922-76140 BEVEL PINION

SHAFT 7D – TRANSFER

• Transfer output retainer

assembly adjustment

Unique

7F - REAR

DIFFERENTIAL

• Differential carrier and

drive bevel pinion

adjustment

09922-76150 BEVEL PINION

NUT 7D – TRANSFER

• Transfer output retainer

assembly adjustment

Unique

7F - REAR

DIFFERENTIAL

• Differential carrier and

drive bevel pinion

adjustment

09922-76230 BEVEL GEAR

DUMMY 7F - REAR

DIFFERENTIAL

• Differential carrier and

drive bevel pinion

adjustment

Unique

09922-76320 REAR COLLAR 7F - REAR

DIFFERENTIAL

• Differential carrier and

drive bevel pinion

adjustment

Unique

Tool No. Spx

Tool No. Description Illustration Section

Number /usage Category

09922-76340 REAR COLLAR 7D – TRANSFER

• Transfer output retainer

assembly adjustment

Unique

7F - REAR

DIFFERENTIAL

• Differential carrier and

drive bevel pinion

adjustment

09922-76410 FRONT COLLAR 7F - REAR

DIFFERENTIAL

• Differential carrier and

drive bevel pinion

adjustment

Unique

09922-76430 FRONT COLLAR 7D – TRANSFER

• Transfer output retainer

assembly adjustment

Unique

09922-76510 GAUGE BLOCK 7F - REAR

DIFFERENTIAL

• Differential carrier and

drive bevel pinion

adjustment

Unique

09922-85811 SPRING PIN

REMOVER

(4.5mm)

7A - MANUAL

TRANSAXLE

•5

gear shift fork spring

pin removal/installation

•5

and reverse gear

shift cam spring pin

removal

•5

and reverse gear

shift guide shaft pin

removal

• Differential pinion shaft

pin removal

Unique

7F - REAR

DIFFERENTIAL

• Differential side pinion

shaft spring pin removal/

installation

09923-36320 CLUTCH CENTRE

GUIDE 7C – CLUTCH

• Clutch disc – flywheel

alignment

Unique

09923-46020 JOINT PIPE 7C – CLUTCH

• Clutch release sys tem

No. 1 bush removal

Unique

Tool No. Spx

Tool No. Description Illustration Section

Number /usage Category

09923-46030 JOINT PIPE 7C – CLUTCH

• Clutch release sys tem

No. 1 bush installation

Unique

09923-73210 BEARING

REMOVER 1B – AIR CONDITIONING

• Compres sor clutc h front

cylinder head lip seal

removal

Unique

09923-74510 BEARING

REMOVER 7A - MANUAL

TRANSAXLE

• Right input shaft oil seal

removal

Unique

09923-78210 BEARING

INSTALLER 7A - MANUAL

TRANSAXLE

• Countershaft right

bearing cone installation

• Countershaft low speed

sleeve and hub

assembly installat ion

•3

gear and spacer

installation

• Countershaft left bearing

cone installation

Unique

7B - AUTOMAT IC

TRANSAXLE

• Planetary ring gear

subassembly

09924-17811 FLYWHEEL

HOLDER 6A1 - ENGINE

MECHANICAL (M15)

• Holds flywheel

stationary (clutch cover

bolts removal)

Desirable

7C – CLUTCH

• Holds flywheel

stationary (clutch cover

bolts removal)

• Flywhe el installation

09924-57610 GEAR HOLDER 7D – TRANSFER

• Bevel gear retainer

(bevel gear nut removal/

installation)

Unique

Tool No. Spx

Tool No. Description Illustration Section

Number /usage Category

09924-74510 BEARING

INSTALL ER

HANDLE

3E – REAR SUSPE NSI O N

• Rear axle shaft oil seal

installation

Unique

7A - MANUAL

TRANSAXLE

• Countershaft right

bearing cup

7B - AUTOMAT IC

TRANSAXLE

• Differential left/right side

oil seal installation

• Differential side left/right

hand bearing cup

installation

7D – TRANSFER

• Bevel pinion oil seal

installation

7F - REAR

DIFFERENTIAL

• Bevel pinion bearing

outer races installation

09924-84510-

002 BEARING

INSTALLER 7B - AUTOMATIC

TRANSAXLE

• Countershaft left hand

bearing cup and shim

installation

Unique

09924-84510-

005 BEARING

INSTALL ER

ATTACHMENT

7D – TRANSFER

• Reduct ion drive gear oil

seals removal/

installation

• Pinion shaft bearing

outer races (front and

rear) installation

Unique

09925-15410 OIL SEAL

INSTALLER 7D – TRANSFER

• Left/right case oil seal

installation

Unique

09925-18011 BEARING

INSTALLER 7A - MANUAL

TRANSAXLE

• Countershaft low speed

sleeve and hub

assembly

Unique

09925-37811-

001 OIL PRESSURE

GAUGE 7B - AUTOMATIC

TRANSAXLE

• Fluid pressure check

Desirable

09925-58210 OIL SEAL

INSTALLER 7D – TRANSFER

• Driven gear right side

bearing removal

Unique

Tool No. Spx

Tool No. Description Illustration Section

Number /usage Category

09925-68210 BEARING OU TER

RACE INSTALLER 7A - MANUAL

TRANSAXLE

• Countershaft right

bearing cup

Unique

09925-78210 SPRING PIN

REMOVER (6mm) 7A - MANUAL

TRANSAXLE

• Gear shift and select

lever spring pin removal

Unique

09925-88210 BEARING PULLER

ATTACHMENT 7A - MANUAL

TRANSAXLE

• Differential assembly

right/left bearing removal

Unique

7B - AUTOMAT IC

TRANSAXLE

• Countershaft reduction

driven gear installation

• Countershaft left hand

bearing installation

7F - REAR

DIFFERENTIAL

• Differential side bearings

removal

09925-98210 BEARING

INSTALLER 3B - MANUAL RACK AND

PINION

• Pinion bearing plug oil

seal installation

Unique

7B - AUTOMAT IC

TRANSAXLE

• Manual shif t shaft oil

seal installation

7C – CLUTCH

• Input shaf t bearing

installation

7F - REAR

DIFFERENTIAL

• Bevel pinion bearing

outer races installation

09925-98221 BEARING

INSTALLER 7A - MANUAL

TRANSAXLE

• Countershaft left bearing

cone installation

• Input shaf t left bearing

Unique

7B - AUTOMAT IC

TRANSAXLE

• Countershaft left hand

bearing and reduction

gear removal

7C – CLUTCH

• Clutch release shaft seal

installation

09926-27610 OIL SEAL

INSTALLER 7D – TRANSFER

• Bevel pinion oil seal

installation

Unique

Tool No. Spx

Tool No. Description Illustration Section

Number /usage Category

09926-37610 BEARING

INSTALLER 7B - AUTOMATIC

TRANSAXLE

• Differential left/right

hand side bearing

removal

Unique

09926-37610-

001 BEARING PULLER 7B - AUTOMA TIC

TRANSAXLE

• Differential left/right

hand side bearing

removal (part of 09926-

37610)

Unique

09926-37610-

002 BEARING PULLER

ATTACHMENT 7B - AUTOMATIC

TRANSAXLE

• Differential left/right

hand side bearing

removal (part of 09926-

37610)

Unique

09926-37610-

003 BEARING

REMOVER

ATTACHMENT

7B - AUTOMAT IC

TRANSAXLE

• Differential left/right

hand side bearing

removal (part of 09926-

37610)

Unique

09926-58010 BEARING PULLER

ATTACHMENT 3D - FRONT

SUSPENSION

• Front wheel bearing

outside inner race

removal

Unique

6A1 - ENGINE

MECHANICAL (M15)

• Crankshaft pulley

removal

7B - AUTOMAT IC

TRANSAXLE

• Countershaft RH

bearing removal

09926-68310 BEARING

INSTALLER 3D - FRONT

SUSPENSION

• Front wheel bearing

installation

Unique

09926-96030 CLUTCH SPRING

COMPRESSOR 7B - AUTOMAT IC

TRANSAXLE

• Transaxle rear cover

snap ring removal

• O/D and 2

coast brake

return spring

subassembly installation

Unique

09926-96050 BRAKE PI STON

COMPRESSOR 7B - AUTOMAT IC

TRANSAXLE

•2

brake piston snap

ring removal/inst allation

Unique

Tool No. Spx

Tool No. Description Illustration Section

Number /usage Category

09926-97610 SPRING

COMPRESSOR 7B - AUTOMAT IC

TRANSAXLE

• Forward and reverse

clutch assembly

balancer snap ring

removal/installation

Unique

09926-97620 SPRING

COMPRESSOR 7B - AUTOMAT IC

TRANSAXLE

•1

and reverse brake

piston return spring

compression (snap ring

removal/installation)

Unique

09926-98310 CLUTCH SPRING

COMPRESSOR 7B - AUTOMAT IC

TRANSAXLE

• Direct clutch assembly

input shaft snap ring

removal

Unique

09927-18411 UNIVERSAL

PULLER 3E - REAR SUSPENSI O N

• Rear brake back plate

and wheel bearing

spacer

Unique

09927-76010 GEAR HOLDER 7A - MANUAL

TRANSAXLE

• Counter shaft and input

shaft holder

(countershaft nut

removal/installation)

Unique

09928-06050 DIFFERENTIAL

PRELOAD

ADAPTER

7B - AUTOMAT IC

TRANSAXLE

• Differential side bearing

preload measurement

• Countershaft bearing

preload measurement

Unique

09930-30102 SLIDING SHAFT 3B - MANUAL RACK AND

PINION

• Gear case pinion

bearing removal

Unique

09930-30104 SLIDING SHAFT 7A - MANUAL

TRANSAXLE

• Right input shaft oil seal

removal

Unique

7C – CLUTCH

• Clutch release sys tem

No. 1 bush removal/

installation

Tool No. Spx

Tool No. Description Illustration Section

Number /usage Category

09930-40113 ROTOR HOLDER 7D – TRANSFER

• Transfer output retainer

assembly flange retainer

(flange nut removal)

Unique

7F - REAR

DIFFERENTIAL

• Companion flange

retainer (drive bevel

pinion nut removal/

installation

09930-88530 INJECTOR TEST

LEAD 6 – ENGINE GENERAL

INFORMATION &

DIAGNOSIS

• Diagnosis

Desirable

6E1 – ENGINE AND

EMISSION CONTROL

SYSTEM

• Fuel injector diagnosis

09932-75010 AIRBAG DRIVER /

PASSENGER

LOAD TOOL

10B - AIRBAG SY ST EM

• Safe ty (to prevent

accidental deployment)

and diagnosis

Mandatory

09932-75030 J41367 AIRBAG

DEPLOYMENT

HARNESS

10B - AIRBAG SY ST EM

• Airbag/seat belt

pretensioner activation

Unique

09932-75041 J39401-A PASSENGER

AIRBAG MODULE

DEPLOYMENT

FIXTURE

10B - AIRBAG SY ST EM

• Airbag deployment Unique

09932-75410 SPARE

CONNECTOR

(FOR ADAPTOR

CABLE 09932-

78331)

10B – AIRBAG SYSTEM

• Spares connectors for

adaptor cable 09932-

78331

Unique

09932-76010 J35616-A CONNECTOR

TEST ADAPTOR

SET

10B - AIRBAG SY ST EM

• Diagn osis – checking or

probing terminals

Items included

in No. 2 -

Mandatory

09932-78310 ADAPTER CABLE 10B - AIRBAG SYSTEM

• Diagnosis Mandatory

Tool No. Spx

Tool No. Description Illustration Section

Number /usage Category

09932-78331 ADAPTER CABLE 10B - AIRBAG SYSTEM

• Airbag deployment Unique

09932-78340 ADAPTER CABLE 10B - AIRBAG SYSTEM

• Diagnosis Mandatory

09940-51710 BEARING

INSTALLER 7F - REAR

DIFFERENTIAL

• Rear bearing installation

Unique

09940-53111 BEARING

INSTALLER 7A - MANUAL

TRANSAXLE

• Countershaft low speed

sleeve and hub

assembly installat ion

Unique

09940-54910 SENSOR ROTOR

INSTALLER 7A - AUTOMATIC

TRANSAXLE

• Differential sensor rotor

installation

Unique

09940-71431 6072 OR7294 SPRING

COMPRESSOR 3D - FRONT

SUSPENSION

• Front str ut remova l

Available

09941-34513-

004 BEARING

INSTALLER 7F - REAR

DIFFERENTIAL

• Bevel pinion bearing

outer races installation

Unique

09941-54911 BEARING OU TE R

RACE REMOVER 7D – TRANSFER

• Driven gear bearing

outer race (left and right

case) remo val

Unique

Tool No. Spx

Tool No. Description Illustration Section

Number /usage Category

09941-58020 SOCKET

WRENCH (40mm) 7D – TRANSFER

• Bevel gear retainer

(bevel gear nut removal/

installation)

Unique

09941-64511 BEARING

REMOVER 7A - MANUAL

TRANSAXLE

• Countershaft right

bearing cup removal

Unique

09942-15510 SLIDING

HAMMER 3D - FRONT

SUSPENSION

• Front hub removal

Available

09942-15511 SLIDING

HAMMER 3E - REAR SUSPENSI O N

• Rear brake back plate

and axle shaft removal

Available

7B - AUTOMAT IC

TRANSAXLE

• Countershaft left/right

hand bearing cup

removal

• Differential side left/right

hand bearing cup

removal

09943-17912 FRONT

WHEEL HUB/

REAR BR A KE

DRUM REMOVER

3D - FRONT

SUSPENSION

• Front hub removal

Available

3E - REAR SUSPENSION

• Rear brake back plate

and axle shaft removal

09943-77910 BUSHING

REMOVER 3D - FRONT

SUSPENSION

• Front suspens ion

bushing removal

Unique

09944-18211 PINION TORQUE

CHECKING

SOCKET

3B - MANUAL RACK AND

PINION

• Gear case pinion

bearing installation

Unique

Tool No. Spx

Tool No. Description Illustration Section

Number /usage Category

09944-26011 43mm SOCK ET

(PINION BEARING

PLUG REMOVER)

3B – MANUAL RACK AND

PINION

• Steering pinion bearing

plug removal/installation

Unique

09944-36011 7245 OR

KM210-B STEERING

WHEEL

REMOVER

3C – STEERING WHEE L

& COLUMN

• Steering wheel removal

Mandatory

6A1 – ENGINE

MECHANICAL (M15)

• Crankshaft pulley

removal

09944-67010 OIL SEAL

INSTALLER 3E - REAR SUSPE NSI O N

• Rear axle shaft oil seal

installation

Unique

09944-68210 BEARING

INSTALLER 7B - AUTOMATIC

TRANSAXLE

• Differential side left/right

hand bearing cup

installation

Unique

09944-78210 BEARING

INSTALL ER

SUPPORT

7B - AUTOMAT IC

TRANSAXLE

• Reduct ion drive gear

installation

• Reduct ion drive gear

planetary ring gear

subassembly installation

Unique

09944-88220 OIL SEAL

INSTALLER 7B - AUTOMATIC

TRANSAXLE

• Differential left/right side

oil seal installation

Unique

09944-96011 BEARING OU TE R

RACE REMOVER 7B - AUTOMATIC

TRANSAXLE

• Countershaft left/right

hand bearing cup

removal

• Differential side left/right

hand bearing cup

removal

Unique

09945-16070 RETA IN ER RING

INSTALL ER SET 7D – TRANSFER

• Driven gear bearings

(left and right)

installation

Unique

Tool No. Spx

Tool No. Description Illustration Section

Number /usage Category

09945-26010 SOCKET

WRENCH 17mm 3D - FRONT

SUSPENSION

• Strut nut loosening/

removal/installation

Unique

09946-06710 BEARING

RETA IN ER

DUMMY

7B - AUTOMAT IC

TRANSAXLE

• Transaxle rear cover

snap ring removal

• O/D and 2

coast brake

return spring

subassembly installation

Unique

09950-78220 FLARE NUT

WRENCH (10mm) 5E – ANTILOCK

BRAKING SYSTEM (ABS)

• ABS brake pipe

removal/installation

Available

09950-78230 FLARE NUT

WRENCH (10/

11mm)

5 – BRAKES

• Brake pipe removal/

installation

Available

09951-16060 BUSH REMO VE R 7A - MANUAL

TRANSAXLE

• Differential assembly left

bearing installation

Unique

7F - REAR

DIFFERENTIAL

• Differential side bearings

installation

09951-16090 OIL SEAL

INSTALLER 7F - REAR

DIFFERENTIAL

• Bevel pinion bearing

outer races installation

Unique

09951-18210 OIL SEAL

INSTALLER 3D – FRONT

SUSPENSION

• Front wheel bearing

installation

Unique

7B - AUTOMAT IC

TRANSAXLE

• Reduct ion drive gear

installation

• Reduct ion drive gear

planetary ring gear

subassembly installation

09951-18220 SECONDARY

CUP INSTALLER

SET

5 – BRAKES

• Mast er cylinder

secondary cup

installation

Desirable

09951-76010 BEARING

INSTALLER 7A – MANUAL

TRANSAXLE

• Input shaft oil seal

installation

• Differential assembly

left/right bearing

installation

Unique

7F – REAR

DIFFERENTIAL

• Differential side bearings

installation

Tool No. Spx

Tool No. Description Illustration Section

Number /usage Category

09952-06020 DIAL GAUGE

PLATE No. 2 7B – AUTOMATIC

TRANSAXLE

•1

and reverse piston

stroke measurement

• Forward clutch piston

stroke measurement

Unique

09952-16020 BOOSTER

PISTON ROD

ADJUSTMER

5 – BRAKES

• Brake booster

adjustment

Desirable

09952-26020 MASTER

CYLINDER PLUG 5 – BRAKES

• Inspection/testing (Non

ABS Vehicl es)

Desirable

09952-36311 PRESSURE

GAUGE

ATTACHMENT

5 – BRAKES

• Fluid pressure test Desirable

09952-46010 MASTER

CYLINDER

ATTACHMENT

5 – BRAKES

• Inspection/testing Desirable

09952-76011 SNAP RING

PLIERS (CLOSING

TYPE)

7D – TRANSFER

• Intermediate shaft snap

ring installation

Available

09956-02310 FLUID PRESSURE

GAUGE 5 – BRAKES

• Fluid pressure test Unique

09990-06010 MANIFOLD

GAUGE SET 1B - AIR CONDITIONING

• Diagnosis Available

09990-86011 16600 OR

TIFZX-1

(ROBINAIR

NUMBERS)

GAS LEA K

DETECTOR 1B - AIR CONDITIONING

• Diagnosis Available

Tool No. Spx

Tool No. Description Illustration Section

Number /usage Category

09991-06010 MAGNET CLUTCH

PULLEY

INSTALLER

1B - AIR CONDITIONING

• Compressor clutch

pulley installation

Unique

09991-06020 ARMATURE

PLATE SPAN NER 1B - AIR CONDITIONING

• Compressor clutch plate

bolt removal/installation

Unique

09991-06030 ARMATURE

PLATE SPAN NER 1B - AIR CONDITIONING

• Compressor clutch plate

removal/installation

Unique

09991-06040 LIP TYPE SEAL

PROTECTOR 1B - AIR CONDITIONING

• Compres sor clutc h front

cylinder head installation

Unique

09991-06050 LIP TYPE SEAL

INSTALLER 1B - A IR CONDITIONING

• Compres sor clutc h front

cylinder head lip seal

installation

Unique

SD28018 or

AU338 -

(Released for

‘V’ and ‘W’

car)

FUEL PR ESS U RE

GAUGE - HIGH

PRESSURE

6 - ENGINE GENE RAL

INFORMATION &

DIAGNOSIS

• Fuel press ure test

Mandatory

6E1 - ENGINE AND

EMISSION CONTROL

SYSTEM

• Fuel press ure test

SD28057 -

(Released for

‘V’ and ‘W’ car

with the quick

connect

release tools

removed)

FUEL PR ESS U RE

GAUGE H OSE 6 - ENGINE GENERAL

INFORMATION &

DIAGNOSIS

• Fuel press ure test

Mandatory

6E1 - ENGINE AND

EMISSION CONTROL

SYSTEM

• Fuel press ure test

Tool No. Spx

Tool No. Description Illustration Section

Number /usage Category

Tech 2 0C – TECH 2

• Diagnosis Mandatory

3B-1 – POWER

STEERING

• Diagnosis

5E – ANTILOCK BRAKE

SYSTEMS

• Diagnosis

6 – ENGINE GENE RAL

INFORMATION &

DIAGNOSIS

• Diagnosis

6E1 – ENGINE EMISSION

AND CONTROL

SYSTE.MS

• Diagnosis

7B – AUTO.MATIC

TRANSAXLE

• Diagnosis

8G – IM .MOB ILISE R

CONTROL SYSTE.M

• Diagnosis

10B – AIRBAG

• Diagnosis

AU505

6B –- ENGINE COOLING

• Testing of coolant

concentration level

Mandatory

Tool No. Spx

Tool No. Description Illustration Section

Number /usage Category