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SERVICE MANUAL

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1. Throttle position switch e Starter reiay automatic transmission only Battery voltage signal The ECU provides a ground path for the fuel pump relay and the fue pump is energized The ECU restricts EGR and canister purge operation by energizing the EGR canister purge solenoid Voltage is supplied to the injectors The ECU controls injector pulse width by controlling the length of time that the injector circuit ground path remains completed extra fuel delivery continues for a few seconds after the engine starts To eliminate the possibility of engine flooding the ECU limits the number of times that the injectors can be energized twice per engine revolution This limit is calculated solely on the basis of engine coolant temperature Under conditions of extremely low coolant tempera tures the ECU increases the number of times that the double injection sequence is possible during engine start If coolant temperatures are high the ECU permits fewer double injections When the ignition switch is turned to START a crank signal is sent to the ECU If the vehicle is equipped with an automatic transmission the Starter relay prevents the signal from reaching the ECU if the transmission is not in Park or Neutral NOTE This is an OPEN LOOP mode Warm up Mode During engine warm up the ECU responds to the following inputs e Manifold absolute pressure MAP sensor e Engine speed sensor e Air temperature sen
2. Replace fuel filter at each 20 000 mila main tenance interval inspect fuel lines and tank far leakage and connections for tightness Inspect fue system electrical connections Check filler cap for proper venting Exhaust System At each 15 000 mile main tenanca interval inspect condition of all exhaust system components for leakage damage Clearance and mounting Replace components as necessary Ignition System Qualifled Techniclan Re quired Inspect distributor cap rotor and ignition wiring and check timing Fluid Checks During the 1 000 mile main tenance check and at subsequent maintenance interval check the level of fluids listed and add or replace as necessary transmission fluid differential oil brake fluid e power steering tluig coolant e windshield washer solvent Cooling System Drain and replace coolant at 30 000 miles and at the beginning of each winter season thereafter Check hoses and connections for leakage or flaws Use only Prestone I brand anti freeze coolant when replacing or adding Pressure test the coolant reseryoit cup This is very important to ensure proper engine cooling Evaporative System Inspect evaporative system hases and connections for leakage or cracks at the maintenance intervals indicated Soe FLUIDS AND FILTERS lor recommendations 87 21 23 24 25 26 27 28 29 30 Timing Belt Qualified Technician Required Repiace the toot
3. the switch low speed contacts ciose This enargizes a low speed relay which supplies battery voltage In series to each fan for low speed operation In a series circuit each fan receives 1 2 bat tery voltage Approximately 6 volts When coolant temperature rises above 100 C 212 Fj the high speed switch contacts close This energizes two high speed relays which supply battery voltage in parallei to each fan for high speed operation in a parallel circuit each receives full battery voltage On A C models the cooling fans operate continuously at low speed while the A C system is being used Fan speed is varied according to coolant temperature dur lng operation However a pressure switch in the A C system will Immediately switch the fana to high speed if systam pressura exceeds 225 psi Was tt punoly RET pojonuo OY NOD OL AU t I uo ury OV LOM 1 1n0 1n2 908 G OSI L E MD msouA0u O V O e601 m puno D syeojod af NA moj UB jo uonvuejdxo 304 oBed snood OOS 3LON O oSI 1e punoiD sojeAnoy 123 L e 1 kejo O V ISd Sv 19d 94 9 oGbt ees A l F S gs S Yo Hamo OW adm ur EE d MEE er ee MW J swa hr CPt Ag pee i E oviuoz ounou M H n a a t l l I ISd ued OV WVH5VIG 9NIHIM SNINOI LIGNOO HIV SNY3 9NI 10OOD COOLING SYSTEM COMPONENTS The 2 2L engins cooling system components A Radi
4. 1 oa 5 rt 8 U 5 ni D 5 im o m re 3 o 2 21 4 c w uw lu 1 o 4 n ct I0 c c ea tv fo in gt 14 o m ab a 13 3 10 i ia j m LN CE Ro 3 4 a y z 1 bx 2 a m ea m xz M puncuy BENDIX INJECTION SYSTEM WIRING HARNESS Oxygen Sanson battery OM low j voc witch A nur Temperature Sensor Thormlstos i ile alt bynaes valve Thermo Geman A Alr Tomporaturo Sannor Va idia thratile poaltion awtich Speed Sensor pleos pea r o de Es tp 3 PE Lr p XR r Modulo y 2 battory x 5 SN Q Alternator N fuel Pump j NE Sd ed W Bianor Vick den ay yy eu O Vigulnl e i 3 PUN m 4 ogee r So S CJ con OY w De Latch Solanos O tt 15 Startar Solonold i N talay Around To WO conor X e harness A Diagnosis sedkei Fun Yo radintor fan idiom eng Y ij pansion bolfla Pghi Pump harnose Jf harnesn c n T D LF Map Sensor IM N i i n Fa To tra P int engine f 4 bntlory Y Fd itwlor rotny burnous Irunsmlsnton harmona 12 2 2L MULTI POINT FUEL INJECTION GENERAL INFORMATION MODES OF OPERATION The 2 2L engine used a Pressure Speed type fuel in jection system This means that the amount of fuel In jected Into the engine depends aimoat entirely upon in take manifold pressure and engine speed Other fac tors such as engine coolant temperature air temperatur
5. B Vi 1089 Tool for fitting the dcuble lip seal B Vi 1090 Tool for centralising the final drive CONSUMABLES LOCTITE 518 Housing assembly faces GREASE No 20 Sun wheel splines GEARSOX OIL Oil all the parts and lip seals before refitting then FINAL DRIVE ASSEMBLY Dismantling Disconnect the clutch housing from the Extract the three bearings using tool step down housing type FACOM U53G US3E or a similar tool Mark the position of the differential nut sm DIFFERENTIAL E iy lum Remove the differential casing cover Take put the differential Remove the bolts that secure the crown wheei they cannot be re used Leave two diametrically opposite one snother Check the parts in position Check the condition of the gear teath of the bearing areas of the washers planet wheel of the splines in the housing of the area an which the Lip seal locates on sun wheel The pinion shaft and related paris cannot be rebuilt in the field so the intermediate seclion must be replaced as an assembly intermediate section remanufacturing is an extremely pracise operation requiring specialized tools and highly accurate measuring instruments This is only possible at the origina assembly factory 81 FINAL DRIVE UNIT Reassembling Adjusting Oil all the parts before reassembly The taper roller bearing on the crown wheel side of the differential is larger i
6. backward a short distance to ensure that fluid is distributed throughout the transmission Fluid is hot when the transmission is at normal operating temperature such as after driving for at least 5 10 miles t Park the vehicle on a level surface with the engine idling and the gear selector in Park P Fully engage the handbrake 2 Pulli out the transmission dipstick and wipe clean 3 Reinsert the dipstick fully than pull out again to read leval Cold Level read lower slot Hot Level read upper slot Do not allow level to go below Min or above Max mark or transmission damage may occur if necessary add the appropriate amount of trans mission fluid through the dipstick tube using a funnel See FLUIDS AND FILTERS for recom mended fluid TOT COLD Min Max Min Max 4utomahe Transmission Dipstick 1 Engine Oll Dipstick 2 OH FI Cap 3 Transmission Dipstick See FLUIDS AND FILTERS for recommendations 89 FLUIDS AND FILTERS OIL Engine Oil used must correspond to the standard MIL L 46152B or API SF The suffix SF must appear on the container singly or in conjunction with other designations Refer to the viscosity chart below for recommendations according to ambient tempera tures DO NOT USE 10W 39 above 60 F 15 C NEVER USE 10W 40 oils in this engine 10 F 23 C Cose TSAE 10w 20 ES 50 F 10 C 60 F 15 C 15 F 10 C 5 Speed Manual Transm
7. COOLING SYSTEM Loosen the serpentine drive belt adjustment bolt B and nut C Loosen the belt and remove it from the water pump D Loosen the power steering pump belt A Remove the water pump pulley boit F Then remove the pulley G from the pump shaft 70 ENGINE ENGINE COOLING SYSTEM Remove the pump attaching bolts H Remove the pump and gasket J and the timing belt and belt tensioner K Clean the gasket surfaces of the pump and en gine block WATER PUMP INSTALLATION Position a replacement gasket on the water pump Install the pump beit tensioner and timing belt Loosen the timing belt tensioner bolts L and allow the tensioner spring to tighten the belt M 71 install the timing belt cover Install the water pump pulley and the pulley re taining boit Adjust the serpentine and power steering balts to spacified tension and only in the sequence outlined in the belt adjustment procedures Connect the radiator hoses and fill and purge the cooling system DRIVE BELT ADJUSTMENT The drive belts must be adjusted in sequence to avoid over or under tightening the belts ENGINE ENGINE COOLING SYSTEM The correct tightening sequence is power The correct method of using deflection gauge steering pump belt first serpentine belt last Ele 346 02 is outlined in this section Use a tension gauge or deflection gauge Ele 346 02 to check verify drive belt t
8. ECU are Manifold Absolute Pressure MAP Sensor Engine Speed Sensor e Air Temperature Sensor e Coolant Temperature Sensor e Throttle Position Switch e Engine Crank Signal Battery Voltage Signal e Exhaust Oxygen Sensor e Knock Sensor e Air Conditioning Select Signa e Gear Indicator Signal MANIFOLD ABSOLUTE PRESSURE MAP SENSOR The MAP sensor reacts to absolute pressure in the intake manifold and provides a voltage signal to the ECU This signal is the main factor used to calculate the amount of fuel that enters the engine The ECU provides the sensor with a 5 volt reference voltage The sensor is connected to the intake manifold by a tube Changes in intake manifold pressure alter the resistance of areas 19 2 2L MULTI POINT FUEL INJECTION coated with a silicon crystal inside the sensor Due to this resistance the voltage signal sent back to the ECU wili be something less than 5 volts By measuring the difference between reference voltage and the MAP sensor signal the ECU is able to determine the absolute pressure inside the intake manifold As the pressure in the intake manifold changes the resistance of the MAP sensor changes The ECU determines the pressure in the intake manifold by measuring the voitage drop across the MAP sensor as it changes A Ground B Output Voltage C 5 Volts The MAP sensor is located at the firewall below the ignition module 2 2L MULTI POINT FUEL INJE
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10. O rings eviously been ciled to the casing cover A rt 9g b 7 tho rt m 1 t P t y a 7 ngs to ensure that Goes not make con rential casing hous 1 yw m b 3 o ra nor o 4D n o bom th m rt Y LY rt ey ct tbe ip o0 o m0 d or Horn om p ye i Q 1 us 3 x zi qi qe bh w faces on the casings LOCTITE 518 and ass ing a few of their ly tightening the 0 0 3 w nm jph Q ul V ou m uU uU or Du m u o D IJ rt BJ n o uU E rt ort P ore ce port ential nut using tool B Vi using a new oiled O Ln dt w lt H D orn Q Un n E l it makes contact l bearing outer ng the straight roller by pushing it in uptil it Loosen the differential nut by half a turn Tighten the bolts on the casing to the specified torque Fit to the large sun wheel side the snap ring the plastic ring ELNAL DRIVE UNIT Reassembling Adjusting ADIUSTING THE DIFFERENTIAL BEARING PRELOAD One of two sets af circumstances may arise JE the original hearings are refitted The differential should rotate with out play LE all the original machanical compon ents have been refitted fit a new oiled O ring seal to the nut and re fit the nut by screwing it in the same number of turns noted durinq dismantling and aligning it with the marks If naw bearings are fitted Ensure that the differ
11. R amp R 2469 Water Pump R amp R 2 69271 Prive Belt Adjustment orn 71 73 Coolant Protection Level Checking 74 75 Filling Purging System sees ee FINAL DRIVE asn eauter eee Pe eeerrraree 76 tc 85 Gear Specifications Ratios s 75 Pinion Bearing Pre Load ess 77 Exploded View 2 rr rtt 79 Special Tools 4 eee eene w 80 Tightening Torques sateeoneene 30 Lubricants Sealants 4er 80 Disassembly 26 62 44 81 Reassembly seen nhan 82 83 Differential Bearing Pre Load 85 MAINTENANCE seee en nee B6 to 90 Chassis Maintenance Schedule 86 Service Operation Descriptions 87 88 Engine Oil amp Filter Change 4 38 Differential Final Drive Oil Change 39 Transmission Fluid Change 89 Transmission Fluid Checking a BY Recommended Fluids and Filters s s s 30 Fluid Capacities eres sive s 90 Copyright 1997 Winnebago Industries Inc Copyright 1999 Mobility RV Inc Winnebago itasca LeSharo Phasar Centauri and Utility Van are registered trademarks of Winnebago Industries Inc ENGINE SPECIFICATIONS General Specifications lading 4 Cytinder OHG M mm 2 48 Ih weve ane as B mm 3 50 IA 22 Une 192 cu In a an BS mem 5 845 11 BS mm 2484 i S36 mm 3585 i Liner Prorusion iwio O angl gt 006 io 0 ma 0 003 10 0 006 m toner Height i
12. T IN CELSTUS cpi TESTER TESTER LINE TESTER DISPLAY LIGHT READOUT COMMENTS CONGT TION CODE MIER ON OR OFF ENGINE HOT AT IOLE ALL ACCESSORIES OFF FANS A C LIGHTS POWER STEERING FUP gt ros THROTTLE POSTTION SWITCH ANTI ENK SYSTWUM CLOSED THROTTLE LIGHT THROTTLE RETURN GENTLY TU CLOSED THROTTLE L10 L10 L10 ENGINE RUNNING AT nt3 Y ason 200 RPN 000 RPN Lv Mas TO BE OFF pd REH IN NEUTRAL 150 XXX 850 a 2 BCX XX 3 5 HAS TO BE VARIABLE USIT FE ZERO AT IOLE SENSCR OFERATIONAL OSG XXX US8 HUNN NT Hod Megi T IH 001 Gy OS N33 4139 HOO NOIIVH3 300V 9NINIO UNNA ON WOI LY LOA 1 0 TWNOLL YEA YOSNSS NGDAKD SINJ3AA72V LDOON 3H EE P HO UNO IHI AvIeSIO MALSAL YANN INE uais3l 3009 H3LS3L qo XA UGLSORYSHE NANU M3 0l NO IY Nun MOTLWSHOINT 72v UAn C EH OL SWS HONOA WSIIH 0001 0 V LOSNNOD Al MEA 3 Hedi 38 LENY 3NICN3 Q33gS JIG 1Y HOSNSS NISA NOLLIONCO MOLLINA panujjucz Buruung pue 39 euifuz J NOLLIS 51 BENDIX MULTI POINT FUEL INJECTION SYSTEM ECU WIRING amp COMPONENT TEST Vol Ohmmeter Special Approximate Test Probe Locations Conditions or Test Display No ECU Connecter Pin No Remarks Values m 3 Ignition switch ON 12 volts A C relay test i Ignition in START 12 volts 30 1 Ignition switch ON
13. V6 B A C fan switch ON 02 2 Ground verify ground ignition switch ON olt V7 AJC fan and thermostat ON i ch ES i 5 Org Wht wire connector at EGR Solenoid EGR Solenoid 11 TDC RPM Sensor resistance 12 1 relay ATX MP switch continuity Engine cold not running Air Temp Sensor Transmission in P or N Starter t Many multimeters are not capable of measuring resitance in the MegaOhm range On these meters the resistance will register as infinite ohms co 52 BENDIX MULTI POINT FUEL INJECTION SYSTEM ECU WIRING amp COMPONENT TEST Volt Ohmmeater Special Approximate Probe Locations Conditions or Test Display ECU Connector Pin No Remarks Valuea Engine cold not running a AM Iw 18 D2 1 Diagnostic plug verify wire continuity Injector signal clrcult os i 0 20 or 21 Brn 10 ga wire i at fuel pump relay Injector resistance good bad Idle speed regulator pu 7 ground circuit continulty Eoo wem qe speed regulator fuel pump relay ground circuit 27 Pin B connector 2 021 of ignition module harness See page 31 30 Pin C of 3 nin Female connector AIC plug by igntion module 31 Any ona pin of 2 pin Knock sensor connector 32 Other pin of 2 pin Knock sensor connector 84 Pin A 1 of amp pin male 0 A C fan connector Cr v 53 2 2L MULTI POINT FUEL INJECTION DIAGNOS
14. bar graphs Test Card code guide Data Input Keypad Function Keys Indicator Lights Digital Display LCD readout Memory Cartridge Location Canridge Ready Light Voltmeter Puise Sensor Input Jack Continuity Isclation Test Inputs Pulse Generator Output Jack Diagnostic Plug amp Test Cord i Error or Waiting for command No Data E No Data Oonnmumsmons omz Function Keys Press the corresponding key to change functional mode of the XR25 analyzer V Voltmeter Mode C Continuity Tester G Pulse Generator Sensor D Diagnostic Mode Generally indicates an open circuit or a strong signal Generally indicates a short circuit or a weak signal XR25 DIAGNOSTIC ANALYZER OPERATING INSTRUCTIONS STATIONARY SHOP TESTS Raise the hood and place the XA25 on a stand or cart near the front of the vehiclo for easy visibility Plug the XR25 test cord Into the D2 diagnostic con nector large plug The diagnostic plugs are located on the buikhead firewall at the center of the engine compartment Just above the valve cover Turn Igntlon key to ON position Be sure ail accessories lights fans etc are OFF for initial testing Some items may be switchad on later in test procedure Plug other end of test cord Into XR25 Analyzer The instant the cord is plugged in you will hear a rapid series of electronic tones The XA25 will then start a self diagnosis sequences Self test
15. by pulling it out of the air inlet duct Install replacement sensor in position by pushing sensor into the air inlet duct grommet Connect the electrical connector 58 COOLANT TEMPERATURE SENSOR REPLACEMENT CAUTION DO NOT remove the coolant temperature sensor from the engine when the coolant is hot as serious burns may result With the engine cold disconnect the electrical connector from the coolant sensor A f Unscrew the sensor and quickly plug the hole to prevent coolant loss Install replacement sensor into position and tighten securely Connect the electrical connector to the coolant sensor THROTTLE POSITION SWITEH TPS Removat Remove the TPS retaining screws A Disconnect the electrical connector B Slide the TPS away from the throttle plate assembly and remove the TPS 2 2L MULTI POINT FUEL INJECTION Connect the wire harness to connector EXHAUST OXYGEN 0 SENSOR Removal Disconnect the O sensor wire connector Remove the O sensor from the exhaust manifold to exhaust pipe adapter Installation Align the flat ofthe TPS with the flat cf the throttle shait Install retaining screws but do not tightan Slowly rotate the TPS in the direction of the arrow until the closed throttle switch clicks Tighten the retaining screws 59 Installation The replacement O sensor comes with anti Seize compound applied to the threads Install the O sensor
16. canister saturation This would result in driveability pro blems such as flooding and over rich conditions EMISSION SYSTEM SCHEMATICS EXHAUST EMISSION SYSTEM SCHEMATIC Manifold Vacuum Fuel Idle i Pressure Speed Regulator Regulator p idle By Pass i Engine Ar Alr Supply Front Cleaner Throttle t COO Plate I D M L a eC vu Map Sensor ia To Fuel Tank Jh ni ERAI SYA wy wm Roliover cul aca om y r Valve Charcoal z Canister M PR Es ch EGR B X Vale H EGA Solenoid Delay Valve To Automatic Transmission Vacuum Modulator ELECTRONIC CONTROL UNIT ECU The 2 2L multipoint fuel injection system is controlled by a digital microprocessor referred to as an Electronic Control Unit or ECU The ECU iS actually a microcomputer that receives information from various input sensors Based on this information the ECU is programmed to provide a precise amount of fuel and the correct ignition timing to meet existing engine speed and load conditions The fuel system s ECU also calculates ignition timing and operates the ignition power module Ignition timing is modified by the ECU to meet any engine operating condition Information such as air temperature engine coolant temperature engine speed absolute pressure inthe intake manifold or the presence of a spark Knock is used by the ECU when calculating the correct ignitio
17. into the exhaust manifold adapter KNOCK SENSOR Removal Disconnect the knock sensor connector Remove the knock sensor by loosening it with an open end wrench from underneath the intake manifold Ac cess from beneath vehicle Installation Install the knock sensor into position in the cylinder head Connect the knock sensor wire connector 2 2L MULTI POINT FUEL INJECTION FUEL PUMP RELAY REPLACEMENT For fuel pump relay Removal Installation refer to 8 relay Removal installation FUEL PUMP Removal The fuel pump is mounted to the left frame rail beneath the driver s seat area Install clamps MOT 453 01 to the fuel pump iniet and outlet hoses Disconnact and remove the fuel hoses from the fuel pump Disconnect the electrical connectors from the fuel pump Remove the retaining strap and remove the fuel pump Installation Position the fuel pump into place and secure with strap Connect the electrical connectors The pump terminals are different sizes to ensure that the fuel pump rotates in the correct direction The wire connectors have different size inside diameters that correspond to the correct terminal Connect the hoses to tha fuel pump and tighten the clamps Remove clamps MOT 453 01 FUEL FIETER Removal Install clamps MOT 453 01 to the iniet and outlet hoses of the fuel filter Disconnect and remove the fuel hoses from the filter assembly Remove the filter re
18. is over 1 500 RPM the ECU determines that the engine is in a hard deceleration condition and responds by completely shutting off fuel injection Fuel injection is resumed when engine speed decreases to 1 500 RPM NOTE This is an OPEN LOOP mode Key OFF Mode When the ignition switch is moved to the OFF position the ECU breaks the injector ground circuit and all fuel injection stops The ignition power module 1s deactivated The ECU opens the ground circuit for the B relay The relay opens and voltage supply to ali fuel injection circuitry is terminated SPECIAL OPERATING CONDITIONS Full Load Altitude Correction When the pressure in the intake manifold is near at mospheric pressure normally at or near WOT position the ECU will modify tha fuel mixture to increase gradually from normal enrichment to full enrichment Voltage is supplied to the injactors The ECU controls injection pulse width by controlling the time that the injector circuit ground path remains closed The atmospheric pressure is stored in the ECU It is measured each time the key 1s turned to the ON positian and brought up to date each time the throttle is fully opened or each time the pressure noted is higher than atmospheric pressura All four injectors are energized simultaneously once per engine revolution The ECU determines correct ignition timing and triggers the ignition power module 2 2L MULTI POINT FUEL INJECTION GENERAL I
19. of antifreeze containing Borax or similar alkaline producis Coolant Mixture Concantration A 50 50 mixture of clean water and the recommended antifreeze will provide protection lo 40 C 40 F The 50 50 mixture i recommended for very cold climates Do not use a pure antifreeze solution at any time Pure antifreeze provides considerably less protection ihan a mixture of antifreeze and water The maximum concentration of antitresza In the system should not exceed 60 percent Coolant Level Check engine coolant level when the engine Is cold and the coolant at ambient temperature The correct coolant level is between the ADD and FULL marks on the coolant expansion tank when the coolant is al an ambient temperature Thermostat A pol at type thermostat is used in 2 2L engines The thermostat is located in the 2 2L engines The ther mostat ia located n the end of the radiator upper hose connected to the cylinder head Thermostat operation is as follows Starts to open at BWC 1920F Fully open at 1019C 2130F Tharmostat opening travel ls 7 5 mm 0 295 In 85 Cooling Fan Operation Models with air conditioning and or automatic transaxle are equipped with a dual coolant thermo switch The switch is located in the radi ator The switch allows the cooling fans to op erate at high or low speed depending upon coolant temperature When coolant temperature is above 92 C 198 F but below 100 C 2120F
20. perform diagnostics on all model ME and ML automatic transmissions Follow the Functional Test as described on pages 49 thru 51 Key in the required diagnostic code for each test NOTE The key must be pressed before each number code Do not press Keys too quickly or the code may not register WARNING Fully engage the handbrake before working in front of Di OT the vehicle with the engine running uz Diagnostic Codes Ecc Using key m s 01 Atmospheric Pressure mBar 02 Coolant Temperature C 203 Air Temperature C 04 Battery Voltage 705 0 Sensor Voltage 06 Engine RPM 08 Ignition Timing GBTDC 712 idle Speed Governor Volts 13 Knock Sensor Volts at 3600 RPM 46 XR25 DIAGNOSTIC ANALYZER TRANSITORY ROAD TESTS Using Memory Function Place the XA25 Inside the driver compartment The best location is on tha floor between the front seats Connect the test cord to the diagnosic harness and to the XH25 Anaiyzer Route the cord through the engine access panel in the bulkhead firewall DO NOT route the cord out the side of the hood and through a window This could damage the cord Start the vehlc e and let the XH25 completa Ita selt test aequence Key In 0 0 3 Then key In D 0 and begin the road tast The XR25 will ba in wait mode until you key in the store command The displays should look tike this When the engine malfunctio
21. sequence This is the sequence that should occur dur ng the self test The XR25 is checking itself only not ihe engine components 1 All segments of the bar graph display will come on briefly then go out 2 Each segment will came on and go off in tum begin ning with the top left segment and ending with the bottom right segment No segment should remain on 3 The digital readout display will cycle numbers 0000 1111 2222 etc thru 9999 then hold with a single 0 Whan the self test is complete the displays should look like this 45 XR25 DIAGNOSTIC ANALYZER NOTE fan abnormality occurs it means that a pro i blem exists with the XR25 First check to Fig A see that the diagnostic cartridge is properiy i inserted If this is not the case an internal aor problem may exist Return the XR25 to Win nebago Part Sales for repair zs Key In D 0 3 The displays should look like this A Key ON Engine not running B Engine Running inme NOTE If the digital display does not read 43 3 it indicates one of two things 1 an incorrect diagnostic cartridge is in stalled in the XR25 or 2 an incorrect ECU is installed in the MR wis vehicle The proper cartridge for Bendix system diagnostics is imprinted with the name WIN NEBAGO and the number 21 063 This cartridge will also
22. the fuel pump and inspect the injector tips for leaks Replace any leaking injectors NOTE A slight dampness atthe tip of an injector is acceptable Replace injectors if required Reinstall the injectors and tuej rail as described in Component Replacement 41 2 2L MULTI POINT FUEL INJECTION INJECTOR TEST WITH ENGINE RUNNING Disconnect the electrical connector WARNING Use extreme caution when the CAUTION Never supply the connector at the engine is running Do NOT put your hands near ECU end with 12 volts The ECU will be the pulleys belts or fans Do NOT wear loose damaged clothing Supply 12 volts to terminal 4 on valve side of Disconnect each injector wire harness connector Connect to ground briefly connector in turn e Terminal 5 A loss of engine speed should be noticed while The valve should close if the engine is each injector is inoperative running the speed should drop rapidly to below norma idting speed If any one cylinder is not operational because of an inoperative injector switch the wire harness e Terminal 3 connectors between the inoperative injector and The valve should open if the engine is an operational injector running the speed should increase to above 2000 RPM If the previously operational injector does not function the wire harness is fauity To further test the regulator connect the XR25 tester to the vehicle IDLE SPEED REGULATOR TEST With the regulato
23. 4 2 2L MULTI POINT FUEL INJECTION DIAGNOSIS SPECIAL TOOLS Checking the injectors With tha engine stopped Disconnect the connectors Remove the Iniector fuel tali Pull out the assembly so that each injector can be placed in a 100 cc flask Mot 845 When the fuel railinjector assembly Is removed from the engine the injector retaining clips are not strong enough to hold the injectors to the fuel rall when fuel pump pressure is applled MATERIALS Therefore it ig necessary to make a retaining clamp See sketch below Attach this tool as scon as the in lake manifold Injection gallery is removed before star ting the electric fuel pump This clamp can be made at a local machinist shop us ing the plans shown below Dimensions are shown in Metric mm with approximate English dimensions shown in parenthesis Since the engine is designed In Metric the center to center distance between injector holes is crucial and must be measured only in mm as shown Bar Flat Stock 30m x 5mm x 350 mm long 1 04 x 114 x 13 3 4 Drilled as shown Hook Round Stock 8mm x 125 mm 1 4 x 5 long Band and thread as shown or usa threaded stock if desired Nut Wing Nut 8mm 1 47 Corresponding to hock threads INJECTOR RETAINING CLAMP 49mm 98mm 3 places 6 9mny 35 In dia 6 18mm 70 in dia 4 holes 175mm 6 84 In 2 places 350mrv 13 67 In 1 2 3 4 5 6 37 7 1
24. 5mrm 4 10 in 8 30mm 1 17 In 9 25mm 98 in Q 15mm 59 in r 1 15mm 59 in a a a tt 2 2L MULTI POINT FUEL INJECTION CHECKING FUEL PRESSURE Disconnect the hose from the fuel pressure regulator to the fuel rail Connect a fuel pressure gauge to the fuel rail Disconnect the vacuum hose from the pressure regulator and connect it to a vacuum pump Start the engine Check and record the pressure reading The reading should be 2 5 0 2 bars 36 3 psi Apply a vacuum of approximately 15 inches Hg to the pressure regulator The fuel pressure should drop to 2 0 0 2 bars 29 3 psi Disconnect the ECU Start the fue pump by placing a jumper wire between terminals D1 5 and D1 6 diagnostic plug CHECKING THE FUEL PUMP DELIVERY Disconnect the fuel return hose at the pressure regulator and place it in a 2000 m graduated beaker 38 Minimum delivery should be 130 liters hour 137 quarts hour or more than 1 8 liters 2 quarts in one minute MAP SENSOR TEST Inspect the MAP sensor vacuum hose connections at the intake manifold and sensor for kinks or sharp bends in the hose Repair as necessary Test the MAP sensor output voltage at the MAP sensor connector terminal B as marked on the sensor body with the ignition switch ON and the engine OFF 2 A Ground B Output Voltage C 5 Voits The output voltage should be 4 to 5 volts NOTE The voltage s
25. Ail four injectors are energized simultaneously once per engine revolution By monitoring the O sensor signal the ECU can fine tune injector pulse width until the ideal air fuel mixture of 14 7 parts air to 1 part fuei is achieved The ECU establishes correct idle speed by providing the required momentary ground to the idle speed regulating valve If required the idle speed is also adjusted to meet the increased engine load from A C compressor operation The ECU determines correct ignition timing and triggers the ignition coil NOTE This is a CLOSED LOOP mode Cruise Mode When the vehicle is at cruising speed the ECU responds to the following inputs e Manifold absolute pressure MAP sensor e Engine speed sensor e Air temperature sensor e Coolant temperature sensor Throttle position switch e Battery voltage signal e O sensor e Knock sensor e Air conditioning select signal The ECU opens the ground path for the EGR canister purge solenoid The EGR transducer and the evaporative vapor canister receive manifold vacuum Voltage is supplied to the injectors The ECU controls injection pulse width by controlling the time that the injector circuit ground path remains closed All four injectors are energized simultaneously once per engine revolution 2 2L MULTI POINT FUEL INJECTION The ECU determines correct ignition timing and tnggers the ignition power module NOTE This is a CLOSED LOO
26. CTION ECU INPUTS This sensor detects the passing of teeth on the flywheel and is able to send engine speed and crankshaft angle information to the ECU The ENGINE SPEED TDC SENSOR ECU in turn uses this information to determine proper fuel injection and ignition timing Two of the flywheel teeth are special trigger teeth These trigger teeth provide the ECU with an absolute indication 90 before and after top dead center Because the sensor is a magnetized component when the tngger tooth nears the speed sensors magnet the magnetic lines cf force are concentrated and the strength of the magnetic field increases The magnetic field is at its maximum strength when the tooth is aligned with the sensor s magnet _ When the field strength is increasing at its most rapid rate a voltage is induced in the speed sensor s inductive pickup coil As the trigger tooth passes and moves away from the sensor the magnetic field collapses inducing a voltage in the sensor s pickup coil This voltage is then sent to the ECU Weaker voltages are generated each time one of the smaller teeth passes the sensor These voltages allow the ECU to actually count the passing teeth Because the ECU knows that top dead center occurs 12 teeth after the trigger tooth and notch it can adjust the timing by counting these smalier teeth AIR TEMPERATURE SENSOR This sensor is a thermistor that receives a 5 voit reference volt
27. ER dct ai SRM Je M S TCAA Fuol Pump ICA DT ZI kn U rotay ce ee 2 I Be Latch 1 DI I d oL m PF pe ul lh gt J pl nU D eo en qoo e Junction to automatic transmission harnasa c Copper E b 10 BENDIX INJECTION SCHEMATIC DIAGRAM ECU CONNECTOR Sraun EEH System powen D f3 Ground Gy E Injectors output slgnal __ Injactors sutput sigril Permanent memory powse supply je AC relay ground out pu t PM EGR valve canister purga 3 ESA motor AAG Fuel pump relay E amp n ISA moter 15 m System power relay laten relay 3 Closed throrttle idle a2uitch G wOT awitch an Ignltion contral ien Speed sensor input Speed eensar input B Crank signal input Park ngeutral uitch oO _ AC select input Knock sensar input Manifold air T sensor T sensor ground Caolant T sensor MAP aensar output Manifold absolute prossuro AC thermostat input Absolute preasure ground sensi G2 sensor input Dlagnasti egy elgnal output TEE i a com An won ul T tot on23u es o t 0k ec X06 x para a l T ksi Hee amp ct 1 c 4 be a aa IN 2 3 x z T o SR abo 3o 4 1 0E O2 d a woe t m z nm u o a e o 3 n ha e a Ex a 3 i A
28. ERVICE OPERATION DESCRIPTIONS NOTE NOTE 3 Your need for service is determined by a mileage or time interval in most cases the odometer mieage will indicate when service is cequired However if you drive very little your vehicle should be serviced at least every twelve months Under severe driving conditions such as driving in dusty areas extensive engine idling towing a trailer or repeated short trips of 5 miles or less in freezing temperature more frequent main tenance is recammended Engine Oil Change engine oi during the 1000 mile maintenance check and at each required Service interval thereafter Check oil at each fuel fil If you use your vehicle under unusual driving conditions such as driving in dusty areas extensive engine idling towing a trailer or repeated short trips af 5 miles or tess in freezing temperatures than change your oil every 3 months or 3000 miles Engine Oil Filler Change engine oil filter during the 1000 mile maintenance check and tharaafter at listed intervals Use only Winne bago approved fitter Automatic Transmission Fluld Change the automotive transaxle fluid and clean filters at the 1000 mile maintenance check and at speci fied intervals thereafter Manval Transmission Oil Change Transmis sionoil must be changed during the 1 000 mile maintenance service and at each prescribed interval thereafter Thoroughly inspect for leaks around gaskets and drain plugs af
29. IS TESTING This is the ECU connector used for the Bendix fuel in jection system Terminal identification and specific ap plication is detailed in the following chart ECU CONNECTOR alela 4 s e 8 9 roni 13 1a 15 1617 18 speeds Topo spas WINNEBAGO BENDIX 1 Ground 18 ECU Diagnostic Signal Output to 02 1 2 Ground 19 System Power 3 3 Not Used 20 injector Output Signal 4 Permanent Memory Power Supply 21 injector Output Signal 5 EGR VaNe Canister Purg 22 AC Relay Ground Output 8 Fuel Purp Relay 23 idle Speed Reculator Cod 1 7 System Power Relay latch relay 24 eor Cod 2 8 WOT Switch 25 ade Swich Not Used 26 10 Not Used 27 Control Signal Tach Outou 11 Speed Sensor Input B 23 ns t A 12 Park Neutral Switch auto trans only 23 E 13 Not Used 30 14 Mando Ar Temperatura Sersor 31 Krock Sensor Input 15 Coolant Temaeratura Sensor 32 Temperature Sensor Ground 18 Manifold Absolute Prassura Supply 33 MAP Sensor Output Votege 34 AIC Thermostat 17 Manifold Absolute Pressure and Oxygen 35 O4 Sensor input Sensor Ground DIAGNOSTIC CONNECTORS The diagnostic connector is located under the hood Ese on the firewall near the ignition module Connector D2 1 ECU Diagnostic Output 9 2 Not Used 10 3 Not Used 11 B Relay 12 Not Used 1 WOT 14 Groun 15 Air Temperature Sensor DNDN 1 11 ES i 2 15 81 11 141 sizi N 2b
30. NFORMATION Air pressure is lower at high altitude which means that it contains less oxygen per volume unit than low altitude air normal pressure Based on low pressure signals from the MAP sensor the ECU maxes tha fuel mixture leaner to correspond to the lower oxygen content Operation In Defect Mode Limp Theinjection system can remain operative when some of its sensors are defective The ECU diagnoses its sensors by comparing their values to preset limits if the value sensed does not lie between these limits the sensor is treated as defective and the system operates in a defect mode If the coolant sensor is inoperative air temperature is used in determining injection pulse and ignition timing values The air temperature value is then increased as a function of engine RPM to simulate coolant sensor output lf the O sensor is inoperative open loop Operation is forced The engine will run without an input signal to the com puter from the following components Coolant Temperature Sensor Air Temperature Sensor Og Sensor Throttle Position Switch Knock Sensor idle Speed Regulator Performance will be affected without this input this in put but the engine will still operate The engine will not run without input from MAP Sensor Engine Speed Sensor TDC Indicator 18 During engine operation the ECU constantly monitors signals from several different input sensors Inputs that influence the
31. P mode Wide Open Throttle WOT Mode During WOT conditions the ECU responds to the following inputs e Manifold absolute pressure MAP sensor e Engine speed sensor e Air temperature sensor e Coolant temperature sensor e Battery voltage signa e Knock sensor e Barometric pressure is updated The ECU restricts EGR and canister purge operation by energizing the EGR canister purge solenoid Voltage is supplied to the injectors The ECU controls injection pulse width by controlling the time that the injector circuit ground path remains closed All four injectors are energized simultaneously once per engine revolution The ECU determines correct ignition timing and triggers the ignition power module 16 If a spark knock is detected the ECU retards ignition timing at the cylinder which is knocking until the knock is eliminated Ignition timing progressively returns to its value prior to when the knock was detected NOTE This is an OPEN LOOP made Deceleration Moda During engine deceleration the ECU responds to the following inputs Manifold absolute pressure MAP sensor e Engine speed sensor Air temperature sensor e Coolant temperature sensor Throttle position switch e Air conditioning select signal The ECU restricts EGR and canister purge by energizing the EGR canister purge solenoid 2 2L MULTI POINT FUEL INJECTION if the ECU receives a closed throttle signal and engine speed
32. Position relay into place and install retaining screw Connect the wire harness to the B relay or the fuel pump relay Install the ECU housing halves together and position the ECU housing into place Install splash proof housing using wing nut Attach retaining strap 2 2L MULTI POINT FUEL INJECTION COMPONENT REPLACEMENT MAP SENSOR Removal The MAP sensor Is located in the engine compartment below the ignition module Remove the MAP sensor retalning screws A Disconnect tha MAP sensor elecirica connector B Disconnect the vacuum hose fram the map sensor and remove the sensor Installation Install the vacuum hose io ihe MAP sensor Connaci the electrical connector to the MAP sensor Remount the MAP sensor and install retaining screws ENGINE SPEED SENSOR TDC Indicator Removal Disconnect the speed sensor electrical connector at the injection loom Remove the sensor retaining bolts Remove the sensor Installation Posillon the sansor on the transmission clutch housing Install the mounting bolts Ensure that the spacers are correctly installed onto the bolts so that the sensor does not contact the flex plate Connect the sensor eiactrical connector to tha injec tion loom NOTE The sensor is not adjustable 87 2 2L MULTI POINT FUEL INJECTION COMPONENT REPLACEMENT AIR TEMPERATURE SENSOR REPLACEMENT Disconnect the electrical connector from the sensor Remove the sensor
33. The oil filter Is unique to this type of engine and is available from Winnebago Part Sales Department No substitutions are recommended NOTE 8esuretoallow forthe additional capacity of the oil filter when refilling crankcase ENGINE OIL GRADE Refer to recommendations listed in the FLUIDS AND FILTERS section of this manual concerning service classifications and viscosity requirements CAUTION The engine must not be flushed out under any circumstances Sse FLUIDS AND FILTERS for recommendations TRANSMISSION AND DIFFERENTIAL OlL AND FLUID CHANGE Differential Oil Change 1 Remove drain plug 2 Allow adequate time far old ail 19 escape 2 Reinsert plug into hole 2 3 Refill reservoir through fill plug hole 3 until oil just starts to run out 4 Reinsert plug into hole 3 Manuat Transmission Oil Change 1 Remove drain plug S Allow adequate time for old oil to escape 2 Reinsert drain plug into drain 3 Retill reservoir through fili plug hole 4 until oil just starts to run out 4 Reinsert plug into hole 4 Automatic Tranmission Fluid Change 1 Remove drain plugs 6 and 8 Allow adequate time for fluid to escape 2 Reinsert drain plug into drain hole 3 Refill reservoir with recommended transmission fluid through transmission dipstick tube 7 AUTOMATIC TRANSMISSION FLUID CHECK The transmission fluid may be checked while either cold or hot When fluid is cold drive the vehicle forward and
34. Winnesaca Xtasto SERVICE MANUAL BENDIX FUEL INJECTION SYSTEM 1989 90 LeSharo Phasar amp Utility Van 701674 11 000 ity yA TABLE OF CONTENTS GENERAL DESCRIPTION Engine Specifications es l Torque Specifications eere n2 ENG INE Emission System anne 329 2 2L MULTI POINT FUEL INJECTION 6 to 54 General Information e 5 18 Component Locations recen T ECU Connector rns B Diagnostic Connectors 2 8 Bendix System Wiring Diagrams 9 12 EQJ Inputs e o0n966 992a6 22nn24 na 19 25 MAP Sensor 19 Engine Speed Sensor n ere 20 Air Temp Sensor E ela dd Coolant Temp Sensor sess 22 Throttle Position Switch 23 Engine Crank Signal e 23 Battery Voltage Signal e 23 Exhaust Oxygen Sensor S 23 24 Knock Sensor nee ae 24 25 AfC Select Signal esee 25 Geer indicator Signal 4 25 Eco Outputs w eft9t22en vt uwuswetSy 26 34 Br Relay 244 Peewee Fuel Purp Relay eooesuveee 26 Fuel Pump ees rea pap ues e dis di Fuel Filter 20 Fuel Pressure Regulator 28 29 Fugi Injectors sesana 29 30 Ignition Medule axes re 4s wu SOL EGR System eren 32 33 idle Speed Regulator e 33 34 Diagnosis Testing 35 54 Reference Chart ee we e eid e 35 Spec
35. age from the ECU The sensor s internal resistance which varies with temperature determines the sensor s voitage 21 2 2L MULTI POINT FUEL INJECTION ECU INPUTS E signal back to the ECU By comparing the sensors signal to the reference voltage the ECU can determine manifold air temperature This provides air density information to the ECU When the air temperature falls its density increases The ECU responds by increasing the amount of fuel injected to maintain the required air fuel mixture ratio At cold temperatures the sensor s resistance is low As the temperature increases the sensors resistance increases If the air temperature sensor fails the ECU is pro grammed to an alr temperature default value of 68 F 26 C This means that whan the computer is not receiving a signa from the air sensor It will autornatical ly assume that the air temperature Is 68 F and it will control ali other systems accordingly Allhough the vehi cle wilt suffer decreased performance it will still be driveable This provision is known as defect moda or limp mode 2 2L MULTI POINT FUEL INJECTION ECU INPUTS The aif temperature sensor A is located in tne air intake duct between the air filter and the intake manifold COOLANT TEMPERATURE SENSOR This sensor is a thermistor that receives a 5 voit reference voltage from the ECU The sensor s nternal resistance which varies with engine coolant temperature det
36. ator J Final Drive Oil Cooler B Cooling Fan Switch K Coolant Expansion Tank C Water Pump L Heater Core D Engine BLock M Engine Cil Cooler E Thermostat N Rear Auto Heater F Ragstrictor 3 mm diameter G Bleed Screw 4 places H ATX Cooler 67 COOLANT LEAK TESTING Leak testing is performed with pressure tester M S 554 03 adapter M S 554 01 and 554 04 Leak Test Procedure Remove the cap from the expansion tank and install adapter M S 554 01 in place of the cap Connect tool M S 554 03 to the adapter just installed on the expansion tank M S 554 01 Run the engine until it reaches normal operating temperature Then stop the engine Pump too M S 554 03 until pressure on the tool gauge is 1 3 bar 18 8 psi Pressure should remain steady If a pressure drop occurs check the system for leaks visually ENGINE COOLING SYSTEM Correct any leaks and test the system again Disconnect the tester tools from the expansion tank and test pressure of the expansion tank cap Install adapter M S 554 04 on pressure tester M S 554 03 Install the expansion tank cap A on adapter M S 554 04 and pressurize the cap 1 2 bars 17 5 psi Cap pressure should stabilize within 0 1 bar 1 1 2 psi of the setting imprinted on the cap Replace the cap if pressure does not stabilize within specified limits ENGINE COOLING SYSTEM THERMOSTAT REMOVAL WARNING Do not laosen the
37. ave contacis the ig nition clrcu try in the module the module chargea the coil primary windings CONNECTOR 1 CONNECTOR 1 A Ignition B Ground C Tach Output D1 Pin 1 31 B A 9 u V When coi saturation occurs the module circuitry opens the primary windings to collapse the magnetic field in the windings This induces the high voltage in the coil secondary windings which is then transmitted to the spark plugs via the rotor distributor cap and coil wire CONNECTOR 2 NOT USED CONNECTOR 2 A Not Used B ECU Ignition Coil Timing Input CAUTION Never allow a high voltage spark to ground on the electronic control module The Distributor is mounted at the rear of the cylinder head and is driven by the camshaft The distributor contains no electrical components other than the rotor and distributor cap The sole function of the distributor is to transmit the high voltage Ceveloped in the ignition coil secondary windings to the spark plugs in the required firing sequence The only connection between the ignition coil and distributor is the coil wire Proper advance is provided by a load table in the ECU that accurately determines the require ments of the engine If the ECU determines that there is a knock it will automatically retard ignition timing and then slowly return timing to the preset value as determined by engine load The ignition power module is mounted in t
38. ay Fuel Supply System Fuel injectors Ignition Power Module e EGR Canister Purge Solenoid e idle Speed Regulating Valve B RELAY This relay is energized whenever the ignition Switch is moved to the ON position With the relay s contacts closed battery voltage is supplied to the ECU and to the fuel pump relay The relay is disengaged whenever the ignition switch is moved to the OFF position The B relay is located in the ECU housing on the left inner fender FUEL PUMP RELAY Fuel Supply System System voltage to operate the fuel pump is routed through the fuel pump relay The relay contacts are nor mally open and close when the ECU provides a ground path for the relay coil When the fuel pump relay s contacts close power is supplied to the injectors idle speed regulator EGR canister solenoid and the fuel pump When the ECU opens the coil s circuit the coil s magnetic field collapses spring pressure opens the relay contacts and the pump s operation ceases The fuel pump relay is located in the ECU housing on the left inner fender Electric Fuel Pump The function of the pump is to supply fuel under pressure to the injectors The pump capacity is greater than the maximum engine consumption so that the pressure in the fuel system is always maintained The fuel pump is a multi cell roller type driven by a per manent magnet field type electric motor Because it is a one speed positive displacement d
39. cer C Delay Valve G From Exhaust Gases D Solenoid Valve H To Charcoai Canister IDLE SPEED REGULATOR A permanent magnet motor inside this component positions the regulating valve between the fully open and fully ciosed positions The motor receives system voltage from the fuel pump relay The ECU provides the motor with two ground leads The motor will turn one way or the other depending on which ground lead the ECU selects The regulator valve A consists of two coils fed by battery voltage and grounded through ECU control When the ignition is turned to the ON position and the engine is not running the ECU wil ground one coil and open the reguiating valve to provide maximum air bypass The valve will remain open during crank 33 2 2L MULTI POINT FUEL INJECTION When engine speed increases above a preset adjustment speed the ECU grounds the second coil while opening the circuit of the first coil By alternating the ground control of these coils the ECU can adjust the air bypass flow rate to maintain proper idle speed The idle regulating valve cannot be adjusted The idle regulating valve is mounted on the front of the intake manifold Idle Speed According to Coolant Temperature Base Idla 800 50 rpm Coolant Temp RPM 40 F 40 C 1300 F 20 C 1200 32 F 09C 1050 6 amp F 20 C 1000 140F 60 C 900 176 F 80 C 800 Tolerance 50 rpm GENERAL INFORMATION Before performi
40. cooling system pressure caps hoses or blaed screws while the coolant is stilt hot and the system presaurized Hot englne coolant can cause severe burns Allow the system to cool down before beginning service operations Disconnect the radiator lower hose and drain the coolant into a container Loosen the upper radiator hose clamp A and disconnect the hose B from the housing C Loosen the thermostat retaining clamp D and remove the thermostat from the upper hose B sl a ig Mt I uy X m i ith an Uy ae peus TA rtd y e dips Pinal ni Vr tai cm m hg li aN Ne f THERMOSTAT INSTALLATION Insert the thermostat E into tha upper radiator hose NOTE Be sure the thermostat check bail F is positioned at the top and the valve G is to wards the housing H Install and tighten the thermostat retaining clamp Connect the radiator upper hose ta the housing and tighten the hose clamp Connect the radiator lower hose Fit and purge the cooling system Refer to the procedure in this section WATER PUMP REMOVAL WARNING Do not loosen the cooling system pressure caps hoses or bleed screws while the coolant is still hot and the system pressurized Hot engine coolant can cause severe burns Al low the system to cool down before beginning service operations Disconnect the battery negative cabie Disconnect the radiator lower hose and drain the coolant into a container ENGINE ENGINE
41. dary 25 Second Step Down Gears Primary 23 Secondary 32 Final Drive Radio 11 42 Tachometer Ratio 5 21 TYPE NE FINAL DRIVE UNIT Special festures The oil capacity of the final drive section has been increased The diameter of the cron wheel has been increased The final drive pinion is mounted on taper roller bearings The seal between the final drive sec tion and the gearbex section consists of a double lip type seal SPECIFICATIONS Adjustments ADJUSTING THE FINAL DRIVE PINION BEARING PRELOAD ADJUSTING THE DIFFERENTIAL BEARING PR LOAD Free without play 0 7 to 2 5 N m 0 to 0 7 N m Q to 6 Ib in 6 to 22 ib n The pinion depth is not adjustable ADJUSTING THE BACKLASH The backlash cannot be maasured once the gearbox is assembled and is thare fore to be adjusted when the differ ential bearings are fitted by measuring the following dimensions Dimension E nominal dimension 93 93 90 07 9 Dimension F dimension between the differential bearing loc ating facas Frag without play 2 to 2 5 daN 15 to 18 ib ft Dimension X thickness of the shim to be placed between tha bearing and the different ial casing 77 n TS af SPEC Clutch housing and final drive unit housing l if H 78 PARTS THAT MUST BE REPLACED BY NEW ONES Paper gaskets Lip seals Differential housing securing bolts Speedometer dri
42. determines that the engine is in a hard deceferation condition and responds by completely shutting off fuel injection If the ECU receives a closed throttle signal and engine speed is urider 1500 RPM the ECU concludes that the engine is at or approaching idle and it must maintain idle speed by using the idle speed regulator Refer to Deceleration Mode for more information 22 2 2L MULTI POINT FUEL INJECTION ENGINE CRANK SIGNAL When the starter relay is energized the relay provides a vollage signal to the ECU Thrs voltage signal informs the ECU that the engine starter is engaged The starter relay is mounted on the lett side of the radiator support bracket BATTERY VOLTAGE SIGNAL The vehicle battery provides a nominal supply of 12 volts Depending on cperating conditions Ihis voltage can vary between 8 and 16 volts This affects the time the injectors are open Tha time increases as the battery voltage falls To compensate for this change in the opening time the actuat injection time at the injectors is corrected to correspond to the battery voltage EXHAUST OXYGEN 0 SENSOR The O sensor is a variable battery which sends exhaust oxygen content information to the ECU The O sensor determines the exhaust gas oxygen ratio which changes depending on the nchness of the mixture As the air fuel ratio varies from ideal the O sensor output voltage changes 2 2L MULTI POINT FUEL INJECTION ECU INPUTS The se
43. e throtile position exhaust oxygen content and even batlery voltage are monitored and used to calculate fuel injection As input signals to the ECU change the ECU must adjust its response to the output devices For example the ECU must calculate a different injector pulse width and ignition timing for idle that it calculates for wide open throttle WOT There are eight different modes of operation that determine haw and why the ECU responds to various input signals The sight modes are e Key ON mode Crank mode e Warm Up mode e idie mode Operating Temperature e Cruise mode Operating Temperature e Deceleration mode Wide Open Throttle WOT mode e Key OFF mode Modes of operation exist as two different types Crank Warm Up Deceleration and WOT modes are OPEN LOOP modes The Idle and Cruise modes at operating temperature are CLOSED LOOP modes 13 In the OPEN LOOP modes the ECU receives input signals and responds only according to the preset ECU programming In the CLOSED LOOP modes the ECU also receives a signal from the exhaust oxygen O sensor which indicates whether or not the Calculated injector pulse width results in the ideal air fuel mixture of 14 7 parts air to 1 part fuel By monitoring the exhaust oxygen content with the O sensor the ECU can fine tune the injector pulsa width and achieve close to perfect economic and low emission engine operation Key ON Made When the ignit
44. e Seat Width VOVIT EN Cylinder Head Warpage jmaximum 1 6 mm 007 in 1 6 mm 008 a 6 05 mm 0 092 Rocker Arm Clearance Cold 0310 10 015 mm 0 604 ta 0 006 i 0 20 to 025 mm 0 008 to 0 010 in Valve Train CamshaN End Play Intake Valve in 0 05 to O13 mm 0 002 15 0 065 mj xhausl Valve Timing 52 BHDC 2 ATDC 24 Valves Valve Stem Diameter 6 0 mm 0 315 Intake Vala Heed Diameter 2 44 mmi 792 n intake Valve Face Angle oor Exhaual Valve Head Diameter Exhaust Vaie Face Angie Lubrication System On Capacity With Filer Ctange 05 55 sees 6 Litera 5 5 quarts Gparaiing Pressure wl Id iulio nnn 0 3 bare 12 pal Operaing Pressure at 3 000 rpm daeessorres 3 0 bere 44 pal 5 0 Liters 6 3 quarta 0 42 mm 0 008 Me 0 02 mm 0 001 In Maximum 0 10 mm 0 004 fn EMISSION SYSTEM PCV SYSTEM 5 0mm 0 236 in E Inlet Air Circuit Iniet ra Air Throttle Orifice Body ij Manifold B Vacuum gt k ps 2 2mm 0 086 in Sl Manifold Vacuum Circuit Orifice ENGINE EMISSION SYSTEM SCHEMATICS FUEL EVAPORATIVE SYSTEM SCHEMATIC Throttle Plate Housing To Signal To Fuel Pump l ECU J Intake Purge Line EN Manifold I 1 Press Vacuum Fuel Filler Cap TA gt Fuel Return Line Rollover Valve Fuel Tank Charcoal Canister NOTE Overfilling the fuel tank may cause charcoal
45. ension Belt Adjustment Procedure Loosen the power steering pump belt Then loosen the serpentine belt adjusting boit A and nut B Adjust the power steering pump beit to speci Using Belt Deflection Gauge Ele 345 02 fied tension and tighten the pump bolts Position the rubber indicator ring A opposite Adjust the serpentine belt to specified tension the zero line B on the gauge plunger C and tighten the adjusting bolt and nut in the Specifications section for measuring Refer to the Belt Tension Specifications Chart points and adjustment specifications 72 ENGINE COOLING SYSTEM Remove the gauge and note amount of deflec tion indicated at the underside of the rubber ring P Place the Els 346 02 gauge bar D on the nec essary belt span ry d Serpentine Drive Belt insert the gauge plunger through the bar Then Measure the tension at F press the gauge barrel downward until the shoulder of the barrel E contacts tne gauge DUNS TE ITO PANI TORIO RT bar D used 2 5 mm 623 712 N 140 160 Ibs ft Power Steering Beit Measure the tension at F1 new 3 5 mm 556 689 N 125 155 Iba Jft used 5 3 mm 400 512 90 115 Ibs ft Crankshaft Water Pump Alternator A G Compressor Power Steering Pump Idler Pulley PoP or ENGINE COOLING SYSTEM CHECKING COOLANT PROTECTION LEVEL Protection level of engine coolant can be checked with a hydrometer Be sure to follow the ma
46. ential bearings area correctly positioned by turning the assembly Place the plunger of the torque mensur ing instrument B V 906 against one of the crown wheal teeth at its largest diameter square with the differential centreline Apply a progressively increasing press ure in tha same direction as was used when fitting the bearings until the diffarential starts to move s Release the torque measuring instrument and take the reading from the recording pointer Red Tighten or joagen the differential nut using tools B Vi 645 and B Vi 805 and recommence the operation until the torque is between 2 and 2 5 daN 15 and 18 Ib ft NN B vi 80 B Vi 645 SS Tu Whan the correct reading has been odb tained lock the nut with its locking plata Assemble the clutch shaft ta the primary shaft and assemble the housings after coating their assambly faces with LOCTITE 518 THE READING SHOULD BE BETWEEN 2 and 2 5 daN 15 and 18 I ft CHASSIS MAINTENANCE SCHEDULE Vehicles Equipped with Bendix Fuel Injection Only MONTHS or 1 6 12 1 138 24 30 136 42 48 54 60 65 72 MILES x 1000 1 10 5 20 25 130 385 40 48 50 55 6D 90 Re Operation Engine Ow a R E a a 2 AiR a a 2 Qu Fiter E a a A a R 3 Auto Transmsson Fhad a 1 I A i i R l I a ie R 4 Manual Transmrss on Ou Ei i E i a 1 zi R 5 CHer
47. entu Oil A A I i R i i 5 I R 6 C uten Adjustment 1 i 4 7 isie Speed Not Adjustable 8 A Futerr u a 9 Spars Pwgs 0 o1 1 1 4 l i 10 Drive Beits 1 A i A 11 Hoses Connectons I L i 4 12 Oxyge Sensor l 13 Valwe Lasn d 14 PCY System a 15 Fue Futerr a a lp 16 Exnagust System l I i i 17 gaban System s 18 Find Cneces l l i an La 19 Erg ne Coolant A R 20 Evaporatwe System h 4 1 2 u v J E i 24 res i I I 25 Aries Suspension Sreenng i i i XLI 25 Wrhees l I I I j r i t I 28 Lights Eiectrcal System l t 28 Rocker Shatt Ou Peter R R m i 358 asad Teer i i i l Fog I I I M ll eee R Reolacecmect necessary After 60 000 miles maintenance should be continued at equrvaiert A nad 28tT80 c2c28530y nt rwals by repeaung tne chassis ma ntenance schedule cercen Te ang aGus add or replace of necessary for tha 1 000 milemactenance check For reterence 5000 mies e P mm tjnagras srna r t i 2Q red t9 maintain emissions standards and warranty would equa 65 000 mes 10 000 would equa 70000 etc NOTE ifthe venicieis used under unusual driving conditions such as driving in dusty areas extensive engine idling trailer towing or repeated short trips of 5 miles or less more frequent service is recommended 86 S
48. er gt ie er 4 pats Ty xt p 1 5 742 ties yt f pt rir f i Tae
49. ermines the sensors voltage signal back to the ECU By comparing the sensor s signal to the reference voltage the ECU can determine the engine coolant temperature The ECU changes the fuel mixture and timing advance based on the coolant temperature sensor input At cold temperatures the sensors resistance is low As the temperature increases th sensors resistance increases The coolant temperature sensor A is mounted near the upper radiator nose If the coolant temperature sensor fails the ECU is pro grammed to a coolant temperature default value of 198 F 90 C This means that when the computer is not receiving a signal from the coolant sensor it will automatically assume that the coolant temperature is 1280F and it will control all other systems accordingly Although the vehicle will suffer decreased performance it will stil be driveable This provision is known as defect mode or limp mode 22 THROTTLE POSITION SWITCH This switch provides a voltage signal to the ECU when the throttle is either fully open WOT or whan it is fully closed The signal is sent to the ECU 10 before WOT and 2 before it is fully closed The WOT signal is used to tell the ECU that the injectors must supply more fuel because of the increased air flow The closed throttle signal tells the ECU that the engine is in one of two conditions If the ECU receives a closed throttle signal and engine speed is over 1500 RPM the ECU
50. esign the pump requires a pressure regulation device Whenever pressure inside the pump exceeds a predetermined imit a pressure relief valve bypasses fue inside the pump There is also a check valve that maintains fuel pressure in the system when the engine and or fue pump are not operating 2 2L MULTI POINT FUEL INJECTION ECU OUTPUTS FUEL PUMP cj ee be Aint J H Y AM A Suction S de B Safety Valve C Multi ce l Roller Pump D Eleciric Motor Armature E Check Valve F Pressure Side A Pressure Sida B Suction Side C Pump Rotor D Pump Housing E Roller The fuel pump operates when the key is turned to the ON position but will stop after 3 seconds if the engine is not started The pump operates continuously when the key is in the START position The pump terminals are marked and and the connectors are different in size to ensure that the pump rotates in the correct direction Since the pump uses a permanent magnet motor it will turn backwards if the electrical connections are reversed Fuel Filter The fuel filter removes any dirt or contaminants which might plug the fue injectors It is specially designed to separate water from the fuel and withstand high pumping pressures The fuel filter is located on the left frame rail benea the driver s seat area 2 2L MULTI POINT FUEL INJECTION 28 Fuel Pressure Regulato
51. ey G then key in N This generates a frequency of 2 pulses second Sea whether there is spark at tne nigh tension secom dary winding Voitmeter Measures DC voltage Press function key V Connect test lead to terminal V Continuity Detector Allows you to check continuity of a wiring harness or coil Press function key C Connect test leads from N terminals on the XR25 to component to be tested If the resistance is less than 1000 N a buzzer will sound on the XR25 HVBH S201 gt XKXX gt C0G6 NO AJH HERNIE 10n SJULOH LPOIT O3S070 JULO ND ABM HIJE HOILINSI 340 ANION NOIlISnd 37110 H4 aat dqWwaiceQi U3iN3O OWS AL XNOIIVSA WALSAS ND AX uaigai NOILVJiJIIN3OI NJA NOLLINOT 44Q 3MISNJ p p 44D MO NO YISH NOILICNCO NOLLOTH XiV HD3j E EP LMT AV IASIG YUSA ALT HSA UNHON LONH aurbug Du 3 e3s a09 NOIL233 gum ung dsuy NS N S auj6ug i435 XIGN39 HYALSAL SZYX DNISN 1S3J TWNOILONASA 49 SECTION i Engine Warm and at Idle After one cooling fan cycle FUNG T TON Dr T SENSOR Ala T ENR SEC TION 1H Engine Hot and Running FUNCTION INE SEED CONCI TION TESTER TESTER LINE TESTER DISPLAY LIGHT REACCUT COMMENTS COCE NUMBER ON OR OFF ENGINE WARI IDLE no L5 mohhi Medi BOSC lt xxxe_ 110 C ENGINE AT IOLE naa i Lx XKXOUTSIOE
52. f and intake manifold vacuum in the upper half of the regulator act in unison to open the fuel outlet against spring pressure e 9 ie EAE E Ze zz Ze E E E z 7 24 e zx Zs Fuel Connection Return to Tank Valve Support Diaphragm Compression Sprlng Intake Manifold Connection Valve Ommoom 2 2L MULTI POINT FUEL INJECTION FUEL INJECTORS A fuel injector is an electro mechanical device which acts as a valve for controlling tuel flow into the engine The injector consists of a body which contains an electro magnetic coil a fuel metering plunger with a magnetic core and a spring When the magnetic coil is energized the piunger is puiled off its seat and pressurized fuel is alowed to pass into the intake manifold Because each injector is connected to system voltage through the fuel pump relay the injectors wilt open whenever they are provided a ground path by ihe ECU This area colored Grey for Bendix Blus for Bosch 1 Injector Needle 2 Magnetic Core 3 Magnetic Coil 4 Electrical Connection 5 Filter CAUTION Bendix and Bosch Injactors INTERCHANGEABLEI ARE NOT 2 2L MULTI POINT FUEL INJECTION ECU OUTPUTS Fuel injector operation is controlied exclusively by the ECU Because the injectors receive system voltage from the fuel pump relay the injectors are only open when a ground path is provided by the ECU T
53. gnals in a range from 1800 5500 rpm but the ECU is programmed not to receive the signals until ai least 3600 rpm Knock Sensor Piezo Element Senis Mass Normal sound wave Knock sound wave Sound waves conducted through block Although only one knack sensor is used the system is adjusted cylinder by cylinder If the knock detector or its circuit fails no further signais transmitted the system operates in defect mode and retards timing by 3 in relation to its nominal settings AIR CONDITIONING SELECT SIGNAL The ECU receives a voltage signal whenever the A C contro switch Is turned ON Since A C compressor operation increases engine kag the A C select signa is used by the ECU as an indication that an increased alr fuel charga may be required to maintain correct engine speed GEAR INDICATOR SIGNAL The neutral safety switch senda a voltage signal to the ECU whenever the gear ssleci lever has been placed in a drive mode 25 2 2L MULTI POINT FUEL INJECTION Simifar to the A C select signal the gear indicator signal is an indication to the ECU that an increased air fuel charge may be required to maintain the correct engine speed N 2 2L MULTI POINT FUEL INJECTION ECU OUTPUTS Based on the information received from the various input sensors the ECU controls seven output components The components that receive output signals from the ECU are B Relay e Fuel Pump Rel
54. he ECU completes the ground path of the coil which sets up a magnetic field The magnetic core is attracted and the needie lifts from its seat to allow the pressurized fuel to pass When the ground path is turned cff the spring returns the needle to its seat and fuel flow stops After receiving inputs from various sensors the ECU determines the correct injector pulse width to meet the existing engine speed and load conditions The ECU performs this task by varying the length of time that the injector is provided with a ground path Each cylinder has an injector mounted on its inlet duct that sprays fuel in front of the intake valve The injectors operate as a group which simplifies the system They inject twice per cycle once per engine revolution except on starting when a special procedure is used IGNITION MODULE Based on information received from the input sensors the ECU calculates the precise ignition timing for any given engine condition As ignition timing is calculated the ECU provides the power module with the signal to trigger the ignition coil The module consists of a coil and a power control operated by the ECU 2 2L MULTI PGINT FUEL INJECTION EGU OUTPUTS Ignition firing signals from ECU terminal 27 are transmitted through terminal B of connector 2 on the Ignition module The ignition signal from the ECU ls received by the module in the form of a 5 volt square wave As the loading edge of the w
55. he engine compartment on the center of the firewall 2 2L MULTI POINT FUEL INJECTION 32 EGR CANISTER PURGE SOLENOID The vacuum source for both the EGR valve and the evaporative vapor control canister is controlled by one solenoid This solenoid receives system voltage from the fuel pump relay and is energized when provided a ground path by the ECU When energized the EGR canister purge solenoid restricts vacuum to the EGR valve and the evaporative vapor control canister With vacuum restricted the EGR valve is closed and the evaporative vapor contro canister is not being purged During certain conditions the ECU breaks the solenoid path to ground When the solenoid is not energized both the EGR transducer and the evaporative vapor control canister receive manifold vacuum The EGR canister purge solenoid is located in the ECU housing on the left inner fender NOTE If the solenoid s electrical connector is removed the EGR valve and canister purge will be ON at all times Tne EGR varme is functional from 1200 4300 rpm under the following conditions water temperature at least 133 F 56 C air intake temperature at least 59 F 15 C Manifold Absolute Pressure MAP between 391 1024 Millibars 2 2L MULTI POINT FUEL INJECTION EXHAUST GAS RECIRCULATION EGR SYSTEM IU x S Bow EN a e EC EE 1 i A Engine EB EGR Valve A H 8 Throttle G F EGR Valve Transdu
56. hed timing belt at 60 000 miles Battery At 1 000 miles and at each 000 mile maintenance interval check battery terminais clean and tighten if necessary voltage battery case and hold downs and electrolyte level if applicable Brakes Perform the following services at 1 000 miles and at each 15 000 mile maintenance interval e Check operation and performance of service rakes Add fluid if necessary e inspect condition and thickness of front pads and rear linings Replace if necessary Adjust handbrake Inspect brake servo filter and clean or replace as necessary Tires Inspect tires and spare for abnormal wear or damage and adjust airinflation pressure ifnecessary at 1 000 miles and at each specified interval therafter or whenever any visible or handling problem is apparent Axles Suspension During the 1 000 mile main tenance check and at each 15 000 mile main tenance interval perform the following and replace as necessary e Steering and suspension components check for play and wear Drive axie boots inspect for Cracks Rear wheel bearings inspect condition and repack e Torque axle nuts to correct specifications Wheels Check tightness of lug nuts and inspect condition of wheels at 1 000 miles and at each 5 000 mile service interval Mountings All engine and transmission mounting bolts must be torqued to proper specifications every 15 000 miles Lights and Electrical System During
57. hould drop to 0 5 to 1 5 voits with a hot engine at idle and in neutral Test ECU terminal 33 for the same voltage described previously to verify the wire harness condition 39 2 2L MULTI POINT FUEL INJECTION Repair as necessary Test MAP sensor suppiy voltage at the sensor connector terminal C with the ignition ON The voltage should be 5 0 5 volts The same voltage should also be at terminal 16 of the ECU wire harness connector Repair or repiace the wire harness as necessary Using an ahmmetar test the MAP sensor ground circuit at sensor connector termina A and ECU connector terminal 17 Repair the wire harness if necessary Test the MAP sensor ground circuit at the ECU connector between terminal 17 and terminal 2 with an ohmmeter If the ohmmeter indicates an open circuit inspect for a defective sensor ground connection located on the right side of the cylinder block Test the MAP circuit using the XR25 tester ENGINE SPEED TDC SENSOR TEST Disconnect the TDC sensor connector from tha igni tion conirol module Place an ohmmeter between terminals A and B marked on the connector Reading should be 200 75 ohms hot engine Replace sensor if readings are not ta specifications 2 2L MULTI POINT FUEL INJECTION AIR TEMPERATURE SENSOR TEST Measure the resistance of the sensor as a function of the ambient air temperature An accurate thermometer can be placec in the air filter in
58. i9 a CONNECTOR Not Used EGR Idle Speed Regulator Coil 1 Coolant Temperature Sensor Closed Throttle Switch Idle Speed Regulator Coil 2 Automatic Transmission Diagnosis BY A module 54 Connector D1 1 Tach Signal 2 Ignition 3 Ground 4 Start Relay 5 Battery 8 Fuel Pump Relay 2 2 MULTI POINT FUEL INJECTION COMPONENT REPLACEMENT ECU Removal The ECU is contalned in a splash proof housing located In the engine compartment behind ihe air filter Remove retaining strap Remove the wing nut A and tha splash proof hous ing B Remove the plastic housing and open it Disconnect the ECU connector C Remove tho ECU retaining nuts D 55 2 2L MULTI POINT FUEL INJECTION COMPONENT REPLACEMENT Installation Install the ECU into the housing and install the retain ing nuts Connect the ECU connector to the ECU install the ECU housing halves together and position the ECU housing into place Install splash proof housing using wing nut Attach re taining strap B RELAY Removal The ECU is contained ina splash proof housing located n tha engine compartment behind the air filter Remove retaining strap Remove the wing nut A and the splash proof hous ing B Remove the plastic housing and open it Disconnect the wire connectors from the B relay A or the fuel pump relay B Remove the retaining screw and remove the relay Installation
59. ial Tools 4 esee ree 36 37 Fuel Pressure m 38 Fuel Pump Delivery eee 36 HAP Sensor saveeeeee PEOR Engine Speed TOC Sensor 39 Air Temp Sensar sessareneescecees 40 Coolant Temp Sensor s 40 Throttle Position Switch 41 ENV GCCOES ofc Wier o vlan wee ies RS 41 42 Zn25 Diagnostic Anahyzer 43 48 Ferctional Tests sees 49451 ECU Hiring amp Component Test 52 53 EQJ amp Diagnostic Connectors e 54 Component Replacement 55 64 EDS Ac ange EED OCA LL Br Relay ecce rrt 96 MAP Sensor crravreewscecvas sea 27 Engine Speed Sensor TDC 57 Air Temp Sensor crees wae 50 Coolant Tetp Sensor 58 Throttle Position Switch TPS 9 Exhaust Oxygen Sensor ees 59 Knock Sensor e soovcoss 60 Fuel Pump Relay esse s 60 Fuel Pump Nivea aip eee aie eee 60 61 Fuel Filter MET isu ete abet 61 Fuel Pressure Regulator 62 Fuel Rail seas 63 Injectors TOT T 63 64 Idle Speed Regulator K ENGINE COOLING SYSTEM 65 to 75 Recommended Coolant enn 65 Thermostat res essesoutocacee 65 Cooling Fan Operation Hi Lo Speed 65 Cooling Fan amp A C Wiring Diagram 5 Cooling System Exploded View 67 Coolant Leak Test lere 68 Thermostat
60. ion switch is placed in the ON position with the engine not running the ECU responds to the following inputs e Manifold absolute pressure MAP sensor e Air temperature sensor Coolant temperature sensor e Throttle position switch Battery voltage signal The ignition switch supplies voltage to the B relay The ECU provides a ground path and the B relay is energized The ECU recaives and stores a barometric pressure value from the MAP sensor in preparation for engine start Voltage is supplied to the fuel pump relay from the B relay The ECU provides a ground path for 1 to 3 seconds During this period the fuel pump relay is energized and the fue pump pressurizes the fuel supply system 2 2L MULTI POINT FUEL INJECTION Based on signals received from the engine speed sensor the ECU determines correct ignition timing and triggers the ignition coil All four injectors are energized simultaneously once per engine revolution except during cold Voltage is supplied to the injectors via the fuel pump relay The ECU regulates duration and timing of the in jectors by controlling the injector ground circuit engine start conditions when the injectors are energized twice per engine revolution This The idle regulating valve opens fully Crank Mode During engine cranking the ECU responds to the following inputs e Manifold absolute pressure MAP sensor e Engine speed sensor e Air temperature sensor
61. ission Oil used must correspond to the standard MIL L 21058 or API GLS Above 32 F 10 C SAE s0W 90 Below 32 F 10 C SAE 75W Differential Oil used must correspond to the standard MIL L 2105B or API GLS All temperatures SAE 60 90 FLUIDS Automatic Transmission Mobil 220ATF Dexron Type Il or equivalent Power Steering Mobil 220 ATF Dexron Type ll or equivalent Brakes Clutch SAE J 1703F DOT 3 or SAE J1703F DOT4 Coolant Prestone I anti freeze coolant only FILTERS Oil Filter Part R77007 20 077 Air Filter Part R77013 48 175 Fuel Filter Part R14636 35 181 CAUTION We recommend using high octane un leaded gasolineif your vehicle is operates during hot weather under severe condi tions such as mountain driving heavy vehicle loading or sustained high speed driving FLUID CAPACITIES VEHICLES EQUIPPED WITH J7T 239 FUEL INJECTED GASOLINE ENGINE Fuel Tank 15 5 gallons 58 7 litres Engine Oil Crankcase 5 3 quarts 5 0 litres Engine Oil Filter 52 quart 50 litre Cooling System 11 0 quarts 10 4 litres Automatic Transmission 2 1 2 6 quarts 2 0 2 5 litres Manual Transmission 1 9 quarts 1 8 litres Differential 1 48 quart 1 4 litre Brake Circuit single 42 quart 0 4 litre Brake Circuit dual 74 quart 0 7 litre Power Steering 1 22 quart 1 15 litre Approximate capacity excluding Motoraid Water Heater or Rear Heat
62. move the injector retaining clips E 1 clip for 2 injectors Remove the injector F from the fuel rail by pulling it out Remove the fuel rail and injectors as an assembly Installation Position the fuel rail and iniector assembly with injectors in position 83 2 2L MULTI POINT FUEL INJECTION Installation IDLE SPEED REGULATOR NOTE Before installation inspect that the O ring seals A are in good condition Replace the seals if they are cut or damaged in any way Removal Install seals Part No R14636 35 261 after applying a fight coat of silicone grease Disconnect the idle speed regulator A electrical connector Remove the air hoses from the regulator Remove the regulator retaining clamp screws and remove the regulator This area colored Grey tor Bendix Bue for Bosch CAUTION Bendix and Bosch injectors ARE NOT INTERCHANGEABLE Install the injectors to the fuel rail and install retaininer clips install the fuel rail assembly as previously described Installation Install the regulator into position with the arrow on the base of the valve pointing in the direction of the air flow Install retaining clamp and screws Install the air hoses to the regulator Connect the wire harness to the regulator ENGINE COOLING SYSTEM GENERAL SERVICE INFORMATION Recommended Coolant Recommended coolant for tha 2 2L engine cooling system is Prestene II Do not use any type
63. n Flange ane 3065 16 93 096 m 3 663 16 3 685 a Cynder Block Depth ie Flanges 82 942 to 92 985 rm 3 659 3 660 1 Cyber Block Depth 149 25 to 149 75 mn 5 875 to 5 895 i 7bhattansssavv rb thee rranum Crankshatt Number of Maw Bearings Man Gearing Journal rameter Reged Ciameiet Gnihhg Tolerance 82 892 mm 2 475 i so 2842 erm 2 466 n Dot oss fer iia Connecang Rod Jouns Diameter 8296 mm i2216 in Regnnd Damat nsee a 58048 mm 2206 i UU 9 oo 0 029 n 0 0004 t9 0 00 i 0 07 to 1 3 mm 0 002 ip 0009 n Peston io Connecong Ro FR LL Connachng Rod End Play Large End 24 O31 10057 mm 0 012 to 0022 mj 75 min 2 952 wx 29 mm 0 905 in ses d amp mmios5t m Piston Pin Langh Piston Pin External Qianeior Pigion Fin Internal Oe meter Piston Rings Piston Fig Thickness Top Compression see nt 1 75 mm 0 088 in Upper Commvessign ccelo mM 200 mm 0078 1 CM Scrap t ccsose ease iet 4 00 mm 1015 3 Pistan Aing Gao Pre Acusied GENERAL DESCRIPTION Cylinder Head Cylinder Head Haight RES Combustion Chambar Volume a a aa Ln Vaive Guide Ingata Diameter iiu issue Valve Siem 1o Guide Clearance Intake Vate Seal Angie 1 5 mm 4 354 in 5835 cc 4 mm 0 315 in ET mm 0 004 in beet tee wean Exhaust Valve Seat Angle een imaka Valve Seal Width A SR Exhaust Valv
64. n diameter than that on the housing side Asseable the differential housing and the crown wheel by fitting the three bolts ADJUSTING THE BACKLASH Measure dimension F using a vernier calliper with jaws 90 zm long The backlash cannot be measured after the gearbox has been assembled and X 9F F must therefore be adjusted vhen the differential bearings are refitted Shins are available in thickness froma by measuring the folloving dimensions 0 8 to 1 4 ra in increments of 0 05 za Dimension nominal dimension 93 93 0 07 U Dizension F disension between the differential bearing locating faces Dimension X thickness of the shim to De inserted between the bearing and the differ ential housing 82 FINAL DRIVE UNIT Reassambling Adjusting Assemble the crown wheel ta the housing Fit the assembly into the differential using new bolts casing bearing 34 is not in its final position hien Ihe bolts to a torque of 12 5 daN m 92 Pa t Check that the following are in place the locating dowel C on the casing the breather D in its location Fit the lip seal to the sun wheel Push the straight roller banring 34 on to tha large sun wheel by a few millimetres in ordar to centralise it 83 FINAL DRIVE UNIT Reassembling Adjusting INVOLVING THE WATER OIL ted to certain versions rt m n th rt J g w ip om o B ler E using new
65. n occurs key In 0 zero This Is the memory store command Yau will hear a rapid series of electronic tones while the XR25 stores the memory The displays should look like this You can now discontinue the toad test IMPORTANT DO NOT SWITCH IGNITION OFF or you will lose the stored data To Aecall the diagnostic readouts just key In the desired diagnostic code s Press followed by any of the two number codes To Reset or Clear the mamory key In D 0 3 This is useful whan you want to stop along the road sida to record test results then repeat the road test to get a second opinion The memory will be cleared automatically when the ignition is switched OFF for at least 5 seconds A XR25 DIAGNOSTIC ANALYZER OTHER FUNCTIONS Pulse Sensor Measures the duration of a pulse Tests the ignition module signa emitted by the ECU if high tension is not present Allows detection of an incorrect contact on a ground feed or return line Connect a test lead between the test point and ter minal V of the XR25 Then press function G Recreate the conditions under which the malfunc tion occurs such as moving the wiring then read the digita display Range N to 1999 milliseconds Frequency Generator Simulates a running condition to test ignition module high tension Connect a test lead between terminal G of the XR25 and termina B of Connector 2 on the ignition module See pg 31 Press function k
66. n timing The ECU controis the engine by receiving the following input values Manifold Absolute Pressure MAP e Engine Speed Sensor e Knock Sensor Exhaust Oxygen O Sensor e Throttle Position Switch e Coolant Temperature Sensor e Ar Temperature Sensor e Battery Voltace 2 2L MULTI POINT FUEL INJECTION Then sending output signals to the following components Fuel Pump Relay Fuel Delivery System e Fuel Injectors e Idle Speed Regulator e Ignition Power Module e EGR Valve 2 2L MULTI POINT FUEL INJECTION GENERAL INFORMATION POSITIONS OF COMPONENTS Throttle Position Switch Air Temperature Sansor idio Speed Regulator Diagnostic Plug Ignition Module Map Sensor Below iga Module Distributor 0v 9 9 3 3 9 7 8 9 10 it 12 13 Computer and Protective Housing Coolant Temperature Sensor Protective Housing Speed Sensor Air Filter Throttle CEA Wu wy d amp cm 1 2 3 4 6 2 2L MULTI POINT FUEL INJECTION ECU CONNECTOR This is the ECU connector used for the Bendix fuel in jection system Terminal identification and specific ap plication is detailed in the following chart WINNEBAGO BENDIX DIAGNOSTIC CONNECTORS The diagnostic connector is located under the hood on the firewall near the ignition module jaja fe s ojzje o nopsprajra e s rep io pe zoaslee esas es s eres c 21 saa oes 1 Ground 18 ECU Diagnostic Signal Ou
67. ng any tests ensure that the trouble is not caused by a component that is not part of the injection system spark plugs ignition module etc there are no air leaks into the intake and or exhaust systems the injectors are supplied with fuel check pressure in the circuit do not disconnect or connect any component without first turning off the ignition with the engine stopped the fuel pump should run for a few seconds when the ignition is turned to the ON position After any tests reset the injection system memories by disconnecting the ECU Disconnect the battery before charging CAUTION Before doing any electric welding on the vehicle disconnect the ECU 2 2L MULTI POINT FUEL INJECTION DIAGNOSIS TESTING DIAGNOSTIC REFERENCE CHART 1 Engine not starting or starts poorly 2 Engine starts then stalls 3 Rough idle 4 Poor acceleration 5 Misfiring at all speeds 6 Excessive fuel consumption 7 Loss of power 8 Engine spark knocks 9 Idle speed too high 10 Idle speed too low LE Ed E s POSSIBLE CAUSE CHECK Electric fuel pump not running Check for voltage at fuel pump relay and at fuel pump Check fuel pressure Ze Throtile Position Switch Check the closed throttle adjustment Check for fully closed throttle Intake manifold air leak Check the intake manifold for leaks Check all hoses and fittings _ injectors Check the injectors individually by 79 moving the electrical connecto
68. nsor is built so that one side of a ceramic detec tor is in contact with the exhaust gases while the other side is in contact with surrounding air Each side is con nected to a terminal The gases always contain a small amount of oxygen depending on the mixture ratio while surrounding air has a very high oxygen content This difference of concentration causes a motion of oxygen ions through the ceramic detector which generates a voltage The voltage is picked up at a terminal and transmitted to the control box which reacts by modify ing the width of the injection pulses LAMBDA sensor in section 1 Shield 2 Ceramic detector 3 Threaded sockar 4 Contact sleeve 5 Protection casing 8 Contact spring 7 Venting hole 8 Terminal 9 Exhaust gas 10 Surrounding air 24 The O sensor A is located in the exhaust pipe behind the exhaust manifold KNOCK SENSOR This sensor is an electro mechanical device capable of measuring a vibration and converting it into an electrical signal The sensor is designed to vibrate at the same frequency as a spark knock During knock a variation in pressure on a body with a crystalline structure produces a current A cable consisting of two shielded wires transmits this current to the ECU If knock occurs vibrations of a given frequency appear and produce electrical pulses of the same frequency and the ECU retards the advance The knock sensor emits si
69. nufacturers in Structions carefully when using the hydrometer Incor rect use will produce inaccurate readings If coolant freeze protection is insufficient for anticipated temperatures add only enough anti freeze to increase protection to the necessary level A 50 50 mixture of antifreeze and water will provide protection to 40 C 40 F The max imum concentration of antifreeze in the mixture must not exceed 60 percent Use the following chart as a general quide when pure antifreeze must be added to increase cool ant protection level 74 ENGINE COOLING SYSTEM Coolant Protection Level Guide Amount of Pura Antifreeze Needed New Protection Level After for 23 C 9 F Add Antif Protection ing Pure C 23 F 18L 19 at 10 C 14 F 13L 14 qt 15 C 6 F 10L 1 1 qi 20 C 4 F 0 3L 0 3 qf 5 C 23 F 28L 2 9 qt 10 C 14 F 2 5L 2 6 qt 18 C 6 F 221 23qt 20 C 4F 171 1 8 qt 28 C 13 F 14L 15 qh 30 C 22 F 12L 13qt 35 C 3t F 0 61 0 7 qt 2 Protection level checked with coolant at temperature ot 40 C 104 F FILLING AND PURGING THE COOLING SYSTEM Verify that all hose connectlons are secure Open the 4 cooling system bleed screws Refer io Item G on page 67 75 ATX GEAR SPECIFICATIONS amp RATIOS Sun Wheel Forward 16 Reverse 16 Planet Wheel Forward 30 Reverse 31 First Step Down Gears Primary 28 Secon
70. r The fuel system pressure is held constant by the pressure regulator The regulator is connected through a vacuum line to intake manifold vacuum As a result the difference between the intake manifold pressure and the fuel pressure i held constant The drop in pressure across the injectors is the same for all load conditions The connection to manifold vacuum is necessary to maintain the correct fuel flow through the fuel injectors Since less fuel is required at idle more fuel must be bypassed back to the fuel tank to Maintain the correct pressure differential At higher engine speeds and loads more fuel must be directed to the injectors Under these conditions the bypass flow back to the tank must be restricted In effect the fuel pressure regulator maintains a constant fuel fiow through the injectors by controlling the amount of fuel allowed to return to the fuel tank The fuel pressure is preset When the pressure exceeds 2 5 bars 36 psi 0 2 bars 3 psi the regulator valve will open and allow fuel to return to the fuel tank through the fuel return line The regulator contains a diaphragm and a calibrated spring The lower side of the diaphragm is influenced by fue pressure while the upper side of the diaphragm is influenced by intake manifold vacuum The spring in the upper side of the regulator is constantly working to keep the outlet to the fuel return line closed The combination of fuel pressure in the lower hal
71. r valve removed rotate it rapidly by hand in both directions and the valve should open and close 42 XR25 DIAGNOSTIC ANALYZER The XR25 Analyzer i5 an electronic tester that can be connected to the diagnostic output plug on the vehi cle The XR25 analyzes the diagnostic codes transmit ted by the ECU This provides quick and easy Go No Go functional tests of vital electronic components in the Bendix tuet injection system It alsa provides a digital readout of several engine operating conditions such as coolant temperature air temperature air pressure battery voltage engine RPM etc The XA25 s memory function is an extremely useful feature This allows you to perform a road test to recreate a malfunction then store the actual engine operating conditions under which the malfunction ac cured Later you can recall them one at a lime for diagnostic evaluation in addition to analyzing malfunctions the XA25 can be used as a Voltmeter continuity tester pulse sensor and puise generator The XR25 can also be used to diagnose transmission malfunctions on all type ME and ML automatic transmissions ATX Functional tests can be found in the Centauri LeSharo Phasar amp Utility Van Service Manuai 43 XR25 DIAGNOSTIC ANALYZER Digital Displays 7 Pow From 0000 to 999 LLI OK No Diagnostic Grid DESCRIPTION Go No Go Display LCD
72. rs one at a time and measuring RPM drop J Fuel pressure too iow Chack fuel pressure fuel filter the OF zero pS fuel lines the pressure regulator and the tuei pump Fual pressure too high Check pressure reguiator check for vacuum to pressure regulator check for pinched fuel return line Inoperative idle speed regulator Check operation of valve If it is defective replace the regulator valve CUBES MAP sensor defective Check vacuum at sensor check MAP sensor input and output voliages E Eod Eri Speedsensordefective aed sensor defective Check speed sensor resistance eet power module delectiva Check module voltage suppiy and call resistance Aur sensor detective Check sensor resistance REPEL OE Throttle not closing Free throttle linkage adjust throttle linkage Ep TTE PES eed DL Throttle not opening full Adjust accelerator cabte Open in wiring harness ar Check wiring harness and poor connection connections ECU Defective Test vehicle with XR25 diagnostic taster before replacing ECU pee He B Relay Detective Check voltage at relay Replace relay if defective Check wiring 35 2 2L MULTI POINT FUEL INJECTION DIAGNOSTIC SPECIAL TOOLS Part No 700001 04 800 ECU Test Circuit Board Used for ECU Wiring amp Component Test Tool No MS 1048 Part No 700000 90 400 Fuel Pressure Extension Hose Must be used with a fuel pressure gauge of 0 to 6 bars e Tool No Mot 90
73. sor e Coolant temperature sensor 14 e Throttle position switch e Gear indicator signal Air conditioning select signal e Knock sensor The ECU restricts EGR and canister purge operation by energizing the EGR canister purge solenoid Voltage is supplied to the injectors The ECU controls injector pulse width by controlling the length of time that the injector circuit ground path remains closed All four injectors are energized simultaneously once per engine revolution The ECU establishes correct idle speed by providing the required ground to the idle regulating valve If required idle speed is also adjusted to meet the increased engine laad from A C compressor operation The ECU determines the correct ignition timing and triggers tne ignition power module NOTE This is an OPEN LOOP mode Idle Mode Ounng engine idle the ECU responds to the following inputs f8 2 2L MULTI POINT FUEL INJECTION Manifold absolute pressura MAP sensor Engine speed sensor e Air temperature sensor Cociant temperature sensor e Throttle position switch Battery voltage signal e sensor Knock sensor e Air conditioning select signal The ECU restricts EGR and cantster purge operation by energizing the EGR canister purge solenoid Voltage is supplied to the injectors The ECU controls injector pulse width by controlling the length of time that the injector circuit ground path remains closed
74. taining strap 61 2 2L MULTI POINT FUEL INJECTION Remove the fuel fiiter installation Position the filter in place and secure with retaining strap Connectthe hoses to the fuel filter assembly and tighten clamps Remove clamps MOT 453 01 FUEL PRESSURE REGULATOR Removal Remove the fuel hose from the front of the fuel rail Disconnect the vacuum hose from the pressure regulator Locate and remove the 3 bolts A that retain the pressure regulator to the bottom of the intake manifold Remove the fuel return line from the bottom of the pressure regulator Remove the pressure regulator B from its bracket C 62 2 2L MULTI POINT FUEL INJECTION Installation Install the pressure regulator to its bracket Connect the fue return line to the bottom of the pressure regulator Install the pressure regulator and bracket into position and install retaining bolts Connect the fuel hose to the front of the fuel rail assembly Connect the vacuum hose to the pressure regulator 2 2L MULTI POINT FUEL INJECTION FUEL RAIL Install retaining bolts to the fuel rail at D Removal Connect the fuel hoses to the fuel rail assembly Disconnect the injector electrica connectors Connect the injector electrical connectors Remove the fuel hoses from each end of the fue rail INJECTOR Remove the fuel rail retaining boits D Removal Remove the fuel rail as previously described Re
75. take Replace the sensor if the temperature and resistance dont match the chart COOLANT TEMPERATURE SENSOR TEST Measure the sensor resistance as a function of the temperature after leaving it to stabilize for a minimum of 10 minutes with tne sensor removed from the engine Replace the sensor if the temperature and resistance don t match the chart ee Ci 20 s 80tV 9390s Temperature F 67 to 697 175 to 179 193 t 283 0 297 38310 397 2 2L MULTI POINT FUEL INJECTION DIAGNOSIS TESTING THROTTLE POSITION SWITCH TEST INJECTOR TEST WITH ENGINE STOPPED AND ADJUSTMENT Disconnect the injector connectors Testing and Adjustment Pul out the fuel rali and Injectors as an assembly so Rasistance between connector ecto 100 cc beaker FHROTTLE terminals in ohms 1 Piat sach i Coen De co C and B B and A The injector retaining clips are not strong enough to a ome hold ihe injectors in place when the fuai pressure ia ap piled It Is therefore necessary to install a retaining clamp to the fuel rail assembly before starting the elec tric fuei pump See Special Tools Sectlon page 37 far Information on fabricating this retaining clamp NOTE The switch is adjusted by moving it on the throttle housing when screws A have been loosened When the switch is properly adjusted it should click as soon as the throttle is moved toward the open position Energize
76. ter an oil change Differential Oi Change final drive oi during the 1 000 mite maintenance check and there after at intervals listed Check level at each engine oil change Cluich Check and Adjustment Check opera tian clearance and adjust if necessary during the 1 000 mile maintenance service and at prescribed intervals thereafter Idle Speed Not adjustable Air Fitter Replace aw cleaner element at 30 000 miles Use only Winnebago approved air fiiter Spark Plugs Reoiace the spark nlugs at 30 000 miles See Engine Specifications for recommended spark plugs and gap settings 10 11 12 13 14 15 t6 17 t8 19 Drive Belts Qualifled Technician Required Inspect condition and tension of belts driving the water pump alternator and air conditioner compressor at the 1 000 mile maintenance check and at specified intervals thereafter Hoses and Connections At each 15 000 mile interval check the condition of hoses con nections and fittings of the foliowing systems Tighten connections it necessary a Cooling system Brake system Fuelsystem Power steering b Vacuum system emissions related Oxygen Sensor At 80 000 miles chack sensor operation and repiace it necessary Valve Lash Adjust valve lash as required at each 30 000 mule interval PCV Sysiem Check and replace defective components if necessary at 50 000 miles Fuel Filter Qualified Technician Required
77. the 1 000 mile maintenance check and at each 5 000 mile interval check operation of ali lights turn signals warning lights hazard flashes instru ments horn wipers heater fan etc Adjust headlight alignment if necessary at each 15 000 mile interval Rocker Shaft Oil Filter Replace rocker shaft oil filter and check valve clearances at each 30 000 mile interval Road Test During the 1 000 mile maintenance check and ateach 000 mile interval thereafter road test the vehicle and check the following Acceleration and braking e Steering suspension and nandiirg e Fluid and body leakage Doors and hood lubricate if necessary e Body components e Accessory operation ENGINE OIL CHANGE The first oil change must be performed during the 1 000 mile maintenance service and thereafter at each interval specified in the maintenance schedule It is recommended that engine oil be changed more frequently if the vehicle is subjected to very hard use To change engine oil 1 Remove drain plug Allow time for old oi to escape Reinsert drain plug into drain hole 3 Refill crackcase through filler hole on top of engine a MS P i f YA QE aS SS ho CAUTION The engine must not be flushed out uncer any circumstances ENGINE OIL FILTER CHANGE The engine oil filter must be changed during the 1 000 mile maintenance service and thereafter at each specified interval
78. tput to D2 1 2 Ground 18 System Power B Not Used 20 Injector Output Signal 4 Permanent Memory Power Supply 21 injector Output Signal 5 EGR Vae Canistar Purge 22 AC Relay Ground Output amp Fuel Pump Relay 23 ide Speed Regulator Coil 1 7 System Power Relay latch relay 24 s Speed Regulator Coll 2 8 WOT Switch 25 Closed Throttle ile Switch 9 Not Used 28 Not used 10 Not Used 27 Timing Control Signal Tach Ovtowt 11 Speed Sensor Input 8 28 Speed Sansor Inout A 12 Park Neutral Switch auto trans only 29 Crank Signal leout 13 Not Used 30 AC Select 14 Manifold Ax Temperature Sensor 31 Knock Sensor input 15 Coolant Temperature Sensor 32 Temperature Sensor Ground 16 Manifold Absolute Pressure Supply 33 MAP Sensor Output vVoraga 34 AIC Thermostat 17 Maniolg Absolute Pressura and Oxygen 35 O Sensor input Sensor Ground Connector D2 CONNECTOR o2 CONNECTOR o Connector D1 1 ECU Diagnostic Output 9 Not Used 1 Tach Signal 2 Not Used 10 EGR 2 Ignition 3 Not Used 11 Idle Speed Regulator Coil 1 3 Ground 4 B Relay 12 Coolant Temperature Sensor 4 Start Relay 5 Not Used 13 Closed Throttle Switch 5 Battery 6 WOT 14 Idle Speed Regulator Coil 2 6 Fuel Pump Relay 7 Ground 15 Automatic Transmission Diagnosis i 8 Air Temperature Sensor BY A module E SARDO t fU mwa A DUE mismo pe eer woswts ar 3 1 na np
79. ve pinion Circlips O ring seals Snap rings Fin drive pinion nut od hort I a m Is onal clip on clutch shaft FINAL DRIVE ASSEMBLY Dismantling 18 19 20 24 22 1 Crown wheel 14 Cup 2 Differential housing 15 Sun wheel 3 Final drive pinion 16 Washer 4 Taper coller bearing 17 Backlash adjusting shim 5 Doubie lip seal 18 Taper roller bearing 6 Step down gear 19 Lip seal 7 Pre load adjusting spacer 20 Ball race 8 Taper roller bearing 21 Circlip 9 Nut 22 Plastic ring 11 Short sun wheel 23 Taper roller bearing 12 Pianet wheel shaft 24 O ring 13 Planet wheel 79 FINAL DRIVE ASSEMBLY Dismantling e s shaft seal bearings pinion TIGHTENING TORQUES daNm Ib ft Final drive pinion nut 4 29 then 18 132 Crown wheel bolts 12 5 92 Bolts on final drive half housing 3 22 5 37 Bolts securing final drive clutch housing to step down housing cover 3 22 Bolts on step down housing cover 3 22 ESSENTIAL SPECIAL TOOLS B Vi 654 Castellated spanner for adjusting the differential clearance Spanner for differential nut B Vi 905 02 Tools for replacing the speedometer driv Torque measuring tool B Vi 1059 Rings for fitting tbe differential Support for step down gear housing B Vi 1088 Tool for tightening the final drive pinion

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