1994 NISSAN STANZA ALTIMA U13 Series Service Manual PDF DOWNLOAD
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1994 NISSAN STANZA ALTIMA U13 Series Service Manual PDF DOWNLOAD
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Pages : 1171
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1994 NISSAN STANZA ALTIMA U13 Series Service Manual PDF DOWNLOAD
FOREWORD
- This manual contains maintenance and repair procedures for the 1994 Nissan STANZA ALTIMA. In order to assure your safety and the efficient functioning of the vehicle, this manual should be read thoroughly.
- It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task. All information in this manual is based on the latest product information at the time of publication.
- The right is reserved to make changes in specifications and methods at any time without notice.
PREPARATION AND PRECAUTIONS
• Before proceeding with disassembly, thoroughly clean the outside of the transaxle. It is important to prevent the internal parts from becoming contaminated by dirt or other foreign matter.
• Disassembly should be done in a clean work area.
• Use a lint-free cloth or towels for wiping parts clean. Common shop rags can leave fibers that could interfere with the operation of the transaxle.
• When disassembling parts, place them in order on a parts rack so that they can be assembled in their proper positions.
• All parts should be carefully cleaned with a general-purpose, non-flammable solvent before inspection or reassembly.
• Gaskets, seals, and O-rings should be replaced any time the transaxle is disassembled.
• It is very important to perform functional tests whenever they are indicated.
• Valve bodies contain precision parts and require extreme care when parts are removed and serviced. Place removed parts in order on a parts rack so they can be put back in the valve body in the same positions and sequences. Care will also prevent springs and small parts from becoming scattered or lost.
• Properly installed valves, sleeves, plugs, etc. will slide along their bores in the valve bodies under their own weight.
• Before assembly, apply a coat of recommended ATF to all parts. Petroleum jelly may be applied to O-rings and seals and used to hold small bearings and washers in place during reassembly. Do not use grease.
• Extreme care should be taken to avoid damage to O-rings, seals, and gaskets when assembling.
• If foreign matter is found to have accumulated in the oil pan in large quantities during overhaul or the oil strainer is excessively clogged, flush or replace ATF cooler as required. For servicing, refer to AT-19.
• After overhaul, refill the transaxle with new ATF.
• Even when the drain plug is removed, the old ATF fluid will remain in the torque converter and the ATF fluid cooling system. Always follow the procedures under “Changing ATF Fluid” in the MA section when changing ATF fluid.
TABLE OF CONTENTS:
1994 NISSAN STANZA ALTIMA U13 Series Service Manual PDF DOWNLOAD
fwd 1
Model Selection 0
QUICK REFERENCE INDEX 1
FOREWORD 2
GI – General Information 0
MA – Maintenance 0
EM – Engine Mechanical 0
LC – Engine Lubrication and Cooling Systems 0
EF & EC – Engine Fuel and Emission Control System 0
FE – Accelerator Control, Fuel and Exhaust Systems 0
CL – Clutch 0
MT – Manual Transaxle 0
AT – Automatic Transaxle 0
FA – Front Axle and Front Suspension 0
RA – Rear Axle and Rear Suspension 0
BR – Brake System 0
ST – Steering System 0
BF – Body 0
HA – Heater and Air Conditioner 0
EL – Electrical System 0
IDX – Alphabetical Index 1
Foldout 0
Quick Reference Chart 3
at 4
QUICK REFERENCE INDEX 0
TABLE OF CONTENTS 4
PREPARATION AND PRECAUTIONS 7
Special Service Tools 7
Commercial Service Tools 11
Precautions 12
DESCRIPTION 14
Cross-sectional View 14
Hydraulic Control Circuits 15
Shift Mechanism 16
Construction 16
Function Of Clutch And Brake 17
Operation Of Clutch And Brake 17
Control System 18
Outline 18
Control System 18
A/T Control Unit Function 19
Input/Output Signal Of A/T Control Unit 19
TROUBLE DIAGNOSES 20
How to Perform Trouble Diagnoses for Quick and Accurate Repair 20
Information From Customer 21
Diagnostic Worksheet 22
Remarks 24
Fail-Safe 24
ATF Cooler Service 24
Diagnosis by CONSULT 25
Application 25
Data Analysis 27
Preliminary Check 28
A/T Fluid Check 28
Fluid leakage check 28
Fluid condition check 28
Fluid level check 28
Road testing 28
Description 28
1 Check before engine is started 29
2 Check at idle 30
3 Cruise test 32
With CONSULT 32
Without CONSULT 35
Cruise test – Part 1 35
Cruise test – Part 2 38
Cruise test – Part 3 40
Vehicle speed when shifting gears 41
Vehicle speed when performing lock-up 41
Shift schedule (Comfort pattern) 42
Shift schedule (Auto power pattern) 42
A/T Electrical Parts Location 43
Circuit Diagram for Quick Pinpoint Check 44
Wiring Diagram 45
Self-diagnosis 51
Self-Diagnostic Procedure (With CONSULT) 51
Self-Diagnostic Procedure (Without CONSULT) 52
Judgement Of Self-Diagnosis Code 54
Revolution Sensor Circuit Check 56
Vehicle Speed Sensor Circuit Check 57
Throttle Position Sensor Circuit Check 58
Shift Solenoid Valve A Circuit Check 59
Shift Solenoid Valve B Circuit Check 60
Overrun Clutch Solenoid Valve Circuit Check 61
Torque Converter Clutch Solenoid Valve Circuit Check 62
Fluid Temperature Sensor Circuit And A/T Control Unit Power Source Circuit Checks 63
Engine Speed Signal Circuit Check 65
Line Pressure Solenoid Valve Circuit Check 66
Inhibitor Switch, Overdrive Switch And Closed Throttle Position Switch Circuit Checks 67
Diagnostic Procedure 1 71
Diagnostic Procedure 2 72
Diagnostic Procedure 3 72
Diagnostic Procedure 4 73
Diagnostic Procedure 5 74
Diagnostic Procedure 6 75
Diagnostic Procedure 7 77
Diagnostic Procedure 8 78
Diagnostic Procedure 9 79
Diagnostic Procedure 10 81
Diagnostic Procedure 11 82
Diagnostic Procedure 12 83
Diagnostic Procedure 13 84
Diagnostic Procedure 14 85
Diagnostic Procedure 15 86
Diagnostic Procedure 16 87
Diagnostic Procedure 17 87
Diagnostic Procedure 18 88
Diagnostic Procedure 19 88
Diagnostic Procedure 20 89
Electrical Components Inspection 90
Inspection Of A/T Control Unit 90
A/T Control Unit Inspection Table 90
Overdrive Switch 94
Inhibitor Switch 94
Revolution Sensor 95
Solenoid Valves And Fluid Temperature Sensor 95
Dropping Resistor 96
Final Check 96
Stall Testing 96
Stall test procedure 96
Judgement of stall test 98
Pressure Testing 99
Line pressure test procedure 99
Judgement of line pressure test 100
Symptom Chart 101
TROUBLE DIAGNOSES – A/T Shift Lock System 104
Shift Lock Electrical Parts Location 104
Circuit Diagram for Quick Pinpoint Check 105
Wiring Diagram 106
Diagnostic Procedure 107
Key Interlock Cable 111
Shift Lock Control Module Inspection 112
Shift Lock Control Module Inspection Table 112
Component Check 113
ON-VEHICLE SERVICE 114
Control Valve Assembly and Accumulator 114
Revolution Sensor Replacement 116
Inhibitor Switch Adjustment 116
Control Cable Adjustment 116
Differential Side Oil Seal Replacement 116
REMOVAL AND INSTALLATION 118
MAJOR OVERHAUL 120
Oil Channel 123
DISASSEMBLY 124
REPAIR FOR COMPONENT PARTS 140
Manual shaft 140
Oil Pump 143
Control Valve Assembly 147
Control Valve Upper Body 156
Control Valve Lower Body 160
Reverse Clutch 163
High Clutch 167
Forward Clutch and Overrun Clutch 172
Low & Reverse Brake 178
Rear Internal Gear, Forward Clutch Hub and Overrun Clutch Hub 181
Output Shaft, Idler Gear, Reduction Gear and Bearing Retainer 185
Band Servo Piston Assembly 190
Final Drive – RE4F04A 195
Final Drive – RE4F04V 199
ASSEMBLY 205
Adjustment 205
Differential Side Bearing Preload 205
Reduction Gear Bearing Preload 207
Output Shaft End Play 209
Assembly 211
Adjustment 217
Total End Play 217
Assembly 219
SERVICE DATA AND SPECIFICATIONS (SDS) 226
General Specifications 226
Specifications and Adjustments 226
Vehicle Speed When Shifting Gears 226
Vehicle Speed When Performing Lock-up 226
Stall Revolution 227
Line Pressure 227
Control Valves 227
Clutches And Brakes 228
Final Drive 229
Planetary Carrier And Oil Pump 230
Input Shaft 230
Reduction Gear 230
Reverse Clutch End Play 231
Accumulator 231
Band Servo 231
Removal And Installation 231
Output Shaft 231
Bearing Retainer 232
Total End Play 232
bf 233
QUICK REFERENCE INDEX 0
TABLE OF CONTENTS 233
GENERAL SERVICING 235
Precautions 235
Supplemental Restraint System “AIG BAG” 235
Circuit Breaker Inspection 235
Clip and Fastener 236
BODY END 238
Body Front End 238
Removal – Front bumper assembly 238
Body Rear End and Opener 240
Removal – Rear bumper assembly 240
DOOR 242
Front Door 242
Rear Door 243
POWER DOOR LOCK 244
System Description 244
Power Door Lock 244
Unlock 244
Lock 244
Circuit Diagram for Quick Pinpoint Check 244
Wiring Diagram 245
Door Lock Timer 247
POWER WINDOW 248
System Description 248
Window Down 248
Window Up 248
Auto Feature 248
Lock Feature 248
Component Layout 249
TROUBLE DIAGNOSES – Power Window 250
Symptom Chart 250
Circuit Diagram for Quick Pinpoint Check 251
Wiring Diagram 252
Main Power Supply and Ground Circuit Check 255
Procedure 1 255
Main power supply 255
Ground circuit 255
Procedure 2 255
Power supply for power window amp (front and rear passengers) 255
Ground circuit for power window amp (front and rear passengers) 255
Procedure 3 255
Power supply for ignition signal 255
Diagnostic Procedure 1 256
Diagnostic Procedure 2 257
Diagnostic Procedure 3 258
Diagnostic Procedure 4 259
Electrical Components Inspection 260
Power Window Motor 260
Power Window Switch 260
INSTRUMENT PANEL 261
Removal – Instrument panel assembly 261
Head-Up Display (Hud) 262
INTERIOR AND EXTERIOR 264
Interior 264
Side And Floor Trim 264
Removal – Body side trim 264
Door Trim Removal – Door trim 265
Room Trim 266
Removal – Headlining 266
Luggage Room Trim 267
Exterior 268
1 Front hood insulator 269
2 Cowl top grille and cowl top front sealing rubber 269
3 Front windshield molding 269
Windshield upper and side molding 270
4 Sunroof lid weatherstrip 270
5 Body side drip weatherstrip 270
6 Door weatherstrip 271
7 Body side welt 271
8 Door waist outside molding 271
9 Front door corner cover 272
10 Rear windshield molding 272
11 Trunk lid weatherstrip 272
12 Rear combination lamp 273
13 Side guard molding 273
14 Center mudguard 274
15 Front door parting seal 274
SEAT 275
Front Seat 275
Rear Seat 276
3-POINT ACTIVE SEAT BELT SYSTEM 277
Unit Location 277
Front Seat 277
Rear Seat 278
SUNROOF 279
System Description 280
Power 280
Tilt And Slide Operation 280
If The Sunroof Does Not Close 280
Removal 280
Sunroof Lid Assembly 280
Shade Assembly 280
Sunroof Assembly 280
Link & Wire Assembly 281
Adjustment 281
Wiring Diagram 282
WINDSHIELD AND WINDOWS 283
Windshield 283
Repairing Water Leaks For Windshield 283
MIRROR 284
Door Mirror 284
Removal 284
Wiring Diagram 285
REAR AIR SPOILER 286
Rear Air Spoiler 286
BODY ALIGNMENT 287
Engine Compartment 287
Measurement 287
Measurement Points 288
Underbody 289
Measurement 289
Measurement Points 290
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 291
Precautions for SRS “Air Bag” Service 291
Special Service Tools 291
Commercial Service Tools 291
Description 292
Self-diagnosis 292
SRS Component Parts Location 293
Caution Labels 294
Maintenance Items 296
Rmoval and Installation – Control Module and Sensors 297
Removal – Driver Air Bag Module and Spiral Cable 298
Removal – Front Passenger Air Bag Module 300
Installation – Driver Air Bag Module and Spiral Cable 301
Installation – Front Passenger Air Bag Module 302
Scrapping the Air Bag 302
Connecting To Battery 302
Deployment Tool Check 303
Air Bag Deployment Tool Lamp Illumination Chart 303
Connecting To Air Bag 303
Deployment 304
TROUBLE DIAGNOSES – Supplemental Restraint System (SRS) 306
Schematic 306
Wiring Diagram 306
Self-diagnosis 309
Using CONSULT 309
Self-diagnosis results 310
Using The Warning Lamp 312
How to alternate self-diagnosis 312
Warning lamp flashing times and repair 314
Diagnostic Procedure 1 315
Diagnostic Procedure 2 315
Diagnostic Procedure 3 316
Collision Diagnosis 317
br 318
QUICK REFERENCE INDEX 0
TABLE OF CONTENTS 318
PRECAUTIONS AND PREPARATION 320
Precautions 320
Supplemental Restraint System “Air Bag” 320
Brake System 320
Special Service Tools 320
Commercial Service Tools 321
CHECK AND ADJUSTMENT 322
Checking Brake Fluid Level 322
Checking Brake Line 322
Changing Brake Fluid 322
AIR BLEEDING 323
Bleeding Procedure 323
BRAKE HYDRAULIC LINE 324
Removal 324
Inspection 324
Installation 324
CONTROL VALVE 325
Proportioning Valve 325
Inspection 325
Removal (Separated type) 325
Installation (Separated type) 326
Removal And Installation (Built-in type) 326
BRAKE PEDAL AND BRACKET 327
Removal and Installation 327
Inspection 327
Adjustment 327
MASTER CYLINDER 329
Removal 329
Disassembly 329
Inspection 330
Assembly 330
Installation 331
BRAKE BOOSTER 332
On-vehicle Service 332
Operating Check 332
Airtight Check 332
Removal 332
Inspection 333
Output Rod Length Check 333
Installation 333
VACUUM HOSE 334
Removal and Installation 334
Inspection 334
Hoses And Connectors 334
Check Valve 334
FRONT DISC BRAKE 335
Pad Replacement 335
Removal 336
Disassembly 337
Inspection – Caliper 337
Cylinder Body 337
Piston 337
Slide Pin, Pin Bolt And Pin Boot 337
Inspection – Rotor 337
Runout 337
Thickness 338
Assembly 338
Installation 338
REAR DRUM BRAKE 339
Removal 339
Inspection – Wheel Cylinder 341
Wheel Cylinder Overhaul 341
Inspection – Drum 341
Inspection – Lining 342
Installation 342
REAR DISC BRAKE 344
Pad Replacement 344
Removal 346
Disassembly 346
Inspection – Caliper 347
Cylinder Body 347
Piston 347
Slide Pin, Pin Bolt And Pin Boot 347
Inspection – Rotor 348
Runout 348
Thickness 348
Assembly 348
Installation 350
PARKING BRAKE CONTROL 351
Removal and Installation 351
Inspection 351
Adjustment 352
ANTI-LOCK BRAKE SYSTEM 353
Purpose 353
Operation 353
System Description 354
Sensor 354
Control Module 354
Removal and Installation 355
Front Wheel Sensor 355
Rear Wheel Sensor 355
Control Module 356
Actuator 356
Actuator Relays 356
Wiring Diagram 357
Component Parts and Harness Connector Location 360
TROUBLE DIAGNOSES 361
How to Perform Trouble Diagnoses for Quick and Accurate Repair 361
Introduction 361
Self-diagnosis 362
Function 362
Self-Diagnosis Procedure 362
How To Read Self-Diagnostic Results (Malfunction codes) 363
How To Erase Self-Diagnostic Results (Malfunction codes) 364
Malfunction Code Chart 364
Preliminary Check 365
Ground Circuit Check 366
Control Module Ground 366
Relay Box Ground 366
Circuit Diagram for Quick Pinpoint Check 367
Diagnostic Procedure 1 (Not self-diagnostic item) 368
Diagnostic Procedure 2 (Not Self-diagnostic Item) 369
Diagnostic Procedure 3 370
Actuator Solenoid (Malfunction code No 45, 41 or 55) 370
Diagnostic Procedure 4 371
Wheel Sensor Or Rotor 371
Diagnostic Procedure 5 373
Motor Relay Or Motor 373
Diagnostic Procedure 6 375
Solenoid Valve Relay 375
Diagnostic Procedure 7 376
Power Supply (Low voltage) 376
Diagnostic Procedure 8 376
Stop Lamp Switch Circuit 376
Diagnostic Procedure 9 376
Control Module 376
Electrical Components Inspection 377
Wheel Sensor 377
Motor Relay 377
Solenoid Valve Relay 377
SERVICE DATA AND SPECIFICATIONS (SDS) 378
General Specifications 378
Inspection and Adjustment 378
Disc Brake 378
Drum Brake 378
Brake Pedal 378
Parking Brake 378
cl 379
QUICK REFERENCE INDEX 0
TABLE OF CONTENTS 379
PRECAUTIONS AND PREPARATION 380
Precautions 380
Special Service Tools 380
CLUTCH SYSTEM – Hydraulic Type 381
INSPECTION AND ADJUSTMENT 382
Adjusting Clutch Pedal 382
For USA model only 383
Bleeding Procedure 383
HYDRAULIC CLUTCH CONTROL 384
Clutch Master Cylinder 384
Disassembly and Assembly 384
Inspection 385
Operating Cylinder 385
Inspection 385
CLUTCH RELEASE MECHANISM 386
Inspection 386
Lubrication 386
CLUTCH DISC AND CLUTCH COVER 387
Clutch Disc 387
Inspection 387
Installation 387
Clutch Cover and Flywheel 388
Inspection and Adjustment 388
Flywheel Inspection 388
Installation 388
SERVICE DATA AND SPECIFICATIONS (SDS) 389
General Specifications 389
Clutch Control System 389
Clutch Master Cylinder 389
Clutch Operating Cylinder 389
Clutch Disc 389
Clutch Cover 389
Inspection and Adjustment 389
Clutch Pedal 389
Clutch Disc 389
Clutch Cover 389
ec 390
QUICK REFERENCE INDEX 0
TABLE OF CONTENTS 390
PREPARATION 393
Special Service Tools 393
PRECAUTIONS 394
ENGINE AND EMISSION CONTROL OVERALL SYSTEM 396
ECCS Component Parts Location 396
System Diagram 398
A/T Models For California And M/T Models 398
A/T Models Except For California 399
System Chart 400
Vacuum Hose Drawing 401
Circuit Diagram 402
ENGINE AND EMISSION CONTROL PARTS DESCRIPTION 403
Engine Control Module (ECM)-ECCS Control Module 403
Camshaft Position (CMP) Sensor 403
Mass Air Flow (MAF) Sensor 403
Engine Coolant Temperature (ECT) Sensor 404
Throttle Position (TP) Sensor & Soft/Hard Closed Throttle Position (CTP) Switch 404
Fuel Injector 405
Fuel Pressure Regulator 405
Oxygen Sensor (O2S) 405
Fuel Pump 405
Ignition Coil with Power Transistor 406
Idle Air Control (IAC) Valve-Air Regulator 406
Idle Air Control (IAC) Valve-Fast Idle Control Device (FICD) Solenoid Valve 406
Idle Air Control (IAC) Valve-Auxiliary Air Control (AAC) Valve 406
Power Steering Pressure Switch 406
Vehicle Speed Sensor (VSS) 407
Knock Sensor (KS) 407
Fuel Filter 407
Data Link Connector (DLC) for CONSULT 407
Exhaust Gas Recirculation (EGR) Valve 407
EGR Control-BPT Valve 408
EGR and Canister Control Solenoid Valve 408
Carbon Canister 408
EGR Temperature Sensor 408
ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION 409
Multiport Fuel Injection (MFI) System 409
Distributor Ignition (DI) System 412
Idle Air Control (IAC) System 414
Exhaust Gas Recirculation (EGR) System 415
Fuel Pump Control 415
Acceleration Cut Control 416
Cooling Fan Control 416
Fail-safe System 417
IDLE SPEED/IGNITION TIMING/IDLE MIXTURE RATIO INSPECTION 419
TROUBLE DIAGNOSES 424
How to Perform Trouble Diagnoses for Quick and Accurate Repair 424
Introduction 424
Work Flow 425
Diagnostic Worksheet 426
Worksheet sample 426
Intermittent Problem Simulation 427
On-board Diagnostic System 428
On-board Diagnostic System – On-board Diagnostic Test Mode I 430
On-board Diagnostic System – On-board Diagnostic Test Mode II (Self-diagnostic results) 431
How To Erase On-Board Diagnostic Test Mode II (Self-Diagnostic Results) 433
On-board Diagnostic System – On-board Diagnostic Test Mode II (Oxygen sensor monitor) 433
How To Check Oxygen Sensor 433
CONSULT 434
CONSULT Inspection Procedure 434
Function 435
ECCS Component Parts Application 435
Work Support Diagnostic Test Mode 436
Self-Diagnostic Results Diagnostic Test Mode 437
Data Monitor Diagnostic Test Mode 438
Active Test Diagnostic Test Mode 440
Function Test Diagnostic Test Mode 441
Diagnostic Procedure 444
Basic Inspection 446
Diagnostic Procedure 1 – High Idling after Warm-up 449
Diagnostic Procedure 2 – Hunting 449
Diagnostic Procedure 3 – Unstable Idle 451
Diagnostic Procedure 4 – Hard to Start or Impossible to Start when the Engine is Cold 454
Diagnostic Procedure 5 – Hard to Start or Impossible to Start when the Engine is Hot 456
Diagnostic Procedure 6 – Hard to Start of Impossible to Start under Normal Conditions 457
Diagnostic Procedure 7 – Hesitation when the Engine is Hot 459
Diagnostic Procedure 8 – Hesitation when the Engine is Cold 460
Diagnostic Procedure 9 – Hesitation under Normal Conditions 461
Diagnostic Procedure 10 – Engine Stalls when Turning 462
Diagnostic Procedure 11 – Engine Stalls when the Engine is Hot 464
Diagnostic Procedure 12 – Engine Stalls when the Engine is Cold 466
Diagnostic Procedure 13 – Engine Stalls when Stepping on the Accelerator Momentarily 468
Diagnostic Procedure 14 – Engine Stalls after Decelerating 470
Diagnostic Procedure 15 – Engine Stalls when Accelerating or when Driving at Constant Speed 474
Diagnostic Procedure 16 – Engine Stalls when the Electrical Load is Heavy 476
Diagnostic Procedure 17 – Lack of Power and Stumble 478
Diagnostic Procedure 18 – Knock 479
Diagnostic Procedure 19 – Surge 481
Diagnostic Procedure 20 – Backfire through the Intake 482
Diagnostic Procedure 21 – Backfire through the Exhause on Deceleration 482
Diagnostic Procedure 22 483
Main Power Supply And Ground Circuit (Not self-diagnostic item) 483
Self-Diagnosis Codes 486
Camshaft Position Sensor (Diagnostic trouble code No 11) 486
Mass Air Flow Sensor (Diagnostic trouble code No 12) (Malfunction Indicator Lamp Item) 489
Engine Coolant Temperature Sensor (Diagnostic trouble code No 13) (Malfunction Indicator Lamp Item) 492
Vehicle Speed Sensor (Diagnostic trouble code No 14) (Malfunction Indicator Lamp Item) 495
Ignition Signal (Diagnostic trouble code No 21) 498
ECM (ECCS Control Module) (Diagnostic trouble code No 31) (Malfunction Indicator Lamp Item) 500
EGR Function (Diagnostic trouble code No 32) (Malfunction Indicator Lamp Item) 501
Oxygen Sensor (Diagnostic trouble code No 33) (Malfunction Indicator Lamp Item) 505
Knock Sensor (Daignostic trouble code No 34) 508
EGR Temperature Sensor (Diagnostic trouble code No 35) (Malfunction Indicator Lamp Item) 510
Throttle Position Sensor (Diagnostic trouble code No 43) (Malfunction Indicator Lamp Item) 513
Injector Leak (Diagnostic trouble code No 45) (Malfunction Indicator Lamp Item) 516
A/T Control (Diagnostic trouble code No 54) 518
Non-Self-Diagnosis Items 520
Start Signal 520
Injector 522
Fuel Pump 524
IAC Valve-AAC Valve 527
Cooling Fan Control 530
Power Steering Pressure Switch 536
Neutral Position Switch/Inhibitor Switch 538
Electrical Components Inspection 544
ECM Input/Output signal Inspection 544
ECM Harness Connector Terminal Layout 544
ECM Inspection table 545
Camshaft Position Sensor 549
Mass Air Flow Sensor 549
Engine Coolant Temperature Sensor 550
Power Transistor 550
Ignition Coil 551
Fuel Pump 551
EGR And Canister Control Solenoid Valve 551
EGR Valve 552
EGR Control-BPT Valve 552
EGR Temperature Sensor 552
Wide Open Throttle Position Switch – A/T model only 552
Closed Throttle Position Switch (Idle position) – A/T model only 553
Throttle Position Sensor 553
Adjustment 553
IAC Valve-AAC Valve 554
Knock Sensor 554
Injector 554
ECM Relay And Fuel Pump Relay 555
Inhibitor Relay (A/T models with ASCD) 555
Inhibitor Relay 9A/T models without ASCD) 555
Cooling Fan Relays-2 And -3 555
Power Steering Pressure Switch 555
IAC Valve-Air Regulator 556
IAC Valve-FICD Solenoid Valve 556
Cooling Fan Motors-1 And -2 556
Resistor 556
MULTIPORT FUEL INJECTION SYSTEM INSPECTION 557
Releasing Fuel Pressure 557
Fuel Pressure Check 557
Fuel Pressure Regulator Check 558
Injector Removal and Installation 558
EVAPORATIVE EMISSION (EVAP) SYSTEM 559
Description 559
Inspection 559
CRANKCASE EMISSION CONTROL SYSTEM 561
Description 561
Inspection 561
SERVICE DATA AND SPECIFICATIONS (SDS) 562
el 563
QUICK REFERENCE INDEX 0
TABLE OF CONTENTS 563
PRECAUTIONS 566
Precautions for Supplemental Restraint System “AIR BAG” 566
HARNESS CONNECTOR 567
Description 567
STANDARDIZED RELAY 568
Description 568
POWER SUPPLY ROUTING 570
Wiring Diagram 570
Fuse 575
Fusible Link 575
BATTERY 576
How to Handle Battery 576
Methods Of Preventing Discharge 576
Checking Electrolyte Level 577
Specific Gravity Check 577
Hydrometer temperature correction 578
Charging The Battery 578
Memory Reset 579
Voltage chart 580
Service Data and Specifications (SDS) 580
STARTING SYSTEM 581
System Description 581
M/T models for USA 581
A/T models and CANADA M/T models 581
Wiring Diagram 583
M/T models for USA 583
A/T models and CANADA M/T models 584
Pinion/Clutch Check 586
Service Data and Specifications (SDS) 586
CHARGING SYSTEM 587
System Description 587
Wiring Diagram 588
Trouble Diagnoses 589
Construction 590
Diode Check 591
Assembly 592
Service Data and Specifications (SDS) 593
COMBINATION SWITCH 594
Combination Switch/Check 594
Combination Switch/Replacement 595
HEADLAMP 596
System Description (For USA) 596
Wiring Diagram (For USA) 598
Trouble Diagnoses (For USA) 600
System Description (For Canada) 601
Headlamp Operation 601
Daytime Light Operation 602
Schematic (For Canada) 603
Wiring Diagram (For Canada) 604
Trouble Diagnoses (For Canada) 608
Daytime Light Control Module Inspection Table 608
Bulb Replacement 610
Aiming Adjustment 610
Low Beam 610
Adjusting After Headlamp Assembly Replacement 611
EXTERIOR LAMP 612
Back-up Lamp/Wiring Diagram 612
Clearance, License, Tail and Stop Lamps/Wiring Diagram 614
Front Fog Lamp/System Description 616
Front Fog Lamp/Wiring Diagram 617
Turn Signal and Hazard Warning Lamps/System Description 618
Turn Signal Operation 618
Hazard Lamp Operation 618
Turn Signal and Hazard Warning Lamps/Wiring Diagram 620
Turn Signal and Hazard Lamps/Trouble Diagnoses 622
Cornering Lamp/System Description 624
Cornering Lamp/Wiring Diagram 625
Flasher Module Check 626
Bulb Specifications 626
INTERIOR LAMP 627
Illumination/System Description 627
Illumination/Wiring Diagram 628
Interior, Personal and Trunk Room Lamps/Wiring Diagram 631
METERS AND GAUGES 632
System Description 632
Combination Meter 633
Without Head-Up Display 633
With Head-Up Display 634
Speedometer, Tachometer, Temp and Fuel Gauges/Wiring Diagram 636
Without Head-Up Display 636
With Head-Up Display 638
Inspection/Fuel Gauge and Water Temperature Gauge 640
Inspection/Tachometer 641
Inspection/Speedometer and Vehicle Speed Sensor 642
Inspection/Speedometer and Fuse 643
Fuel Tank Gauge Unit Check 644
Fuel Warning Lamp Sensor Check 644
Thermal Transmitter Check 644
Oil Pressure Switch Check 645
Vehicle Speed Sensor Signal Check 645
WARNING LAMPS AND CHIME 646
Warning Lamps/System Description 646
Warning Lamps/Schematic 647
Warning Lamps/Wiring Diagram 648
Warning Chime/System Description 653
Warning Chime/Wiring Diagram 654
Diode Check 655
Warning Chime Check 655
TIME CONTROL SYSTEM 656
System Description 656
Function 657
Circuit Diagram for Quick Pinpoint Check 659
Wiring Diagram 660
Trouble Diagnoses 664
Symptom Chart 664
Preliminary Check 665
Preliminary check 1 665
Preliminary check 2 665
Preliminary check 3 665
Main Power Supply And Ground Circuit Check 666
Diagnostic Procedure 1 667
Diagnostic Procedure 2 668
Diagnostic Procedure 3 668
Diagnostic Procedure 4 669
Diagnostic Procedure 5 670
Diagnostic Procedure 6 671
Diagnostic Procedure 7 672
WIPER AND WASHER 673
System Description 673
Wiper Operation 673
Washer Operation 674
Front Wiper and Washer/Wiring Diagram 676
Installation 678
Washer Nozzle Adjustment 679
HORN, CIGARETTE LIGHTER, CLOCK 680
Wiring Diagram 680
REAR WINDOW DEFOGGER 681
System Description 681
Wiring Diagram 682
Filament Check 683
Filament Repair 684
AUDIO AND POWER ANTENNA 685
Audio/System Description 685
With Active Speaker System 685
Except Active Speaker System 685
Audio/Wiring Diagram 686
Active Speaker System 686
Except Active Speaker System 691
Power Antenna/System Description 692
Location of Antenna 692
Power Antenna/Wiring Diagram 693
Trouble Diagnoses 694
Antenna Rod Replacement 696
Window Antenna Repair 697
AUTOMATIC SPEED CONTROL DEVICE (ASCD) 698
System Description 698
Component Parts and Harness Connector Location 700
Schematic 701
Wiring Diagram 702
Trouble Diagnoses 705
Symptom Chart 705
Diagnostic Procedure 1 706
Diagnostic Procedure 2 708
Diagnostic Procedure 3 708
Diagnostic Procedure 4 708
Diagnostic Procedure 5 709
Diagnostic Procedure 6 710
Diagnostic Procedure 7 711
Diagnostic Procedure 8 712
ASCD Wire Adjustment 713
Electrical Components Inspection 714
ASCD actuator/ASCD pump 714
ASCD main switch 715
ASCD steering switch 715
ASCD cancel switch and stop lamp switch 715
ASCD clutch pedal position switch (For M/T models) 715
Inhibitor switch (For A/T models) 716
Vehicle speed sensor 716
THEFT WARNING SYSTEM 717
System Description 717
Theft Warning System Activation (Without Key Used To Lock Front Doors) 717
Theft Warning Sytem Activation (With Key Used To Lock Doors) 717
Theft Warning Sytem Operation 718
Theft Warning System Deactivation 718
Component Parts and Harness Connector Location 719
Circuit Diagram for Quick Pinpoint Check 720
Wiring Diagram 722
Trouble Diagnoses 729
System Operation Check 729
Power Supply And Ground Circuit Check 731
Main power supply circuit check 731
Power supply circuit check for system cancel 731
Ground circuit check 731
Diagnostic Procedure 1 732
Daignostic Procedure 1-(1) 732
Diagnostic Procedure 1-(2) 733
Diagnostic Procedure 1-(3) 734
Diagnostic Procedure 1-(4) 735
Diagnostic Procedure 2 736
Diagnostic Procedure 3 737
Diagnostic Procedure 4 738
Diagnostic Procedure 5 739
Diagnostic Procedure 6 740
Diagnostic Procedure 7 741
Diagnostic Procedure 8 742
Electrical Components Inspection 743
Door switches 743
Hood switch 743
Trunk room lamp switch 743
Key cylinder switch 744
Indicator lamp (security lamp) 744
Door unlock sensor 744
LOCATION OF ELECTRICAL UNITS 745
Engine Compartment 745
Passenger Compartment 746
HARNESS LAYOUT 747
Outline 747
Engine Room Harness 748
Engine Compartment 748
Passenger Compartment 750
Main Harness 752
Body Harness 754
Engine Control Harness 756
Engine Harness No 2 758
Room Lamp Harness 759
Air Bag Harness 760
Tail Harness 761
Door Harness (LH side) 762
Front 762
Rear 762
Door Harness (RH side) 763
Front 763
Rear 763
SUPER MULTIPLE JUNCTION (SMJ) 0
Terminal Arrangement 1
JOINT CONNECTOR (J/C) 2
em 764
QUICK REFERENCE INDEX 0
TABLE OF CONTENTS 764
PRECAUTIONS 766
Precautions for Supplemental Restraint System “AIR BAG” 766
Parts Requiring Angular Tightening 766
Liquid Gasket Application Procedure 767
PREPARATION 768
Special Service Tools 768
Commercial Service Tools 771
OUTER COMPONENT PARTS 772
COMPRESSION PRESSURE 775
Measurement of Compression Pressure 775
OIL PAN 776
Removal 776
Installation 778
TIMING CHAIN 781
Liquid gasket application places 782
Removal 783
Upper Timing Chain 783
Lower Timing Chain 786
Inspection 786
Installation 786
Lower Timing Chain 786
Upper Timing Chain 787
OIL SEAL REPLACEMENT 790
Valve Oil Seal 790
Oil Seal Installing Direction 790
Front Oil Seal 790
Rear Oil Seal 791
ACCEL-DRUM UNIT 792
CYLINDER HEAD 794
Removal and Installation 795
Disassembly 795
Inspection 795
Cylinder Head Distortion 795
Camshaft Visual Check 795
Camshaft Runout 796
Camshaft Cam Height 796
Camshaft Journal Clearance 796
Camshaft End Play 796
Camshaft Sprocket Runout 797
Valve Guide Clearance 797
Valve Guide Replacement 797
Valve Seats 798
Replacing Valve Seat For Service Parts 799
Valve Dimensions 799
Valve Spring 799
Squareness 799
Pressure 800
Valve Lifter And Valve Shim 800
Assembly 800
Valve Clearance 801
Checking 801
Adjusting 801
ENGINE REMOVAL 803
Removal 804
Installation 805
CYLINDER BLOCK 806
Disassembly 807
Piston And Crankshaft 807
Inspection 808
Piston And Piston Pin Clearance 808
Piston Ring Side Clearance 808
Piston Ring End Cap 808
Connecting Rod Bend And Torsion 809
Cylinder Block Distortion And Wear 809
Piston-To-Bore Clearance 809
Crankshaft 810
Bearing Clearance 811
Method A (Using bore gauge & micrometer) 811
Main bearing 811
Connecting rod bearing (Big end) 812
Method B (Using plastigage) 813
Connecting Rod Bushing (Small end) 813
Replacement Of Connecting Rod Bushing (Small end) 814
Flywheel/Drive Plate Runout 814
Assembly 814
Piston 814
Crankshaft 815
SERVICE DATA AND SPECIFICATIONS (SDS) 817
General Specifications 817
Compression Pressure 817
Inspection and Adjustment 817
Cylinder Head 817
Valve 817
Valve spring 818
Valve lifter 818
Valve guide 818
Valve clearance adjustment 819
Available shims 819
Valve seat 820
Cylinder Block 821
Camshaft And Camshaft Bearing 822
Piston, Piston Ring And Piston Pin 823
Piston 823
Piston pin 823
Piston ring 823
Connecting Rod 823
Crankshaft 824
Bearing Clearance 825
Available Main Bearing 825
Standard 825
Undersize (service) 825
Available Connecting Rod Bearing 825
Standard 825
Undersize (service) 825
Miscellaneous Components 825
fa 826
QUICK REFERENCE INDEX 0
TABLE OF CONTENTS 826
PRECAUTIONS AND PREPARATION 827
Precautions 827
Special Service Tools 827
Commercial Service Tools 828
FRONT AXLE AND FRONT SUSPENSION 829
ON-VEHICLE SERVICE 830
Front Axle and Front Suspension Parts 830
Front Wheel Bearing 831
Front Wheel Alignment 831
Preliminary Inspection 832
Camber, Caster And Kingpin Inclination 832
Toe-In 832
Front Wheel Turning Angle 833
Drive Shaft 833
FRONT AXLE 834
FRONT AXLE – Wheel Hub and Knuckle 835
Removal 835
Installation 836
Disassembly 836
Wheel Hub 836
Wheel Bearing 837
Inspection 837
Wheel Hub And Knuckle 837
Snap Ring 837
Assembly 838
FRONT AXLE – Drive Shaft 840
Removal 840
Installation 841
Transaxle Side 841
Wheel Side 841
Components 842
Disassembly 842
Transaxle Side 842
Wheel Side 843
Support Bearing 843
Inspection 844
Drive Shaft 844
Boot 844
Joint Assembly (Transaxle side) 844
Joint Assembly (Wheel side) 844
Support Bearing 844
Support Bearing Bracket 844
Assembly 844
Wheel Side 845
Transaxle Side 846
Support Bearing 847
FRONT SUSPENSION 848
FRONT SUSPENSION – Coil Spring and Strut Assembly 849
Removal and Installation 849
Disassembly 849
Inspection 849
Strut Assembly 849
Strut Mounting Insulator 850
Thrust Bearing 850
Coil Spring And Insulator 850
Assembly 850
FRONT SUSPENSION – Stabilizer Bar 851
Removal and Installation 851
Inspection 851
FRONT SUSPENSION – Transverse Link and Lower Ball Joint 852
Removal and Installation 852
Inspection 852
SERVICE DATA AND SPECIFICATIONS (SDS) 853
General Specifications 853
Coil Spring 853
Strut 853
Front Stabilizer Bar 853
Wheelarch Height 853
Drive Shaft 853
Inspection and Adjustment 854
Wheel Alignment 854
Wheel Bearing 854
Lower Ball Joint 854
Wheel Runout 854
fe 855
QUICK REFERENCE INDEX 0
TABLE OF CONTENTS 855
ACCELERATOR CONTROL SYSTEM 856
Adjusting Accelerator Cable 856
FUEL SYSTEM 857
Fuel Tank 857
Special Service Tool 858
Fuel Pump And Gauge 858
EXHAUST SYSTEM 859
foldout 860
QUICK REFERENCE INDEX 0
ELECTRICAL SYSTEM 0
SUPER MULTIPLE JUNCTION (SMJ) 860
Terminal Arrangement 861
JOINT CONNECTOR (J/C) 862
Location 862
Terminal Arrangement 862
ECCS WIRING DIAGRAM 863
gi 867
QUICK REFERENCE INDEX 0
TABLE OF CONTENTS 867
PRECAUTIONS 868
Precautions for Supplemental Restraint System “AIR BAG” 868
General Precautions 868
Precautions for Multiport Fuel Injection System or ECM Controlled Engine 870
Precautions for Three Way Catalyst 870
Engine Oils 870
Health Protection Precautions 870
Environmental Protection Precautions 871
Precautions for Fuel 871
HOW TO USE THIS MANUAL 872
HOW TO READ WIRING DIAGRAMS – EF & EC section 874
Wiring Diagram 874
Switch Positions 874
Connector Symbols 875
Multiple Switch 875
Super Multiple Junction (SMJ) 876
HOW TO READ WIRING DIAGRAMS – Except EF & EC section 877
Option Abbreviations 877
Wiring Diagram 878
HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES 880
Notice 880
How To Follow This Flow Chart 881
Direction mark 881
Key to symbols signifying measurements or procedures 882
CONSULT CHECKING SYSTEM 883
Function and System Application 883
Lithium Battery Replacement 883
Checking Equipment 883
Data Link Connector for Consult 884
IDENTIFICATION INFORMATION 885
Model Variation 885
Prefix and suffix designations: 885
Identification Number 886
Vehicle Identification Number Arrangement 886
Engine Serial Number 887
Manual Transaxle Number 887
Automatic Transaxle Number 887
Dimensions 888
Wheels and Tires 888
LIFTING POINTS AND TOW TRUCK TOWING 889
Special Service Tools 889
Board-on Lift 890
Garage Jack and Safety Stand 890
2-pole Lift 891
Tow Truck Towing 891
Towing An Automatic Transaxle Model With Four Wheels On Ground 892
Towing An Automatic Transaxle Model With Rear Wheels Raised (With front wheels on ground) 892
Towing Point 892
TIGHTENING TORQUE OF STANDARD BOLTS 893
GLOSSARY 894
The “Glossary of Acronyms” and the “Glossary of Technical Terms and Component Part Names” Related to SAE J1930 894
ha 897
QUICK REFERENCE INDEX 0
TABLE OF CONTENTS 897
MANUAL AND AUTO 900
PRECAUTIONS AND PREPARATION 900
Precautions for Supplemental Restraint Sytem “AIR BAG” 900
Special Service Tools 904
R-134a Service Tools and Equipment 905
Precautions for Service Equipment 907
MANUAL 909
DESCRIPTION 909
Component Layout 910
Discharge Air Flow 911
Control Operation 912
TROUBLE DIAGNOSES 913
How to Perform Trouble Diagnoses for Quick and Accurate Repair 913
Work Flow 913
Operational Check 914
Conditions: 914
Procedure: 914
1 Check blower 914
2 Check discharge air 914
3 Check recirc 915
4 Check temperature decrease 915
5 Check temperature increase 915
6 Check air conditioning switch 915
Symptom Chart 916
Diagnostic Table 916
Preliminary Check 918
Preliminary Check 1 918
Preliminary Check 2 919
Preliminary Check 3 920
Preliminary Check 4 921
Preliminary Check 5 922
Preliminary Check 6 923
Performance Test Diagnoses 924
Insufficient Cooling 924
Performance Chart 926
Test Condition 926
Test Reading 926
Trouble Diagnoses for Abnormal Pressure 927
Harness Layout 931
Circuit Diagram for Quick Pinpoint Check 933
Wiring Diagram 935
Main Power Supply and Ground Circuit Check 942
Power Supply Circuit Check 942
Push Control Module Check 942
Diagnostic Procedure 1 943
Diagnostic Procedure 2 945
Diagnostic Procedure 3 947
Diagnostic Procedure 4 948
Diagnostic Procedure 5 950
Diagnostic Procedure 6 951
Electrical Components Inspection 955
Fan Switch 955
Blower Motor 955
Blower Resistor 955
A/C Switch 955
Thermo Control Amp 956
Thermal Protector 956
Triple-Pressure Switch 956
A/C Relay 956
Control Linkage Adjustment 957
Mode Door 957
Air Mix Door (Water cock) 957
Intake Door 957
Fresh Vent Door 957
AUTO 958
DESCRIPTION 958
Introduction 958
Features 958
Control Operation 958
TROUBLE DIAGNOSES 960
How to Perform Trouble Diagnoses for Quick and Accurate Repair 960
Work Flow 960
Operational Check 961
Conditions: 961
Procedure: 961
1 Check blower 961
2 Check discharge air 961
3 Check recirc 962
4 Check temperature decrease 962
5 Check temperature increase 962
6 Check ECON mode 962
7 Check AUTO mode 962
8 Check memory function 963
Symptom Chart 964
Diagnostic Table 964
Self-diagnosis 969
Checking Procedure 970
Step 1: Checks Leds and segments 972
Step 2: Checks each sensor circuit for open or short circuit 972
Sensors and abnormalities 973
Step 3: Checks mode door operation 973
Step 4: Checks operation of each actuator 974
Step 5: Checks temperature detected by sensors 974
Auxiliary Mechanism: Temperatire setting timmer 976
Preliminary Check 977
Preliminary Check 1 977
Preliminary Check 2 978
Preliminary Check 3 979
Preliminary Check 4 980
Preliminary Check 5 981
Preliminary Check 6 982
Preliminary Check 7 983
Preliminary Check 8 984
Performance Test Diagnoses 985
Insufficient Cooling 985
Performance Chart 987
Test Condition 987
Test Reading 987
Trouble Diagnoses For Abnormal Pressure 988
Harness Layout 992
Circuit Diagram for Quick Pinpoint Check 994
Wiring Diagram 995
Main Power Supply and Ground Circuit Check1002
Power Supply Circuit Check For Auto A/C System1002
Auto Amp Check1002
Diagnostic Procedure 11003
Diagnostic Procedure 21004
Diagnostic Procedure 31005
Diagnostic Procedure 41006
Diagnostic Procedure 51007
Diagnostic Procedure 61009
Diagnostic Procedure 71010
Diagnostic Procedure 81011
Diagnostic Procedure 91012
Diagnostic Procedure 101015
Diagnostic Procedure 111018
Electrical Components Inspection1019
Blower Motor1019
Thermo Control Amp1019
Thermal Protector1019
Triple-Pressure Switch1019
A/C Relay And Blower Hi Relay1019
Control Linkage Adjustment1020
Mode Door1020
Air Mix Door (Water cock)1020
Intake Door1021
Fresh Vent Door1021
SYSTEM DESCRIPTION1022
Overview of Control System1022
Control System Input components1023
Potentio Temperature Control (PTC)1023
In-Vehicle Sensor1023
Aspirator1023
Ambient Sensor1024
Sunload Sensor1024
Control System Automatic Amplifier (Auto amp)1025
Ambient Temperature Input Process1025
Sunload Input Process1025
Control System Output Components1025
Air Mix Door Dontrol (Automatic temperature control)1025
Air Mix Door Motor1027
PBR characteristics1027
Mode Door Control1028
Mode Door Motor1029
Intake Door Control1029
Intake Door Motor1030
Fan Speed Control1031
Component parts1031
System operation1031
Automatic Mode1031
Starting Fan Speed Control1031
Blower Speed Compensation1032
Fan Control amplifier1032
Blower Hi-Relay1033
Magnet Clutch Control1033
MANUAL AND AUTO1034
SERVICE PROCEDURES1034
R-134a Service Procedure1034
Maintenance of Oil Quantity in Compressor1036
Lubrication Oil1036
Checking And Adjusting1036
Refrigerant Lines1038
Compressor Mounting1039
Belt Tension1039
Fast Idle Control Device (FICD)1039
Compressor1040
Compressor Clutch1040
Removal1040
Inspection1041
Installation1042
Break-In Operation1043
Thermal Protector1043
SERVICE DATA AND SPECIFICATIONS (SDS)1044
idx1045
QUICK REFERENCE INDEX 0
lc1052
QUICK REFERENCE INDEX 0
TABLE OF CONTENTS1052
PRECAUTIONS1053
Precautions for Supplemental Restraint System”AIG BAG”1053
Liquid Gasket Application Procedure1053
PREPARATION1054
Special Service Tools1054
ENGINE LUBRICATION SYSTEM1055
Lubrication Circuit1055
Oil Pressure1056
Oil Pump1056
Removal1056
Regulator Valve Inspection1057
Oil Pressure Relief Valve Inspection1058
Oil Pump Inspection1058
ENGINE COOLING SYSTEM1059
Cooling Circuit1059
System Check1059
Checking Cooling System Hoses1059
Checking Cooling System For Leaks1060
Checking Radiator Cap1060
Water Pump1060
Removal1061
Inspection1061
Installation1061
Thermostat1062
Inspection1062
Radiator1063
SERVICE DATA AND SPECIFICATIONS (SDS)1064
Engine Lubrication System1064
Oil pressure check1064
Oil pump1064
Engine cooling System1064
Thermostat1064
Radiator1064
ma1065
QUICK REFERENCE INDEX 0
TABLE OF CONTENTS1065
GENERAL MAINTENANCE1066
PERIODIC MAINTENANCE1068
Schedule 11069
Schedule 21070
RECOMMENDED FLUIDS AND LUBRICANTS1071
Fluids and Lubricants1071
SAE Viscosity Number1071
ENGINE MAINTENANCE1072
Checking Drive Belts1072
Changing Engine Coolant1073
Draining Engine Coolant1073
Flushing Cooling System1074
Refilling Engine Coolant1074
Checking Fuel Lines1074
Changing Fuel Filter1075
Changing Air Cleaner Filter1075
Changing Engine Oil1076
Changing Oil Filter1076
Changing Spark Plugs1077
Checking Vapor Lines1077
Checking Valve Clearance1078
CHASSIS AND BODY MAINTENANCE1078
Checking Clutch Fluid Level and Leaks1078
Checking M/T Oil1078
Changing M/T Oil1078
Checking A/T Fluid1079
ATF Cooler Service1079
Changing A/T Fluid1079
Checking Brake Fluid Level and Leaks1080
Checking Brake Lines and Cables1080
Checking Disc Brake1080
Rotor1080
Caliper1080
Pad1081
Checking Drum Brake1081
Wheel Cylinder1081
Drum1081
Lining1081
Temporary Method For Checking Lining Wear1081
Balancing Wheels1082
Tire Rotation1082
Checking Steering Gear and Linkage1082
Steering Gear1082
Steering Linkage1082
Checking Power Steering Fluid and Lines1082
Checking Exhaust System1082
CHASSIS AND BODY MAINTENANCE1083
Lubricating Locks, Hinges and Hood Latches1083
Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters1083
SERVICE DATA AND SPECIFICATIONS (SDS)1084
Engine Maintenance1084
Inspection And Adjustment1084
Drive belt deflection1084
Spark plug1084
Chassis and Body Maintenance1084
Inspection and Adjustment1084
Brake1084
Wheel balance1084
mt1085
QUICK REFERENCE INDEX 0
TABLE OF CONTENTS1085
PREPARATION1086
Special Service Tools1086
Commercial Service Tools1088
ON-VEHICLE SERVICE1089
Differential Side Oil Seal Replacement1089
Striking Rod Oil Seal Replacement1089
Position Switch Check1090
Back-up Lamp Switch And Neutraul Position Switch1090
Various Coupling Check1090
REMOVAL AND INSTALLATION1091
Removal1091
Intstallation1092
TRANSAXLE GEAR CONTROL1093
MAJOR OVERHAUL1094
Case Components1094
Gear Components1095
Shift Control Components1096
DISASSEMBLY1097
REPAIR FOR COMPONENT PARTS1100
Input Shaft and Gears1100
Disassembly1100
Inspection1101
Gear and shaft1101
Synchronizer1101
Assembly1102
Mainshaft and Gears1105
Disassembly1105
Inspection1106
Gear and shaft1106
Synchronizer1107
Bearing1108
Assembly1108
Final Drive1110
Disassembly1110
Inspection1111
Assembly1112
Shift Control Components1114
Inspection1114
Case Components1114
Removal and Installation1114
Mainshaft front bearing outer race1115
ADJUSTMENT1116
Input Shaft End Play and Differential Side Bearing Preload1116
Mainshaft Bearing Preload1117
ASSEMBLY1120
SERVICE DATA AND SPECIFICATIONS (SDS)1124
General Specifications1124
Inspection and Adjustment1125
Gear End Play1125
Clearance Between Baulk Ring And Gear 1st, 3rd, 4th & 5th1125
Reverse Baulk Ring1125
2nd baulk ring1125
Available Snap Ring1125
Available Washer1126
Available Shim1126
ra1129
QUICK REFERENCE INDEX 0
TABLE OF CONTENTS1129
PRECAUTIONS AND PREPARATION1130
Precautions1130
Special Service Tools1130
Commercial Service Tools1131
REAR AXLE AND REAR SUSPENSION1132
ON-VEHICLE SERVICE1133
Rear Axle and Rear Suspension Parts1133
Rear Wheel Bearing1133
Rear Wheel Alignment1134
Preliminary Inspection1134
Chamber1134
Toe-In1134
REAR AXLE – Wheel Hub1136
Removal1136
Installation1137
REAR SUSPENSION1138
Removal and Installation1139
REAR SUSPENSION – Coil Spring and Strut Assembly1140
Disassembly1140
Inspection1140
Strut Assembly1140
Upper Rubber Seat And Bushing1141
Strut Mounting Insulator1141
Coil Spring1141
Assembly1141
REAR SUSPENSION – Parallel Links, Radius Link and Stabilizer Bar1142
Removal and Installation1142
Parallel Link And Radius Link1142
Stabilizer Bar1142
SERVICE DATA AND SPECIFICATIONS (SDS)1143
General Specifications1143
Coil Spring1143
Stabilizer Bar1143
Strut1143
Inspection and Adjustment1143
Wheel Alignment (Unladen*)1143
Wheel Bearing1143
st1144
QUICK REFERENCE INDEX 0
TABLE OF CONTENTS1144
PRECAUTIONS AND PREPARATION1145
Precautions1145
Supplemental Restraint System “Air Bag”1145
Steering System1145
Special Service Tools1146
Commercial Service Tools1147
ON-VEHICLE SERVICE1148
Checking Steering Wheel Play1148
Checking Neutral Position on Steering Wheel1148
Pre-checking1148
Checking1148
Front Wheel Turning Angle1148
Checking Gear Housing Movement1148
Checking and Adjusting Drive Belts1149
Checking Fluid Level1149
Checking Fluid Leakage1149
Bleeding Hydraulic System1149
Checking Steering Wheel Turning Force1150
Checking Hydraulic System1151
STEERING WHEEL AND STEERING COLUMN1152
Removal1152
Steering Wheel1152
Steering Column1152
Installation1153
Steering Wheel1153
Steering Column1153
Disassembly and Assembly1154
Tilt Mechanism1155
Inspection1155
POWER STEERING GEAR AND LINKAGE1156
Removal and Installation1156
Disassembly1159
Inspection1160
Boot1160
Rack1160
Pinion Assembly1160
Gear Housing1160
Tie-Rod Outer And Inner Socket1161
Assembly1161
Adjustment1165
POWER STEERING OIL PUMP1167
Disassembly and Assembly1167
Pre-disassembly Inspection1167
Disassembly1168
Inspection1168
Pulley And Pulley Shaft1168
Assembly1169
SERVICE DATA AND SPECIFICATIONS (SDS)1170
General Specifications1170
Inspection and Adjustment1170
General1170
Steering Column1170
Steering Gear And Linkage1170
Power Steering1171
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