1997 NISSAN ALTIMA U13 Series Service Manual PDF DOWNLOAD
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1997 NISSAN ALTIMA U13 Series Service Manual PDF DOWNLOAD
Language : English
Pages : 1312
Downloadable :Yes
File Type : PDF
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1997 NISSAN ALTIMA U13 Series Service Manual PDF DOWNLOAD
FOREWORD
- This manual contains maintenance and repair procedures for the 1997 Nissan 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.
IMPORTANT SAFETY NOTICE:
- The proper performance of service is essential for both the safety of the technician and the efficient functioning of the vehicle.
- The service methods in this Service Manual are described in such a manner that the service may be performed safely and accurately.
- Service varies with the procedures used, the skills of the technician and the tools and parts available.
- Accordingly, anyone using service procedures, tools or parts which are not specifically recommended by NISSAN must first be completely satisfied that neither personal safety nor the vehicle’s safety will be jeopardized by the service method selected.
TABLE OF CONTENTS:
1997 NISSAN ALTIMA U13 Series Service Manual PDF DOWNLOAD
fwd 1
QUICK REFERENCE INDEX 1
FOREWORD 2
GI – General Information 0
MA – Maintenance 0
EM – Engine Mechanical 0
LC – Engine Lubrication & Cooling Systems 0
EC – Engine Control System 0
FE – Accelerator Control, Fuel & Exhaust Systems 0
CL – Clutch 0
MT – Manual Transaxle 0
AT – Automatic Transaxle 0
FA – Front Axle & Front Suspension 0
RA – Rear Axle & Rear Suspension 0
BR – Brake System 0
ST – Steering System 0
RS – Restraint System 0
BT – Body & Trim 0
HA – Heater & Air Conditioner 0
EL – Electrical System 0
IDX – Alphabetical Index 1
Foldout 0
COMMENT SHEET 3
QUICK REFERENCE CHART 4
GST Mode 6 – Test Value & Test Limit Chart 5
at 6
QUICK REFERENCE INDEX 0
TABLE OF CONTENTS 6
PREPARATION AND PRECAUTIONS 8
Special Service Tools 8
Commercial Service Tools 11
Service Notice 12
Precautions For Supplemental Restraint System (SRS) “AIR BAG” 13
Precautions for On-Board Diagnostic (OBD) System of A/T and Engine 13
DESCRIPTION 14
Cross-sectional View 14
Hydraulic Control Circuit 15
Shift Mechanism 16
Control System 18
TROUBLE DIAGNOSES 20
How to Perform Trouble Diagnoses for Quick and Accurate Repair 20
Remarks 24
Diagnostic Trouble Code (DTC) Chart 26
Diagnosis by CONSULT 28
Preliminary Check 32
A/T Electrical Parts Location 44
Schematic 45
Wiring Diagram – AT – 46
Self-diagnosis 53
SELF-DIAGNOSTIC PROCEDURE (With CONSULT) 53
SELF-DIAGNOSTIC PROCEDURE (With GST) 54
SELF-DAIGNOSTIC PROCEDURE (No Tools) 54
HOW TO ERASE DTC (With CONSULT) 58
HOW TO ERASE DTC (With GST) 58
HOW TO ERASE DTC (No Tools) 58
DTC P0720, Vehicle Speed Sensor-A/T (Revolution Sensor) Circuit Check 59
Vehicle Speed Sensor-MTR Circuit Check 61
DTC P1705, Throttle Position Sensor Circuit Check 63
DTC P0750, Shift Solenoid Valve “A” Circuit Check 65
DTC P0755, Shift Solenoid Valve “B” Circuit Check 67
DTC P1760, Overrun Clutch Solenoid Valve Circuit Check 69
DTC P0740, Torque Converter Clutch Solenoid Valve Circuit Check 71
DTC P0710, A/T Fluid Temperature Sensor Circuit And A/T Control Unit Power Source Circuit Checks 73
DTC P0725, Engine Speed Signal Circuit Check 76
DTC P0745, Line Pressure Solenoid Valve Circuit Check 78
DTC P0705, Inhibitor, Overdrive and Throttle Position Switch Circuit Checks 80
DTC P0731, Improper Shifting To 1st Gear Position 84
DTC P0732, Improper Shifting To 2nd Gar Position 86
DTC P0733, Improper Shifting To 3rd Gear Position 88
DTC P0734, Improper Shifting To 4th Gear Position Or Improper Torque Converter Clutch Operation 90
Diagnostic Procedures 94
Electrical Components Inspection 109
Final Check 116
Symptom Chart 121
TROUBLE DIAGNOSIS – A/T Shift Lock System 124
Description 124
Shift Lock System Electrical Parts Location 124
Wiring Diagram – SHIFT – 125
Diagnostic Procedure 126
Key Interlock Cable 128
Component Check 129
ON-VEHICLE SERVICE 131
Control Valve Assembly and Accumulator 131
Revolution Sensor Replacement 132
Inhibitor Switch Adjustment 132
Control Cable Adjustment 133
Differential Side Oil Seal Replacement 133
REMOVAL AND INSTALLATION 134
MAJOR OVERHAUL 137
Loations of Adjusting Shims, Needle Bearings, Thrust Washers and Snap Rings 140
Oil Channel 141
DISASSEMBLY 142
REPAIR FOR COMPONENTS PARTS 156
Manual Shaft 156
Oil Pump 158
Control Valve Assembly 162
Control Valve Upper Body 170
Control Valve Lower Body 174
Reverse Clutch 176
High Clutch 179
Forward Clutch and Overrun Clutch 183
Low & Reverse Brake 189
Rear Internal Gear, Forward Clutch Hub and Overrun Clutch Hub 191
Output Shaft, Idler Gear, Reduction Pinion Gear and Bearing Retainer 195
Band Servo Piston Assembly 200
Final Drive – RE4R04A 205
Final Drive – RE4F04V 209
ASSEMBLY 214
Assembly 1 214
Adjustment 1 214
Assembly 2 220
Adjustment 2 226
Assembly 3 228
SERVICE DATA AND SPECIFICATIONS (SDS) 234
General Specifications 234
Specifications and Adjustments 234
br 241
QUICK REFERENCE INDEX 0
TABLE OF CONTENTS 241
PRECAUTIONS AND PREPARATION 243
Precautions 243
Commercial Service Tools 244
CHECK AND ADJUSTMENT 245
Checking Brake Fluid Level 245
Checking Brake Line 245
Changing Brake Fluid 245
AIR BLEEDING 246
Bleeding Procedure 246
BRAKE HYDRAULIC LINE 247
CONTROL VALVE 248
Proportioning Valve 248
BRAKE PEDAL AND BRACKET 250
MASTER CYLINDER 252
BRAKE BOOSTER 255
On-vehicle Service 255
Removal 255
Inspection 256
Installation 256
VACUUM HOSE 257
FRONT DISC BRAKE 258
Pad Replacement 258
Removal 259
Disassembly 260
Inspection – Caliper 260
Inspection – Rotor 261
Assembly 261
Installation 261
REAR DRUM BRAKE 262
Inspection – Wheel Cylinder 264
Wheel Cylinder Overhaul 264
Inspection – Drum 264
Inspection – Lining 265
Intallation 265
REAR DISC BRAKE 267
Pad Replacement 267
Removal 269
Disassembly 269
Inspection – Caliper 270
Inspection – Rotor 271
Assembly 271
Installation 273
PARKING BRAKE CONTROL 274
ANTI-LOCK BRAKE SYSTEM 276
Purpose 276
Operation 276
System Components 277
System Description 277
Removal and Installation 278
Front Wheel Sensor 278
Rear Wheel Sensor 278
Control Unit 279
Actuator 279
Actuator Relays 279
TROUBLE DIAGNOSES 280
How to Perform Trouble Diagnoses for Quick and Accurate Repair 280
Preliminary Check 281
Component Parts and Harness Connector Location 282
Circuit Diagram for Quick Pinpoint Check 283
Wiring Diagram – ABS – 284
Self-diagnosis 288
Function 288
Self-Diagnosis Procedure 288
How To Read Self-Diagnostic Results (Malfunction codes) 289
How To Erase Self-Diagnostic Results (Malfunction codes) 289
Malfunction Code/Symptom Chart 290
Ground Circuit Check 291
Diagnostic Procedure 1 (Not self-diagnostic item) 292
Diagnostic Procedure 2 (Not Self-diagnostic Item) 293
Diagnostic Procedure 3 296
Actuator Solenoid Valve 296
Diagnostic Procedure 4 297
Wheel Sensor Or Rotor 297
Diagnostic Procedure 5 299
Rotor Relay Or Motor 299
Diagnostic Procedure 6 302
Solenoid Valve Relay 302
Diagnostic Procedure 7 304
Power Supply (Low voltage) 304
Diagnostic Procedure 8 305
Stop Lamp Switch Circuit 305
Diagnostic Procedure 9 305
Control Unit 305
Diagnostic Procedure 10 306
Symptom: Pedal vibration and noise 306
Diagnostic Procedure 11 306
Symptom: Long stopping distance 306
Diagnostic Procedure 12 307
Symptom: Unexpected pedal action 307
Diagnostic Procedure 13 307
Symptom: ABS does not work 307
Diagnostic Procedure 14 308
Symptom: ABS works frequently 308
Electrical Components Inspection 309
Wheel Sensor 309
Motor Relay 309
Solenoid Valve Relay 309
SERVICE DATA AND SPECIFICATIONS (SDS) 310
General Specifications 310
Inspection and Adjustment 310
bt 311
QUICK REFERENCE INDEX 0
TABLE OF CONTENTS 311
GENERAL SERVICING 312
Precautions 312
Supplemental Restraint System (SRS) “AIR BAG” 312
Clip and Fastener 313
BODY END 316
Body Front End 316
Body Rear End and Opener 318
DOOR 320
Front Door 320
Rear Door 321
INSTRUMENT PANEL 322
INTERIOR TRIM 325
Side and Floor Trim 325
Door Trim 326
Roof Trim 328
Luggage Room Trim 329
EXTERIOR 330
(1) Front hood insulator 331
(2) Cowl top grille and cowl top front sealing rubber 331
(3) Front windshield molding 331
(3) Windshield upper and side molding 332
(4) Sunroof lid weatherstrip 332
(5) Body side drip weatherstrip 332
(6) Door weatherstrip 333
(7) Body side welt 333
(8) Door waist outside molding 333
(9) Front door corner cover 334
(10) Rear windshield molding 334
(11) Trunk lid weatherstrip 334
(12) Rear combination lamp 335
(13) Side guard molding 335
(14) Fender and center mudguard 336
(15) Front door parting seal 337
SEAT 338
Front Seat 338
Rear Seat 339
SUNROOF 340
Removal 341
Adjustment 342
WINDSHIELD AND WINDOWS 343
Windshield and Rear Window 344
Quarter Window 345
MIRROR 346
Door Mirror 346
Rearview Mirror 347
REAR AIR SPOILER 348
BODY ALIGNMENT 349
Engine Compartment 349
Underbody 351
cl 353
QUICK REFERENCE INDEX 0
TABLE OF CONTENTS 353
PRECAUTIONS 354
Precautions 354
Special Service Tools 354
Commercial Service Tools 354
CLUTCH SYSTEM – Hydraulic Type 355
INSPECTION AND ADJUSTMENT 356
Adjusting Clutch Pedal 356
Bleeding Procedure 357
HYDRAULIC CLUTCH CONTROL 358
Clutch Master Cylinder 358
Operating Cylinder 359
CLUTCH RELEASE MECHANISM 360
CLUTCH DISC AND CLUTCH COVER 361
Clutch Disc 361
Clutch Cover and Flywheel 362
SERVICE DATA AND SPECIFICATIONS (SDS) 363
General Specifications 363
Inspection and Adjustment 363
ec 364
QUICK REFERENCE INDEX 0
TABLE OF CONTENTS 364
PRECAUTIONS AND PREPARATIONS 366
Special Service Tools 366
Supplemental Restraing System (SRS) “AIR BAG” 366
Precautions for On Board Diagnostic (OBD) System of Engine and A/T 367
Engine Fuel & Emission Control System 368
Precautions 369
ENGINE AND EMISSION CONTROL OVERALL SYSTEM 371
Circuit Diagram 371
System Diagram 372
ECCS Component Parts Location 374
Vacuum Hose Drawing 376
Air Assisted Injector System Hose Drawing 377
System Chart 378
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION 379
Multiport Fuel Injection (MFI) System 379
Distributor Ignition (DI) System 382
Air Conditioning Cut Control 384
Fuel Cut Control (at no load & high engine speed) 384
EVAPORATIVE EMISSION SYSTEM 385
Description 385
Inspection 385
POSITIVE CRANKCASE VENTILATION 387
Description 387
Inspection 387
BASIC SERVICE PROCEDURE 388
Fuel Pressure Release 388
Fuel Pressure Check 388
Fue Pressure Regulator Check 389
Injector Removal and Installation 389
Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment 390
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION 396
Introduction 396
Two Trip Detection Logic 396
Emission-related Diagnostic Information 397
OBD System Operation Chart 406
Malfunction Indicator Lamp (MIL) 411
CONSULT 415
Generic Scan Tool (GST) 427
TROUBLE DIAGNOSIS – Introduction 429
Introduction 429
Diagnostic Worksheet 430
TROUBLE DIAGNOSIS – Work Flow 431
Work Flow 431
Description for Work Flow 432
TROUBLE DIAGNOSIS – Basic Inspection 433
Basic Inspection 433
TROUBLE DIAGNOSIS – General Description 436
Diagnostic Trouble Code (DTC) Chart 436
Fail-Safe Chart 447
Symptom Matrix Chart (For New CT/CS) 448
Symptom Matrix Chart (For Old CT/CS) 451
CONSULT Reference Valve in Data Monitor Mode 454
Major Sensor Referene Graph In Data Monitor Mode 456
ECM Terminals and Reference Value 458
TROUBLE DIAGNOSIS FOR POWER SUPPLY 464
Main Power Supply and Ground Circuit 464
DTC P0100, Mass Air Flow Sensor (MAFS) (DTC: 0102) 467
DTC P0110, Intake Air Temperature Sensor (DTC: 0401) 472
DTC P0115, Engine Coolant Temperature Sensor (ECTS) (DTC: 0103) 477
DTC P0120, Throttle Position Sensor (DTC: 0403) 481
DTC P0125, Engine Coolant Temperature (ECT) Sensor (DTC: 0908) 486
DTC P0130, Front Heated Oxygen Sensor (Front O2S) (DTC: 0303) 491
DTC P0130, Closed Loop Conrol (DTC: 0307) 496
DTC P0135, Front Heated Oxygen Sensor Heater (DTC: 0901) 497
DTC P0136, Rear Heated Oxygen Sensor (Rear HO2S) (DTC: 0707) 500
DTC P0141, Rear Heated Oxygen Sensor Heater (DTC: 0902) 505
DTC P0171, Fuel Injection System Function (Lean side) (DTC: 0115) 509
DTC P0172, Fuel Injection System Function (Rich side) (DTC: 0114) 514
DTC P0300 – P0304, No 4 – 1 Cylinder Misfire, Multiple Cylinder Misfire (DTC: 0701 – 0605) 519
DTC P0325, Knock Sensor (KS) (DTC: 0304) 523
DTC P0335, Crankshaft Position Sensor (CKPS) (OBD) (DTC: 0802) 526
DTC P0340, Camshaft Position Sensor (CMPS) (DTC: 0101) 530
DTC P0400, EGR Function (DTC: 0302) 535
DTC P0402, EGRC-BPT Valve Function (DTC: 0306) 544
DTC P0420, Three Way Catalyst Function (DTC: 0702) 546
DTC P0500, Vehicle Speed Sensor (VSS) (DTC: 0104) 549
DTC P0505, Idle Air Control Valve (IACV) – Auxiliary Air Control (AAC) Valve (DTC: 0205) 553
DTC P0600, A/T Control 557
DTC P0605, Engine Control Module (ECM)-ECCS Control Module (DTC: 0301) 560
DTC P0705, Park/Neutral Position Switch (DTC: 1003) 562
DTC P1320, Ignition Signal (DTC: 0201) 569
DTC P1336, Crankshaft Position Sensor (CKPS) (OBD) (COG) (DTC: 0905) 574
DTC P1400, EGR valve and EVAO Canister Purge Control Solenoid Valve (DTC: 1005) 578
DTC P1401, EGR Temperature Sensor (DTC: 0305) 582
DTC P1605, A/T Diagnosis Communication line (DTC: 0804) 587
DTC P1900, Cooling Fan (DTC: 1308) 590
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS 602
Injector 602
Start Signal 605
Fuel Pump 607
Power Steering Oil Pressure Switch 612
IACV-Air Regulator 615
IACV-FICD Solenoid Valve 616
Rear Window Defogger Signal 619
Air Assisted Injector System (A/T models for California) 621
Air Cut Valve 621
MIL & Data Link Connectors 622
TROUBLE DIAGNOSIS – Index 623
Alphabetical & P No Index for DTC 623
SERVICE DATA AND SPECIFICATIONS (SDS) 624
General Specifications 624
Inspection and Adjustment 624
el 626
QUICK REFERENCE INDEX 0
TABLE OF CONTENTS 626
PRECAUTIONS 629
Supplemental Restraint System (SRS) “AIR BAG” 629
HARNESS CONNECTOR 630
Description 630
STANDARDIZED RELAY 631
Description 631
POWER SUPPLY ROUTING 633
Schematic 633
Wiring Diagram – POWER – 634
Fuse 640
Fusible Link 640
Circuit Breaker Inspection 640
GROUND DISTRIBUTION 641
BATTERY 645
How to Handle Battery 645
Service Data and Specifications (SDS) 648
STARTING SYSTEM 649
System Description 649
Wiring Diagram – START – 651
Starter 653
Pinion/Clutch Check 655
Service Data and Specifications (SDS) 655
CHARGING SYSTEM 656
System Description 656
Wiring Diagram – CHARGE – 657
Trouble Diagnoses 658
Generator 659
Diode Check 660
Assembly 661
Service Data and Specifications (SDS) 662
COMBINATION SWITCH 663
Combination Switch/Check 663
Combination Switch/Replacement 664
Steering Switch/Check 665
HEADLAMP 666
System Description (For USA) 666
Wiring Diagram (For USA) – H/LAMP – 667
Trouble Diagnoses (For USA) 668
System Description (For Canada) 669
Operation (Daytime light system for Canada) 670
Schematic (For Canada) 671
Wiring Diagram (For Canada) – DTRL – 672
Trouble Diagnoses (For Canada) 675
Bulb Replacement 677
Aiming Adjustment 677
EXTERIOR LAMP 679
Back-up Lamp/Wiring Diagram – BACK/L – 679
Parking, License, Tail and Stop Lamps/Wiring Diagram – TAIL/L – 680
Front Fog Lamp/System Description 683
Front Fog Lamp/Wiring Diagram – F/FOG – 684
Front Fog Lamp Aiming Adjustment 685
Turn Signal and Hazard Warning Lamps/System Description 686
Turn Signal and Hazard Warning Lamps/Wiring Diagram – TURN – 687
Turn Signal and Hazard Warning Lamps/Trouble Diagnoses 689
Combination Flasher Unit Check 689
Cornering Lamp/System Description 690
Cornering Lamp/Wiring Diagram – CORNER – 691
Bulb Specifications 692
INTERIOR LAMP 693
Illumination/System Description 693
Illumination/Schematic 694
Illimunation/Wiring Diagram – ILL – 695
Interior, Personal and Trunk Room Lamps/Wiring diagram – INT/L – 698
Bulb Specifications 699
METERS AND GAUGES 700
System Description 700
Combination Meter 701
Speedometer, Tachometer, Tamp and Fuel Gauges/Wiring Diagram – METER – 702
Inspection/Fuel Gauge and Water Temperature Gauge 703
Inspection/Tachometer 704
Inspection/Sspeedometer and Vehicle Speed Sensor 705
Inspection/Speedometer and Fuse 706
Fuel Tank Gauge Unit Check 707
Fuel Warning Lamp Sensor Check 707
Thermal Transmitter Check 707
Oil Pressure Switch Check 707
Vehicle Speed Sensor Signal Check 708
WARNING LAMPS AND CHIME 709
Warning Lamps/System Description 709
Warning Lamps/Schematic 711
Warning Lamps/Wiring Diagram – WARN – 712
Warning Chime/System Description 715
Warning Chime/Wiring diagram – CHIME – 716
Diode Check 717
Warning Chime Check 717
TIME CONTROL SYSTEM 718
System Description 718
Schematic 719
Wiring Diagram – TIME – 720
Trouble Diagnoses 723
WIPER AND WASHER 732
System Description 732
Wiring Diagram – WIPER – 735
Installation 737
Washer Nozzle Adjustment 738
MIRROR 739
Wiring Diagram – MIRROR – 739
SUNROOF 740
System Description 740
Wiring Diagram – SROOF – 741
HORN, LIGHTER, CLOCK 742
Wiring Diagram – HORN – 742
REAR WINDOW DEFOGGER 743
System Description 743
Wiring Diagram – DEF – 744
Filament Check 745
Filament Repair 746
AUDIO AND POWER ANTENNA 747
Audio/System Description 747
Audio/Schematic 748
Audio/Wiring Diagram – AUDIO – 749
Power Antenna/System Description 753
Location of Antenna 753
Power Antenna/Wiring Diagram – P/ANT – 754
Trouble Diagnoses 755
Antenna Rod Replacement 757
Window Antenna Repair 758
AUTOMATIC SPEED CONTROL DEVICE (ASCD) 759
System Description 759
Component Parts and Harness Connector Location 761
Schematic 762
Wiring Diagram – ASCD – 763
Trouble Diagnoses 768
POWER WINDOW 782
System Description 782
Component Layout 785
Wiring Diagram – WINDOW – 787
Trouble Diagnoses 789
POWER DOOR LOCK 790
System Description 790
Schematic 791
Wiring Diagram – D/LOCK – 792
Trouble Diagnoses 795
THEFT WARNING SYSTEM 802
System Description 802
Schematic 805
Component Parts and Harness Connector Location 807
Wiring Diagram – THEFT – 808
Trouble Diagnoses 815
LOCATION OF ELECTRICAL UNITS 831
Engine Compartment 831
Passenger Compartment 832
HARNESS LAYOUT 833
Outline 833
Engine Room Harness 835
Main Harness 839
Body Harness 841
Engine Control Harness 843
Engine Harness No 2 845
Room Lamp Harness 846
Air Bag Harness 847
Tail Harness 848
Door Harness (LH side) 849
Door Harness (RH side) 850
SUPER MULTIPLE JUNCTION (SMJ) 0
Terminal Arrangement 1
JOINT CONNECTOR (J/C) 4
Location 4
Terminal Arrangement 4
FUSE BLOCK/FUSIBLE LINK AND FUSE BOX 2
Fuse Arrangement 2
CONTROL UNITS/MODULE 3
em 851
QUICK REFERENCE INDEX 0
TABLE OF CONTENTS 851
PRECAUTIONS 852
Parts and Requiring Angular Tightening 852
Liquid Gasket Application Procedure 852
PREPARATION 853
Special Service Tools 853
Commerical Service Tools 856
OUTER COMPONENT PARTS 857
Except A/T Models for California 857
A/T Models for California 858
COMPRESSION PRESSURE 861
Measurement of Compression Pressure 861
OIL PAN 862
Removal 862
Installation 864
TIMING CHAIN 867
Removal 869
Upper Timing Chain 869
Lower Timing Chain 872
Inspection 872
Installation 872
Lower Timing Chain 872
Upper Timing Chain 873
OIL SEAL REPLACEMENT 876
Valve Oil Seal 876
Front Oil Seal 876
Rear Oil Seal 877
ACCEL-DRUM UNIT 878
Adjustment 878
CYLINDER HEAD 880
Removal and Installation 881
Disassembly 881
Inspection 881
Cylinder Head Distortion 881
Camshaft Visual Check 882
Camshaft Runout 882
Camshaft Height 882
Canshaft Journal Clearance 882
Camshaft End Play 883
Camshaft Sprocket Runout 883
Valve Guide Clearance 883
Valve Guide Replacement 884
Valve Seals 885
Replacing Valve Seat For Service Parts 885
Valve Dimensions 885
Valve Spring 886
Valve Lifter and Valve Shim 886
Assembly 887
Valve Clearance 887
ENGINE REMOVAL 890
Removal 891
Installation 892
CYLINDER BLOCK 893
Disassembly 894
Piston and Crankshaft 894
Inspection 895
Piston and Piston Pin Clearance 895
Piston Ring Side Clearance 895
Piston Ring End Gap 895
Connecting Rod Bend And Torsion 896
Cylinder Block Distortion 896
Piston-To-Bore Clearance 896
Crankshaft 897
Bearing Clearance 898
Connecting Rod Bushing Clearance (Small end) 900
Replacement of Connecting Rod Bushing (Small end) 900
Flywheel/Drive Plate Runout 900
Assembly 901
Piston 901
Crankshaft 902
Replacing Pilot Bushing 903
SERVICE DATA AND SPECIFICATIONS (SDS) 904
General Specifications 904
Inspection and Adjustment 904
fa 913
QUICK REFERENCE INDEX 0
TABLE OF CONTENTS 913
PRECAUTIONS AND PREPARATION 914
Precautions 914
Special Service Tools 914
Commercial Service Tools 915
FRONT AXLE AND FRONT SUSPENSION 916
ON-VEHICLE SERVICE 917
Front Axle and Front Suspension Parts 917
Front Wheel Bearing 918
Front Wheel Alignment 918
Drive Shaft 920
FRONT AXLE 921
Wheel Hub and Knuckle 922
Drive Shaft 926
FRONT SUSPENSION 933
Coil Spring and Strut Assembly 934
Stabilizer Bar 935
Transverse Link and Lower Ball Joint 936
SERVICE DATA AND SPECIFICATIONS (SDS) 938
General Specifications 938
Inspection and Adjustment 939
fe 940
QUICK REFERENCE INDEX 0
TABLE OF CONTENTS 940
PREPARATION 941
Special Service Tool 941
ACCELERATOR CONTROL SYSTEM 942
Accelerator Control System 942
Adjuting Accelerator Wire 942
FUEL SYSTEM 943
Fuel Tank 943
Fuel Pump and Guage 944
EXHAUST SYSTEM 945
California Exhaust System 946
Non-California Exhaust System 947
foldout 948
QUICK REFERENCE INDEX 0
ELECTRICAL SYSTEM 1
SUPER MULTIPLE JUNCTION (SMJ) 948
INSTALLATION 948
Terminal Arrangement 949
JOINT CONNECTOR (J/C) 952
Location 952
Terminal Arrangement 952
FUSE BLOCK/FUSIBLE LINK DAND FUSE BOX 950
Fuse Arrangement 950
CONTROL UNITS/MODULE 951
gi 953
QUICK REFERENCE INDEX 0
TABLE OF CONTENTS 953
PRECAUTIONS 954
Supplemental Restraint System (SRS) “AIR BAG” 954
General Precautions 955
Precautions for Engine Oils 957
Precautions for Multiport Fuel Injection System or ECM Controlled Engine 958
Precautions for Three Way Catalyst 958
Precautions for Fuel 958
Precautions for Air Conditioning 958
HOW TO USE THIS MANUAL 959
HOW TO READ WIRING DIAGRAMS 961
Sample/Wiring Diagram – EXAMPL – 961
Description 963
Wiring Diagram Codes (Cell Codes) 969
HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT 970
Work Flow 970
Incident Simulation Tests 971
Circuit Inspection 975
HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSIS 982
How To Follow This Flow Chart 983
CONSULT CHECKING SYSTEM 985
Function and System Application 985
Lithium Battery Replacement 985
Checking Equipment 985
IDENTIFICATION INFORMATION 986
Model Variation 986
Identification Number 987
Dimensions 989
Wheels and Tires 989
LIFTING POINTS AND TOW TRUCK TOWING 990
Preparation 990
Board-on Lift 991
Garage Jack and Safety Stand 991
2-pole Lift 992
Tow Truck Towing 992
TIGHTENING TORQUE OF STANDARD BOLTS 994
SAE J1930 TERMINOLOGY LIST 995
ha 999
QUICK REFERENCE INDEX 0
TABLE OF CONTENTS 999
MANUAL AND AUTO1001
PRECAUTIONS AND PREPARATION1001
Precautions for Supplemental Restraint System (SRS) “AIR BAG”1001
Precautions for Working with R-134a1001
Precautions for Working with Refrigerants1002
Precautions for Refrigerant Connection1003
Precautions for Servicing Compressor1004
Special Service Tools1005
R-134a Service Tools and Equipment1006
Precautions for Service Equipment1008
DESCRIPTION1010
Refrigeration Cycle1010
Component Layout1011
Discharge Air Flow1012
MANUAL1013
DESCRIPTION1013
Control Operation1013
TROUBLE DIAGNOSES1014
How to Perform Trouble Diagnoses for Quick and Accurate Repair1014
Operational Check1015
Symptom Chart1017
Preliminary Check1019
Performance Test Diagnoses1025
Performance Chart1027
Trouble Diagnoses for Abnormal Pressure1028
Harness Layout1032
Circuit Diagram1034
Wiring Diagram – HEATER -1035
Wiring Diagram – A/Cm M -1036
Main Power Supply and Ground Circuit Check1042
Diagnostic Procedures1043
Electrical Components Inspection1054
Control Linkage Adjustment1055
AUTO1057
DESCRIPTION1057
Introduction1057
Features1057
Control Operation1058
TROUBLE DIAGNOSES1060
How to Perform Trouble Diagnoses for Quick and Accurate Repair1060
Operational Check1061
Symptom Chart1065
Self-diagnosis1069
Preliminary Check1077
Performance Test Diagnoses1085
Performance Chart1087
Trouble Diagnoses for Abnormal Pressure1088
Harness Layout1092
Circuit Diagram1094
Wiring Diagram – A/C, A -1095
Main Power Supplu and Ground Circuit Check1101
Diagnostic Procedures1102
Electrical Components Inspection1118
Control Linkage Adjustment1119
SYSTEM DESCRIPTION1121
Overview of Control System1121
Control System Input Components1122
Control System Automatic Amplifier (Auto amp)1124
Control System Output Components1124
MANUAL AND AUTO1133
SERVICE PROCEDURES1133
Checking Refrigerant Leaks1133
R-134a Service Procedure1135
Compressor Lubricant Quantity1137
Refrigerant Lines1139
Compressor Mounting1140
Belt Tension1140
Fast Idle Control Device (FICD) 1140
Compressor1141
Compressor Clutch1141
Thermal Protector1144
SERVICE DATA AND SPECIFICATIONS (SDS) 1145
General Specifications1145
Inspection and Adjustment1145
idx1146
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lc1155
QUICK REFERENCE INDEX 0
TABLE OF CONTENTS1155
PRECAUTIONS AND PREPARATION1156
Supplemental Restraint System (SRS) “AIR BAG”1156
Liquid Gasket Application Procedure1156
Special Service Tools1157
ENGINE LUBRICATION SYSTEM1158
Lubrication Circuit1158
Oil Pressure Check1159
Oil Pump1160
ENGINE COOLING SYSTEM1163
Cooling Circuit1163
System Check1163
Water Pump1165
Thermostat1167
Radiator1168
Overheating Cause Analysis1169
SERVICE DATA AND SPECIFICATIONS (SDS)1170
Engine Lubrication System1170
Engine Cooling System1170
ma1171
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TABLE OF CONTENTS1171
PREPARATION AND PRECAUTIONS1172
Precautions for Supplemental Restraint System (SRS) “AIR BAG”1172
Special Service Tools1172
GENERAL MAINTENANCE1173
PERIODIC MAINTENANCE1175
Schedule 11176
Schedule 21177
RECOMMENDED FLUIDS AND LUBRICANTS1178
Fluids and Lubricants1178
SAE Viscosity Number1178
Anti-freeze Coolant Mixture Ratio1179
ENGINE MAINTENANCE1180
Checking Drive Belts1180
Changing Engine Coolant1181
Checking Fuel Lines1182
Changing Fuel Filter1183
Changing Air Cleaner Filter1183
Changing Engine Oil1184
Changing Oil Filter1184
Changing Spark Plugs1185
Checking Vapor Lines1185
CHASSIS AND BODY MAINTENANCE1186
Checking Exhaust System1186
Checking Clutch Fluid Level and Leaks1186
Checking M/T Oil1186
Changing M/T Oil1186
Checking A/T Fluid1187
Changing A/T Fluid1187
Checking Brake Fluid Level and Leaks1188
Checking Brake Line Cables1188
Checking Disc Brake1188
Checking Drum Brake1188
Balancing Wheels1189
Tire Rotation1189
Checking Steering Gear and Linkage1189
Checking Power Steering Fluid and Lines1190
Lubricating Locks, Hinges and Hood Latches1191
Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters1191
SERVICE DATA AND SPECIFICATIONS (SDS)1192
Engine Maintenance1192
Chassis and Body Maintenance1192
mt1193
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TABLE OF CONTENTS1193
PREPARATION1194
Special Service Tools1194
Comercial Service Tools1196
ON-VEHICLE SERVICE1197
Replacing Oil Seal1197
Differential Side Oil Seal1197
Striking Rod Oil Seal1197
Position Switch Check1198
Viscous Coupling Check1198
REMOVAL AND INSTALLATION1199
Removal1199
Installation1201
TRANSAXLE GEAR CONTROL1202
MAJOR OVERHAUL1203
Case Components1203
Gear Components1204
Shift Control Components1205
DISASSEMBLY1206
REPAIR FOR COMPONENT PARTS1209
Input Shaft and Gears1209
Mainshaft and Gears1214
Final Drive1218
Shift Control Components1222
Case Components1222
ADJUSTMENT1223
Input Shaft End Play and Differential Side Bearing Preload1223
Mainshaft Bearing Preload1224
ASSEMBLY1227
SERVICE DATA AND SPECIFICATIONS (SDS)1231
General Specifications1231
Inspection and Adjustment1232
ra1236
QUICK REFERENE INDEX 0
TABLE OF CONTENTS1236
PRECAUTIONS AND PREPARATION1237
Precautions1237
Special Service Tools1237
Commerical Service Tools1237
REAR AXLE AND REAR SUSPENSION1238
ON-VEHICLE SERVICE1239
Rear Axle and Rear Suspension Parts1239
Rear Wheel Bearing1239
Rear Wheel Alignment1240
REAR AXLE1243
Wheel Hub1243
REAR SUSPENSION1245
Removal and Installation1246
Coil Spring and Strut Assembly1247
Parallel Link, Radius Link and Stabilizer Bar1249
SERVICE DATA AND SPECIFICATIONS (SDS)1250
General Specifications1250
Inspection and Adjustment1250
rs1251
QUICK REFERENCE INDEX 0
TABLE OF CONTENTS1251
PRECAUTION1252
Supplemental Restraint Sytem (SRS) “AIR BAG”1252
SEAT BELTS1253
Front Seat Belt1254
Rear Seat Belt1256
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)1257
Precautions for SRS “Air Bag” Service1257
Special Service Tools1257
Description1258
SRS Component Parts Location1258
Maintenance Items1259
Diagnosis Sensor Unit1260
Driver Air Bag Module and Spiral Cable1261
Front Passenger Air Bag Module1263
Disposal of Air Bag Module1265
TROUBLE DIAGNOSES – Supplemental Restraing System (SRS)1269
How to Perform Trouble Diagnoses for Quick and Accurate Repair1269
Schematic1271
Wiring diagram – SRS -1272
Self-diagnosis1274
Trouble Diagnoses for “Air Bag” Warning Lamp1287
COLLISION DIAGNOSIS1289
st1290
QUICK REFERENCE INDEX 0
TABLE OF CONTENTS1290
PRECAUTIONS AND PREPARATION1291
Supplemental Restraint System (SRS) “AIR BAG”1291
Special Service Tools1292
Commercial Service Tools1293
ON-VEHICLE SERVICE1294
Checking and Adjusting Drive Belts1294
Checking Fluid Level1294
Checking Fluid Leakage1294
Bleeding Hydraulic System1294
Checking Steering Wheel Turning Force1295
Checking Steering Wheel Play1296
Checking Neutral Position on Steering Wheel1296
Front Wheel Turning Angle1296
Checking Gear Housing Movement1296
Checking Hydraulic System1297
STEERING WHEEL AND STEERING COLUMN1298
Steering Wheel1298
Installation1299
Steering Column1299
Disassembly and Assembly1300
Inspection1301
POWER STEERING GEAR AND LINKAGE1302
Removal and Installation1302
Disassembly1305
Inspection1305
Assembly1306
POWER STEERING OIL PUMP1308
Pre-disassembly Inspection1308
Disassembly1309
Inspection1309
Assembly1310
SERVICE DATA AND SPECIFICAITONS (SDS)1311
General Specifications1311
Inspection and Adjustment1311
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