2001 NISSAN PATHFINDER R50 Series Service Manual PDF DOWNLOAD
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2001 NISSAN PATHFINDER R50 Series Service Manual PDF DOWNLOAD
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2001 NISSAN PATHFINDER R50 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 Transmission............................................................................................... 0 AT - Automatic Transmission............................................................................................ 0 TF - Transfer.......................................................................................................... 0 PD - Propeller Shaft & Differential Carrier............................................................................ 0 AX - Front & Rear Axle................................................................................................. 0 SU - Front & Rear Suspension........................................................................................... 0 BR - Brake System...................................................................................................... 0 ST - Steering System................................................................................................... 0 RS - Restraint System.................................................................................................. 0 BT - Body & Trim....................................................................................................... 0 HA - Heater & Air Conditioner.......................................................................................... 0 SC - Starting & Charging System........................................................................................ 0 EL - Electrical System................................................................................................. 0 IDX - Alphabetical Index............................................................................................... 1 SUPER MULTIPLE JUNCTION (SMJ).......................................................................................... 0 FUSE BLOCK - JUNCTION BOX (J/B)........................................................................................ 2 FUSE AND FUSIBLE LINK BOX.............................................................................................. 3 ELECTRICAL UNITS....................................................................................................... 4 QUICK REFERENCE CHART.................................................................................................. 5 Comment Sheet.......................................................................................................... 3 GST Mode 6 - Test Value & Test Limit Chart............................................................................. 5 at......................................................................................................................... 6 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents...................................................................................................... 6 TROUBLE DIAGNOSIS - INDEX.............................................................................................. 9 Alphabetical & P No. Index for DTC................................................................................. 9 PRECAUTIONS............................................................................................................ 11 Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................ 11 Precautions for On Board Diagnostic (OBD) System of A/T and Engine................................................. 11 Precautions........................................................................................................ 11 Service Notice or Precautions...................................................................................... 13 Wiring Diagrams and Trouble Diagnosis.............................................................................. 14 PREPARATION............................................................................................................ 15 Special Service Tools.............................................................................................. 15 OVERALL SYSTEM......................................................................................................... 17 A/T Electrical Parts Location...................................................................................... 17 Circuit Diagram.................................................................................................... 18 Cross-sectional View............................................................................................... 19 Hydraulic Control Circuit.......................................................................................... 20 Shift Mechanism.................................................................................................... 21 Control System..................................................................................................... 30 Control Mechanism.................................................................................................. 31 Control Valve...................................................................................................... 36 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION................................................................................. 38 Introduction....................................................................................................... 38 OBD-II Function for A/T System..................................................................................... 38 One or Two Trip Detection Logic of OBD-II.......................................................................... 38 OBD-II Diagnostic Trouble Code (DTC)............................................................................... 38 Malfunction Indicator Lamp (MIL)................................................................................... 42 CONSULT-II......................................................................................................... 42 Diagnostic Procedure Without CONSULT-II............................................................................ 51 TROUBLE DIAGNOSIS - INTRODUCTION....................................................................................... 58 Introduction....................................................................................................... 58 Work Flow.......................................................................................................... 62 TROUBLE DIAGNOSIS - BASIC INSPECTION................................................................................... 64 A/T Fluid Check.................................................................................................... 64 Stall Test......................................................................................................... 64 Line Pressure Test................................................................................................. 67 Road Test.......................................................................................................... 68 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION................................................................................ 86 Symptom Chart...................................................................................................... 86 TCM Terminals and Reference Value.................................................................................. 97 TROUBLE DIAGNOSIS FOR POWER SUPPLY..................................................................................... 101 Wiring Diagram - AT - MAIN......................................................................................... 101 Diagnostic Procedure............................................................................................... 102 DTC P0705 PARK/NEUTRAL POSITION SWITCH................................................................................. 104 Description........................................................................................................ 104 Wiring Diagram - AT - PNP/SW....................................................................................... 106 Diagnostic Procedure............................................................................................... 107 Component Inspection............................................................................................... 108 DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT......................................................................... 110 Description........................................................................................................ 110 Wiring Diagram - AT - FTS.......................................................................................... 112 Diagnostic Procedure............................................................................................... 113 Component Inspection............................................................................................... 115 DTC P0720 VEHICLE SPEED SENSOR.A/T (REVOLUTION SENSOR)................................................................. 116 Description........................................................................................................ 116 Wiring Diagram - AT - VSSA/T....................................................................................... 118 Diagnostic Procedure............................................................................................... 119 Component Inspection............................................................................................... 120 DTC P0725 ENGINE SPEED SIGNAL.......................................................................................... 121 Description........................................................................................................ 121 Wiring Diagram - AT - ENGSS........................................................................................ 122 Diagnostic Procedure............................................................................................... 123 DTC P0731 IMPROPER SHIFTING TO 1ST GEAR POSITION....................................................................... 125 Description........................................................................................................ 125 Wiring Diagram - AT - 1ST.......................................................................................... 128 Diagnostic Procedure............................................................................................... 129 Component Inspection............................................................................................... 130 DTC P0732 IMPROPER SHIFTING TO 2ND GEAR POSITION....................................................................... 131 Description........................................................................................................ 131 Wiring Diagram - AT - 2ND.......................................................................................... 134 Diagnostic Procedure............................................................................................... 135 Component Inspection............................................................................................... 136 DTC P0733 IMPROPER SHIFTING TO 3RD GEAR POSITION....................................................................... 137 Description........................................................................................................ 137 Wiring Diagram - AT - 3RD.......................................................................................... 140 Diagnostic Procedure............................................................................................... 141 Component Inspection............................................................................................... 142 DTC P0734 IMPROPER SHIFTING TO 4TH GEAR POSITION....................................................................... 143 Description........................................................................................................ 143 Wiring Diagram - AT - 4TH.......................................................................................... 147 Diagnostic Procedure............................................................................................... 148 Component Inspection............................................................................................... 152 DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE....................................................................... 153 Description........................................................................................................ 153 Wiring Diagram - AT - TCV.......................................................................................... 155 Diagnostic Procedure............................................................................................... 156 Component Inspection............................................................................................... 157 DTC P0744 IMPROPER LOCK-UP OPERATION................................................................................... 158 Description........................................................................................................ 158 Wiring Diagram - AT - TCCSIG....................................................................................... 161 Diagnostic Procedure............................................................................................... 162 Component Inspection............................................................................................... 166 DTC P0745 LINE PRESSURE SOLENOID VALVE................................................................................. 167 Description........................................................................................................ 167 Wiring Diagram - AT - LPSV......................................................................................... 169 Diagnostic Procedure............................................................................................... 170 Component Inspection............................................................................................... 172 DTC P0750 SHIFT SOLENOID VALVE A....................................................................................... 173 Description........................................................................................................ 173 Wiring Diagram - AT - SSV/A........................................................................................ 174 Diagnostic Procedure............................................................................................... 175 Component Inspection............................................................................................... 176 DTC P0755 SHIFT SOLENOID VALVE B....................................................................................... 177 Description........................................................................................................ 177 Wiring Diagram - AT - SSV/B........................................................................................ 178 Diagnostic Procedure............................................................................................... 179 Component Inspection............................................................................................... 180 DTC P1705 THROTTLE POSITION SENSOR..................................................................................... 181 Description........................................................................................................ 181 Wiring Diagram - AT - TPS.......................................................................................... 184 Diagnostic Procedure............................................................................................... 185 Component Inspection............................................................................................... 189 DTC P1760 OVERRUN CLUTCH SOLENOID VALVE................................................................................ 190 Description........................................................................................................ 190 Wiring Diagram - AT - OVRCSV....................................................................................... 192 Diagnostic Procedure............................................................................................... 193 Component Inspection............................................................................................... 194 DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE)........................................... 195 Description........................................................................................................ 195 Wiring Diagram - AT - BA/FTS....................................................................................... 197 Diagnostic Procedure............................................................................................... 198 Component Inspection............................................................................................... 201 DTC VEHICLE SPEED SENSOR.MTR........................................................................................... 202 Description........................................................................................................ 202 Wiring Diagram - AT - VSSMTR....................................................................................... 204 Diagnostic Procedure............................................................................................... 205 DTC TURBINE REVOLUTION SENSOR.......................................................................................... 207 Description........................................................................................................ 207 Wiring Diagram - AT - TRSA/T....................................................................................... 209 Diagnostic Procedure............................................................................................... 210 Component Inspection............................................................................................... 211 DTC A/T COMMUNICATION LINE............................................................................................. 212 Description........................................................................................................ 212 Wiring Diagram - AT - LAN.......................................................................................... 214 Diagnostic Procedure............................................................................................... 215 DTC CONTROL UNIT (RAM), CONTROL UNIT (ROM)............................................................................. 216 Description........................................................................................................ 216 Diagnostic Procedure............................................................................................... 217 DTC CONTROL UNIT (EEP ROM)............................................................................................. 218 Description........................................................................................................ 218 Diagnostic Procedure............................................................................................... 219 TROUBLE DIAGNOSES FOR SYMPTOMS......................................................................................... 220 Wiring Diagram - AT - NONDTC....................................................................................... 220 1. O/D OFF Indicator Lamp Does Not Come On......................................................................... 223 2. Engine Cannot Be Started In "P" and "N" Position................................................................ 226 3. In "P" Position, Vehicle Moves Forward Or Backward When Pushed.................................................. 227 4. In "N" Position, Vehicle Moves.................................................................................. 228 5. Large Shock. "N" -> "R" Position................................................................................ 230 6. Vehicle Does Not Creep Backward In "R" Position................................................................. 232 7. Vehicle Does Not Creep Forward In "D", "2" Or "1" Position...................................................... 235 8. Vehicle Cannot Be Started From D1............................................................................... 238 9. A/T Does Not Shift: D1 -> D2 Or Does Not Kickdown: D4 -> D2..................................................... 241 10. A/T Does Not Shift: D2 -> D3................................................................................... 244 11. A/T Does Not Shift: D3 -> D4................................................................................... 247 12. A/T Does Not Perform Lock-up................................................................................... 250 13. A/T Does Not Hold Lock-up Condition............................................................................ 252 14. Lock-up Is Not Released........................................................................................ 254 15. Engine Speed Does Not Return To Idle (Light Braking D4 -> D3).................................................. 255 16. Vehicle Does Not Start From D1................................................................................. 257 17. A/T Does Not Shift: D4 -> D3, When Overdrive Control Switch "ON" -> "OFF"...................................... 258 18. A/T Does Not Shift: D3 -> 22, When Selector Lever "D" -> "2" Position.......................................... 259 19. A/T Does Not Shift: 22 -> 11, When Selector Lever "2" -> "1" Position.......................................... 260 20. Vehicle Does Not Decelerate By Engine Brake.................................................................... 261 21. TCM Self-diagnosis Does Not Activate (PNP, Overdrive Control and Throttle Position Switches Circuit Checks).... 262 A/T SHIFT LOCK SYSTEM.................................................................................................. 270 Description........................................................................................................ 270 Wiring Diagram - SHIFT -........................................................................................... 271 Diagnostic Procedure............................................................................................... 272 KEY INTERLOCK CABLE.................................................................................................... 276 Components......................................................................................................... 276 Removal............................................................................................................ 276 Installation....................................................................................................... 277 ON-VEHICLE SERVICE..................................................................................................... 278 Control Valve Assembly and Accumulators............................................................................ 278 Revolution Sensor Replacement...................................................................................... 279 Turbine Revolution Sensor Replacement.............................................................................. 279 Rear Oil Seal Replacement.......................................................................................... 279 Rear Oil Seal and Companion Flange Oil Seal Replacement............................................................ 280 Parking Components Inspection...................................................................................... 280 Park/Neutral Position Switch Adjustment............................................................................ 281 Manual Control Linkage Adjustment.................................................................................. 281 REMOVAL AND INSTALLATION............................................................................................... 282 Removal............................................................................................................ 282 Installation....................................................................................................... 283 OVERHAUL............................................................................................................... 287 Components......................................................................................................... 287 Oil Channel........................................................................................................ 290 Locations of Needle Bearings, Thrust Washers and Snap Rings........................................................ 291 DISASSEMBLY............................................................................................................ 292 REPAIR FOR COMPONENT PARTS............................................................................................. 303 Oil Pump........................................................................................................... 303 Control Valve Assembly............................................................................................. 307 Control Valve Upper Body........................................................................................... 313 Control Valve Lower Body........................................................................................... 318 Reverse Clutch..................................................................................................... 320 High Clutch........................................................................................................ 323 Forward and Overrun Clutches....................................................................................... 326 Low & Reverse Brake................................................................................................ 330 Forward Clutch Drum Assembly....................................................................................... 334 Rear Internal Gear and Forward Clutch Hub.......................................................................... 336 Band Servo Piston Assembly......................................................................................... 339 Parking Pawl Components............................................................................................ 343 ASSEMBLY............................................................................................................... 345 Assembly (1)....................................................................................................... 345 Adjustment......................................................................................................... 353 Assembly (2)....................................................................................................... 355 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................. 362 General Specifications............................................................................................. 362 Shift Schedule..................................................................................................... 362 Stall Revolution................................................................................................... 362 Line Pressure...................................................................................................... 362 Return Springs..................................................................................................... 363 Accumulator O-ring................................................................................................. 364 Clutches and Brakes................................................................................................ 364 Oil Pump and Low One-way Clutch.................................................................................... 366 Total End Play..................................................................................................... 366 Reverse Clutch Drum End Play....................................................................................... 367 Removal and Installation........................................................................................... 367 Shift Solenoid Valves.............................................................................................. 367 Solenoid Valves.................................................................................................... 367 A/T Fluid Temperature Sensor....................................................................................... 367 Turbine Revolution Sensor.......................................................................................... 367 Revolution Sensor.................................................................................................. 368 Dropping Resistor.................................................................................................. 368 SUPER MULTIPLE JUNCTION (SMJ).......................................................................................... 0 FUSE BLOCK - JUNCTION BOX (J/B)........................................................................................ 2 FUSE AND FUSIBLE LINK BOX.............................................................................................. 3 ELECTRICAL UNITS....................................................................................................... 4 ax......................................................................................................................... 370 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents...................................................................................................... 370 FRONT AXLE............................................................................................................. 371 Precautions........................................................................................................ 371 PRECAUTIONS.................................................................................................... 371 Preparation........................................................................................................ 371 SPECIAL SERVICE TOOLS.......................................................................................... 371 COMMERCIAL SERVICE TOOLS....................................................................................... 371 Noise, Vibration and Harshness (NVH) Troubleshooting............................................................... 372 NVH TROUBLESHOOTING CHART...................................................................................... 372 On-vehicle Service................................................................................................. 372 FRONT AXLE PARTS............................................................................................... 372 FRONT WHEEL BEARING............................................................................................ 373 DRIVE SHAFT.................................................................................................... 374 Wheel Hub and Rotor Disc........................................................................................... 375 COMPONENTS..................................................................................................... 375 REMOVAL........................................................................................................ 376 INSTALLATION................................................................................................... 378 DISASSEMBLY.................................................................................................... 378 INSPECTION..................................................................................................... 378 ASSEMBLY....................................................................................................... 379 Knuckle Spindle.................................................................................................... 379 REMOVAL........................................................................................................ 379 INSPECTION..................................................................................................... 380 INSTALLATION................................................................................................... 380 Drive Shaft........................................................................................................ 381 COMPONENTS..................................................................................................... 381 REMOVAL........................................................................................................ 381 DISASSEMBLY.................................................................................................... 382 INSPECTION..................................................................................................... 383 ASSEMBLY....................................................................................................... 383 INSTALLATION................................................................................................... 385 Service Data and Specifications (SDS).............................................................................. 386 WHEEL BEARING (FRONT).......................................................................................... 386 DRIVE SHAFT (4WD).............................................................................................. 386 REAR AXLE.............................................................................................................. 387 Precautions........................................................................................................ 387 PRECAUTIONS.................................................................................................... 387 Preparation........................................................................................................ 387 SPECIAL SERVICE TOOLS.......................................................................................... 387 COMMERCIAL SERVICE TOOLS....................................................................................... 388 Noise, Vibration and Harshness (NVH) Troubleshooting............................................................... 388 On-vehicle Service................................................................................................. 388 REAR AXLE PARTS................................................................................................ 388 REAR WHEEL BEARING............................................................................................. 388 Components......................................................................................................... 389 Removal............................................................................................................ 389 Inspection......................................................................................................... 391 AXLE SHAFT..................................................................................................... 391 BEARING CAGE................................................................................................... 391 REAR AXLE HOUSING.............................................................................................. 391 Installation....................................................................................................... 391 Service Data and Specifications (SDS).............................................................................. 392 WHEEL BEARING (REAR)........................................................................................... 392 br......................................................................................................................... 394 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents...................................................................................................... 394 PRECAUTIONS............................................................................................................ 396 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................................ 396 Precautions for Brake System....................................................................................... 396 Wiring Diagrams and Trouble Diagnoses.............................................................................. 397 PREPARATION............................................................................................................ 398 Special Service Tools.............................................................................................. 398 Commercial Service Tools........................................................................................... 398 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING................................................................... 399 NVH Troubleshooting Chart.......................................................................................... 399 ON-VEHICLE SERVICE..................................................................................................... 400 Checking Brake Fluid Level......................................................................................... 400 Checking Brake Line................................................................................................ 400 Changing Brake Fluid............................................................................................... 400 Bleeding Brake System.............................................................................................. 401 BRAKE HYDRAULIC LINE................................................................................................... 402 Hydraulic Circuit.................................................................................................. 402 Removal............................................................................................................ 403 Inspection......................................................................................................... 403 Installation....................................................................................................... 403 PROPORTIONING VALVE (2WD).............................................................................................. 404 Inspection......................................................................................................... 404 Removal and Installation (Built-in type)........................................................................... 404 LOAD SENSING VALVE (4WD)............................................................................................... 405 Inspection......................................................................................................... 405 Removal and Installation........................................................................................... 405 BRAKE PEDAL AND BRACKET................................................................................................ 407 Removal and Installation........................................................................................... 407 Inspection......................................................................................................... 407 Adjustment......................................................................................................... 407 MASTER CYLINDER........................................................................................................ 409 Removal............................................................................................................ 409 Disassembly........................................................................................................ 409 Inspection......................................................................................................... 410 Assembly........................................................................................................... 410 Installation....................................................................................................... 411 BRAKE BOOSTER.......................................................................................................... 412 On-vehicle Service................................................................................................. 412 OPERATING CHECK................................................................................................ 412 AIRTIGHT CHECK................................................................................................. 412 Removal............................................................................................................ 412 Inspection......................................................................................................... 412 OUTPUT ROD LENGTH CHECK........................................................................................ 412 Installation....................................................................................................... 413 VACUUM PIPING.......................................................................................................... 414 Vacuum Hose........................................................................................................ 414 Removal and Installation........................................................................................... 414 Inspection......................................................................................................... 414 HOSES AND CONNECTORS........................................................................................... 414 CHECK VALVE.................................................................................................... 414 FRONT DISC BRAKE....................................................................................................... 415 Components......................................................................................................... 415 Pad Replacement.................................................................................................... 415 Removal............................................................................................................ 416 Disassembly........................................................................................................ 417 Inspection......................................................................................................... 417 CALIPER........................................................................................................ 417 ROTOR.......................................................................................................... 417 Assembly........................................................................................................... 418 Installation....................................................................................................... 418 Brake Burnishing Procedure......................................................................................... 418 REAR DRUM BRAKE........................................................................................................ 419 Components......................................................................................................... 419 Removal............................................................................................................ 419 Inspection......................................................................................................... 420 WHEEL CYLINDER................................................................................................. 420 Wheel Cylinder Overhaul............................................................................................ 421 Inspection......................................................................................................... 421 DRUM........................................................................................................... 421 LINING......................................................................................................... 421 Installation....................................................................................................... 421 PARKING BRAKE CONTROL.................................................................................................. 423 Components......................................................................................................... 423 Removal and Installation........................................................................................... 423 Inspection......................................................................................................... 423 Adjustment......................................................................................................... 424 ABS.................................................................................................................... 425 DESCRIPTION........................................................................................................ 425 Purpose........................................................................................................ 425 Operation...................................................................................................... 425 ABS Hydraulic Circuit.......................................................................................... 425 System Components.............................................................................................. 426 System Description............................................................................................. 426 SENSOR..................................................................................................... 426 CONTROL UNIT (BUILT-IN ABS ACTUATOR AND ELECTRIC UNIT)..................................................... 426 ABS ACTUATOR AND ELECTRIC UNIT............................................................................. 426 G SENSOR (4WD MODELS ONLY)................................................................................. 427 Component Parts and Harness Connector Location................................................................. 428 Schematic...................................................................................................... 429 Wiring Diagram - ABS -......................................................................................... 430 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION............................................................................. 434 Self-diagnosis................................................................................................. 434 FUNCTION................................................................................................... 434 SELF-DIAGNOSIS PROCEDURE................................................................................... 434 HOW TO READ SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES).................................................... 435 HOW TO ERASE SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES)................................................... 435 CONSULT-II..................................................................................................... 436 CONSULT-II APPLICATION TO ABS.............................................................................. 436 ECU (ABS CONTROL UNIT) PART NUMBER MODE.................................................................... 436 CONSULT-II Inspection Procedure................................................................................ 437 SELF-DIAGNOSIS PROCEDURE................................................................................... 437 SELF-DIAGNOSTIC RESULTS MODE............................................................................... 438 DATA MONITOR PROCEDURE..................................................................................... 439 ACTIVE TEST PROCEDURE...................................................................................... 440 DATA MONITOR MODE.......................................................................................... 441 ACTIVE TEST MODE........................................................................................... 441 TROUBLE DIAGNOSIS - INTRODUCTION................................................................................... 442 How to Perform Trouble Diagnoses for Quick and Accurate Repair................................................. 442 INTRODUCTION............................................................................................... 442 TROUBLE DIAGNOSIS - BASIC INSPECTION............................................................................... 443 Preliminary Check.............................................................................................. 443 Ground Circuit Check........................................................................................... 446 ABS ACTUATOR AND ELECTRIC UNIT GROUND...................................................................... 446 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION............................................................................ 447 Malfunction Code/Symptom Chart................................................................................. 447 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS........................................................................ 449 Wheel Sensor or Rotor.......................................................................................... 449 DIAGNOSTIC PROCEDURE....................................................................................... 449 ABS Actuator Solenoid Valve or Solenoid Valve Relay............................................................ 452 DIAGNOSTIC PROCEDURE....................................................................................... 452 Motor Relay or Motor........................................................................................... 454 DIAGNOSTIC PROCEDURE....................................................................................... 454 Low Voltage.................................................................................................... 456 DIAGNOSTIC PROCEDURE....................................................................................... 456 G Sensor and Circuit........................................................................................... 458 DIAGNOSTIC PROCEDURE....................................................................................... 458 ELECTRICAL COMPONENT INSPECTION............................................................................ 460 Control Unit................................................................................................... 461 DIAGNOSTIC PROCEDURE....................................................................................... 461 TROUBLE DIAGNOSES FOR SYMPTOMS..................................................................................... 462 1. ABS Works Frequently........................................................................................ 462 2. Unexpected Pedal Action..................................................................................... 462 3. Long Stopping Distance...................................................................................... 464 4. ABS Does Not Work........................................................................................... 464 5. Pedal Vibration and Noise................................................................................... 465 6. Warning Lamp Does Not Come On When Ignition Switch Is Turned On............................................. 466 7. Warning Lamp Stays On When Ignition Switch Is Turned On..................................................... 468 8. Vehicle Vibrates Excessively When ABS Is Operating.......................................................... 471 REMOVAL AND INSTALLATION........................................................................................... 474 Front Wheel Sensor............................................................................................. 474 Rear Wheel Sensor.............................................................................................. 474 Front Sensor Rotor............................................................................................. 475 REMOVAL.................................................................................................... 475 INSTALLATION............................................................................................... 475 Rear Sensor Rotor.............................................................................................. 475 REMOVAL.................................................................................................... 475 INSTALLATION............................................................................................... 475 G Sensor....................................................................................................... 475 ABS Actuator and Electric Unit................................................................................. 476 REMOVAL.................................................................................................... 476 INSTALLATION............................................................................................... 476 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................. 477 General Specifications............................................................................................. 477 Disc Brake......................................................................................................... 477 Drum Brake......................................................................................................... 477 Brake Pedal........................................................................................................ 477 Parking Brake Control.............................................................................................. 478 SUPER MULTIPLE JUNCTION (SMJ).......................................................................................... 0 FUSE BLOCK - JUNCTION BOX (J/B)........................................................................................ 2 FUSE AND FUSIBLE LINK BOX.............................................................................................. 3 ELECTRICAL UNITS....................................................................................................... 4 bt......................................................................................................................... 480 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents...................................................................................................... 480 PRECAUTIONS............................................................................................................ 482 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................................ 482 PREPARATION............................................................................................................ 483 Special Service Tools.............................................................................................. 483 Commercial Service Tool............................................................................................ 483 SQUEAK AND RATTLE TROUBLE DIAGNOSES.................................................................................... 484 Work Flow.......................................................................................................... 484 CUSTOMER INTERVIEW............................................................................................. 484 DUPLICATE THE NOISE AND TEST DRIVE............................................................................. 485 CHECK RELATED SERVICE BULLETINS................................................................................ 485 LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE................................................................... 485 REPAIR THE CAUSE............................................................................................... 485 CONFIRM THE REPAIR............................................................................................. 486 Generic Squeak and Rattle Troubleshooting.......................................................................... 486 INSTRUMENT PANEL............................................................................................... 486 CENTER CONSOLE................................................................................................. 486 DOORS.......................................................................................................... 486 TRUNK.......................................................................................................... 487 SUNROOF/HEADLINER.............................................................................................. 487 SEATS.......................................................................................................... 487 UNDERHOOD...................................................................................................... 487 Diagnostic Worksheet............................................................................................... 488 CLIP AND FASTENER...................................................................................................... 490 Description........................................................................................................ 490 BODY FRONT END......................................................................................................... 492 Removal and Installation........................................................................................... 492 FRONT BUMPER ASSEMBLY.......................................................................................... 492 BODY REAR END AND OPENER............................................................................................... 495 Removal and Installation........................................................................................... 495 REAR BUMPER ASSEMBLY........................................................................................... 495 FRONT DOOR............................................................................................................. 498 Overhaul........................................................................................................... 498 Front Door Limit Switch Reset...................................................................................... 499 RESET CONDITIONS............................................................................................... 499 RESET PROCEDURES............................................................................................... 499 REAR DOOR.............................................................................................................. 500 Overhaul........................................................................................................... 500 INSTRUMENT PANEL ASSEMBLY.............................................................................................. 501 Removal and Installation........................................................................................... 501 SIDE AND FLOOR TRIM.................................................................................................... 508 Removal and Installation........................................................................................... 508 DOOR TRIM.............................................................................................................. 510 Removal and Installation........................................................................................... 510 TYPE A......................................................................................................... 510 TYPE B......................................................................................................... 511 ROOF TRIM.............................................................................................................. 513 Removal and Installation........................................................................................... 513 BACK DOOR TRIM......................................................................................................... 514 Removal and Installation........................................................................................... 514 EXTERIOR............................................................................................................... 515 Removal and Installation........................................................................................... 515 FRONT SEAT............................................................................................................. 522 Removal and Installation........................................................................................... 522 POWER SEAT..................................................................................................... 523 MANUAL SEAT.................................................................................................... 524 HEATED SEAT.................................................................................................... 525 REAR SEAT.............................................................................................................. 526 Removal and Installation........................................................................................... 526 SUNROOF................................................................................................................ 527 Adjustment......................................................................................................... 527 Removal and Installation........................................................................................... 527 Trouble Diagnoses.................................................................................................. 531 DIAGNOSTIC TABLE............................................................................................... 531 WIND DEFLECTOR................................................................................................. 531 ADJUSTMENT..................................................................................................... 532 DRAIN HOSES.................................................................................................... 533 WEATHERSTRIP................................................................................................... 533 LINK AND WIRE ASSEMBLY......................................................................................... 534 WINDSHIELD AND WINDOWS................................................................................................. 535 Removal and Installation........................................................................................... 535 REMOVAL........................................................................................................ 535 INSTALLATION................................................................................................... 535 WINDSHIELD..................................................................................................... 536 REAR SIDE WINDOW............................................................................................... 537 DOOR MIRROR............................................................................................................ 538 Removal and Installation........................................................................................... 538 BODY (ALIGNMENT)....................................................................................................... 539 Alignment.......................................................................................................... 539 ENGINE COMPARTMENT............................................................................................. 540 UNDERBODY...................................................................................................... 542 cl......................................................................................................................... 544 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents...................................................................................................... 544 PRECAUTIONS............................................................................................................ 545 Precautions........................................................................................................ 545 PREPARATION............................................................................................................ 546 Special Service Tools.............................................................................................. 546 Commercial Service Tools........................................................................................... 546 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING................................................................... 547 NVH Troubleshooting Chart.......................................................................................... 547 CLUTCH......................................................................................................... 547 CLUTCH SYSTEM - HYDRAULIC TYPE......................................................................................... 548 Components......................................................................................................... 548 Inspection and Adjustment.......................................................................................... 549 ADJUSTING CLUTCH PEDAL......................................................................................... 549 AIR BLEEDING PROCEDURE......................................................................................... 550 CLUTCH MASTER CYLINDER................................................................................................. 551 Components......................................................................................................... 551 Disassembly and Assembly........................................................................................... 551 Inspection......................................................................................................... 551 OPERATING CYLINDER..................................................................................................... 552 Components......................................................................................................... 552 Inspection......................................................................................................... 552 CLUTCH RELEASE MECHANISM............................................................................................... 553 Components......................................................................................................... 553 Removal............................................................................................................ 553 Inspection......................................................................................................... 553 Installation....................................................................................................... 554 Lubrication........................................................................................................ 554 Waterproof - for 4WD Model......................................................................................... 555 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL................................................................................. 556 Components......................................................................................................... 556 Removal............................................................................................................ 556 Inspection......................................................................................................... 556 Inspection and Adjustment.......................................................................................... 557 CLUTCH DISC.................................................................................................... 557 FLYWHEEL INSPECTION............................................................................................ 557 Installation....................................................................................................... 557 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................. 559 Clutch Control System.............................................................................................. 559 Clutch Master Cylinder (With damper)............................................................................... 559 Clutch Operating Cylinder.......................................................................................... 559 Clutch Disc........................................................................................................ 559 Clutch Cover....................................................................................................... 559 Clutch Pedal....................................................................................................... 559 ec......................................................................................................................... 560 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents...................................................................................................... 560 TROUBLE DIAGNOSIS - INDEX.............................................................................................. 567 Alphabetical & P No. Index for DTC................................................................................. 567 PRECAUTIONS............................................................................................................ 573 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................................ 573 Precautions for On Board Diagnostic (OBD) System of Engine and A/T................................................. 573 Engine Fuel & Emission Control System.............................................................................. 574 Precautions........................................................................................................ 575 Wiring Diagrams and Trouble Diagnosis.............................................................................. 576 PREPARATION............................................................................................................ 577 Special Service Tools.............................................................................................. 577 Commercial Service Tools........................................................................................... 577 ENGINE AND EMISSION CONTROL OVERALL SYSTEM............................................................................. 579 Engine Control Component Parts Location............................................................................ 579 Circuit Diagram.................................................................................................... 583 System Diagram..................................................................................................... 584 Vacuum Hose Drawing................................................................................................ 585 System Chart....................................................................................................... 586 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION................................................................... 587 Multiport Fuel Injection (MFI) System.............................................................................. 587 Electronic Ignition (EI) System.................................................................................... 589 Air Conditioning Cut Control....................................................................................... 590 Fuel Cut Control (at no load & high engine speed).................................................................. 591 Evaporative Emission System........................................................................................ 591 Positive Crankcase Ventilation..................................................................................... 597 BASIC SERVICE PROCEDURE................................................................................................ 598 Fuel Pressure Release.............................................................................................. 598 Fuel Pressure Check................................................................................................ 598 Fuel Pressure Regulator Check...................................................................................... 599 Injector........................................................................................................... 600 How to Check Idle Speed and Ignition Timing........................................................................ 601 Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment........................................................... 602 Idle Air Volume Learning........................................................................................... 617 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION................................................................................. 619 Introduction....................................................................................................... 619 Two Trip Detection Logic........................................................................................... 619 Emission-related Diagnostic Information............................................................................ 620 Malfunction Indicator Lamp (MIL)................................................................................... 634 OBD System Operation Chart......................................................................................... 635 CONSULT-II......................................................................................................... 641 Generic Scan Tool (GST)............................................................................................ 655 TROUBLE DIAGNOSIS - INTRODUCTION....................................................................................... 657 Introduction....................................................................................................... 657 Work Flow.......................................................................................................... 659 TROUBLE DIAGNOSIS - BASIC INSPECTION................................................................................... 661 Basic Inspection................................................................................................... 661 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION................................................................................ 677 DTC Inspection Priority Chart...................................................................................... 677 Fail-safe Chart.................................................................................................... 678 Symptom Matrix Chart............................................................................................... 679 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 683 Major Sensor Reference Graph in Data Monitor Mode.................................................................. 685 ECM Terminals and Reference Value.................................................................................. 688 TROUBLE DIAGNOSIS - SPECIFICATION VALUE................................................................................ 697 Description........................................................................................................ 697 Testing Condition.................................................................................................. 697 Inspection Procedure............................................................................................... 697 Diagnostic Procedure............................................................................................... 698 TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT............................................................................ 701 Description........................................................................................................ 701 Diagnostic Procedure............................................................................................... 701 TROUBLE DIAGNOSIS FOR POWER SUPPLY..................................................................................... 702 ECM Terminals and Reference Value.................................................................................. 702 Main Power Supply and Ground Circuit............................................................................... 703 DTC P0100 MASS AIR FLOW SENSOR (MAFS).................................................................................. 711 Component Description.............................................................................................. 711 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 711 ECM Terminals and Reference Value.................................................................................. 711 On Board Diagnosis Logic........................................................................................... 712 Possible Cause..................................................................................................... 712 DTC Confirmation Procedure......................................................................................... 712 Overall Function Check............................................................................................. 714 Wiring Diagram..................................................................................................... 715 Diagnostic Procedure............................................................................................... 716 DTC P0105 ABSOLUTE PRESSURE SENSOR..................................................................................... 719 Component Description.............................................................................................. 719 ECM Terminals and Reference Value.................................................................................. 719 On Board Diagnosis Logic........................................................................................... 719 Possible Cause..................................................................................................... 720 DTC Confirmation Procedure......................................................................................... 720 Wiring Diagram..................................................................................................... 721 Diagnostic Procedure............................................................................................... 722 DTC P0110 INTAKE AIR TEMPERATURE SENSOR................................................................................ 725 Component Description.............................................................................................. 725 On Board Diagnosis Logic........................................................................................... 725 Possible Cause..................................................................................................... 725 DTC Confirmation Procedure......................................................................................... 725 Wiring Diagram..................................................................................................... 727 Diagnostic Procedure............................................................................................... 728 DTC P0115 ENGINE COOLANT TEMPERATURE SENSOR (ECTS) (CIRCUIT)........................................................... 730 Component Description.............................................................................................. 730 On Board Diagnosis Logic........................................................................................... 730 Possible Cause..................................................................................................... 731 DTC Confirmation Procedure......................................................................................... 731 Wiring Diagram..................................................................................................... 732 Diagnostic Procedure............................................................................................... 733 DTC P0120 THROTTLE POSITION SENSOR..................................................................................... 735 Description........................................................................................................ 735 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 735 ECM Terminals and Reference Value.................................................................................. 736 On Board Diagnosis Logic........................................................................................... 736 Possible Cause..................................................................................................... 736 DTC Confirmation Procedure......................................................................................... 737 Wiring Diagram..................................................................................................... 741 Diagnostic Procedure............................................................................................... 742 DTC P0125 ENGINE COOLANT TEMPERATURE SENSOR (ECTS)..................................................................... 748 Description........................................................................................................ 748 On Board Diagnosis Logic........................................................................................... 748 Possible Cause..................................................................................................... 749 DTC Confirmation Procedure......................................................................................... 749 Wiring Diagram..................................................................................................... 750 Diagnostic Procedure............................................................................................... 751 DTC P0130, P0150 HEATED OXYGEN SENSOR 1 (FRONT) (BANK 1)/(BANK 2) (CIRCUIT)............................................ 753 Component Description.............................................................................................. 753 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 753 ECM Terminals and Reference Value.................................................................................. 753 On Board Diagnosis Logic........................................................................................... 754 Possible Cause..................................................................................................... 754 DTC Confirmation Procedure......................................................................................... 755 Overall Function Check............................................................................................. 755 Wiring Diagram..................................................................................................... 757 Diagnostic Procedure............................................................................................... 759 DTC P0131, P0151 HEATED OXYGEN SENSOR 1 (FRONT) (BANK 1)/(BANK 2) (LEAN SHIFT MONITORING).............................. 763 Component Description.............................................................................................. 763 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 763 ECM Terminals and Reference Value.................................................................................. 763 On Board Diagnosis Logic........................................................................................... 764 Possible Cause..................................................................................................... 764 DTC Confirmation Procedure......................................................................................... 764 Overall Function Check............................................................................................. 765 Diagnostic Procedure............................................................................................... 766 DTC P0132, P0152 HEATED OXYGEN SENSOR 1 (FRONT) (BANK 1)/(BANK 2) (RICH SHIFT MONITORING).............................. 771 Component Description.............................................................................................. 771 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 771 ECM Terminals and Reference Value.................................................................................. 771 On Board Diagnosis Logic........................................................................................... 772 Possible Cause..................................................................................................... 772 DTC Confirmation Procedure......................................................................................... 772 Overall Function Check............................................................................................. 773 Diagnostic Procedure............................................................................................... 774 DTC P0133, P0153 HEATED OXYGEN SENSOR 1 (FRONT) (BANK 1)/(BANK 2) (RESPONSE MONITORING)................................ 779 Component Description.............................................................................................. 779 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 779 ECM Terminals and Reference Value.................................................................................. 779 On Board Diagnosis Logic........................................................................................... 780 Possible Cause..................................................................................................... 780 DTC Confirmation Procedure......................................................................................... 781 Overall Function Check............................................................................................. 782 Wiring Diagram..................................................................................................... 783 Diagnostic Procedure............................................................................................... 785 DTC P0134, P0154 HEATED OXYGEN SENSOR 1 (FRONT) (BANK 1)/(BANK 2) (HIGH VOLTAGE)....................................... 792 Component Description.............................................................................................. 792 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 792 ECM Terminals and Reference Value.................................................................................. 792 On Board Diagnosis Logic........................................................................................... 793 Possible Cause..................................................................................................... 793 DTC Confirmation Procedure......................................................................................... 793 Wiring Diagram..................................................................................................... 795 Diagnostic Procedure............................................................................................... 797 DTC P0135, P0155 HEATED OXYGEN SENSOR 1 HEATER (FRONT) (BANK 1)/(BANK 2)............................................... 801 Description........................................................................................................ 801 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 801 ECM Terminals and Reference Value.................................................................................. 801 On Board Diagnosis Logic........................................................................................... 802 Possible Cause..................................................................................................... 802 DTC Confirmation Procedure......................................................................................... 802 Wiring Diagram..................................................................................................... 803 Diagnostic Procedure............................................................................................... 805 DTC P0137, P0157 HEATED OXYGEN SENSOR 2 (REAR) (BANK 1)/(BANK 2) (MIN. VOLTAGE MONITORING)............................. 808 Component Description.............................................................................................. 808 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 808 ECM Terminals and Reference Value.................................................................................. 808 On Board Diagnosis Logic........................................................................................... 808 Possible Cause..................................................................................................... 809 DTC Confirmation Procedure......................................................................................... 809 Overall Function Check............................................................................................. 809 Wiring Diagram..................................................................................................... 811 Diagnostic Procedure............................................................................................... 813 DTC P0138, P0158 HEATED OXYGEN SENSOR 2 (REAR) (BANK 1)/(BANK 2) (MAX. VOLTAGE MONITORING)............................. 818 Component Description.............................................................................................. 818 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 818 ECM Terminals and Reference Value.................................................................................. 818 On Board Diagnosis Logic........................................................................................... 818 Possible Cause..................................................................................................... 819 DTC Confirmation Procedure......................................................................................... 819 Overall Function Check............................................................................................. 819 Wiring Diagram..................................................................................................... 821 Diagnostic Procedure............................................................................................... 823 DTC P0139, P0159 HEATED OXYGEN SENSOR 2 (REAR) (BANK 1)/(BANK 2) (RESPONSE MONITORING)................................. 828 Component Description.............................................................................................. 828 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 828 ECM Terminals and Reference Value.................................................................................. 828 On Board Diagnosis Logic........................................................................................... 828 Possible Cause..................................................................................................... 829 DTC Confirmation Procedure......................................................................................... 829 Overall Function Check............................................................................................. 829 Wiring Diagram..................................................................................................... 831 Diagnostic Procedure............................................................................................... 833 DTC P0140, P0160 HEATED OXYGEN SENSOR 2 (REAR) (BANK 1)/(BANK 2) (HIGH VOLTAGE)........................................ 838 Component Description.............................................................................................. 838 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 838 ECM Terminals and Reference Value.................................................................................. 838 On Board Diagnosis Logic........................................................................................... 838 Possible Cause..................................................................................................... 839 DTC Confirmation Procedure......................................................................................... 839 Overall Function Check............................................................................................. 839 Wiring Diagram..................................................................................................... 841 Diagnostic Procedure............................................................................................... 843 DTC P0141, P0161 HEATED OXYGEN SENSOR 2 HEATER (REAR) (BANK 1)/(BANK 2)................................................ 847 Description........................................................................................................ 847 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 847 ECM Terminals and Reference Value.................................................................................. 847 On Board Diagnosis Logic........................................................................................... 848 Possible Cause..................................................................................................... 848 DTC Confirmation Procedure......................................................................................... 848 Wiring Diagram..................................................................................................... 850 Diagnostic Procedure............................................................................................... 852 DTC P0171 (RIGHT, -B1), P0174 (LEFT, -B2) FUEL INJECTION SYSTEM FUNCTION (LEAN)........................................ 855 On Board Diagnosis Logic........................................................................................... 855 Possible Cause..................................................................................................... 855 DTC Confirmation Procedure......................................................................................... 855 Wiring Diagram..................................................................................................... 857 Diagnostic Procedure............................................................................................... 859 DTC P0172 (RIGHT, -B1), P0175 (LEFT, -B2) FUEL INJECTION SYSTEM FUNCTION (RICH)........................................ 863 On Board Diagnosis Logic........................................................................................... 863 Possible Cause..................................................................................................... 863 DTC Confirmation Procedure......................................................................................... 863 Wiring Diagram..................................................................................................... 865 Diagnostic Procedure............................................................................................... 867 DTC P0180 FUEL TANK TEMPERATURE SENSOR................................................................................. 870 Component Description.............................................................................................. 870 On Board Diagnosis Logic........................................................................................... 870 Possible Cause..................................................................................................... 870 DTC Confirmation Procedure......................................................................................... 871 Wiring Diagram..................................................................................................... 872 Diagnostic Procedure............................................................................................... 873 DTC P0217 COOLANT OVERTEMPERATURE ENRICHMENT PROTECTION................................................................ 875 On Board Diagnosis Logic........................................................................................... 875 Possible Cause..................................................................................................... 875 Overall Function Check............................................................................................. 875 Diagnostic Procedure............................................................................................... 877 Main 12 Causes of Overheating...................................................................................... 880 DTC P0300 - P0306 NO. 6 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE................................................ 881 On Board Diagnosis Logic........................................................................................... 881 Possible Cause..................................................................................................... 881 DTC Confirmation Procedure......................................................................................... 882 Diagnostic Procedure............................................................................................... 882 DTC P0325 KNOCK SENSOR (KS)............................................................................................ 889 Component Description.............................................................................................. 889 ECM Terminals and Reference Value.................................................................................. 889 On Board Diagnosis Logic........................................................................................... 889 Possible Cause..................................................................................................... 889 DTC Confirmation Procedure......................................................................................... 889 Wiring Diagram..................................................................................................... 891 Diagnostic Procedure............................................................................................... 892 DTC P0335 CRANKSHAFT POSITION SENSOR (CKPS) (POS)...................................................................... 895 Component Description.............................................................................................. 895 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 895 ECM Terminals and Reference Value.................................................................................. 896 On Board Diagnosis Logic........................................................................................... 896 Possible Cause..................................................................................................... 896 DTC Confirmation Procedure......................................................................................... 897 Wiring Diagram..................................................................................................... 898 Diagnostic Procedure............................................................................................... 899 DTC P0340 CAMSHAFT POSITION SENSOR (CMPS) (PHASE)...................................................................... 903 Component Description.............................................................................................. 903 ECM Terminals and Reference Value.................................................................................. 903 On Board Diagnosis Logic........................................................................................... 903 Possible Cause..................................................................................................... 904 DTC Confirmation Procedure......................................................................................... 904 Wiring Diagram..................................................................................................... 905 Diagnostic Procedure............................................................................................... 906 DTC P0420 (RIGHT BANK, -B1), P0430 (LEFT BANK, -B2) THREE WAY CATALYST FUNCTION........................................ 908 On Board Diagnosis Logic........................................................................................... 908 Possible Cause..................................................................................................... 908 DTC Confirmation Procedure......................................................................................... 909 Overall Function Check............................................................................................. 909 Diagnostic Procedure............................................................................................... 910 DTC P0440 EVAP CONTROL SYSTEM (SMALL LEAK) (NEGATIVE PRESSURE)......................................................... 913 On Board Diagnosis Logic........................................................................................... 913 Possible Cause..................................................................................................... 913 DTC Confirmation Procedure......................................................................................... 915 Diagnostic Procedure............................................................................................... 916 DTC P0443 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE (CIRCUIT).................................................. 928 Description........................................................................................................ 928 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 928 ECM Terminals and Reference Value.................................................................................. 929 On Board Diagnosis Logic........................................................................................... 929 Possible Cause..................................................................................................... 929 DTC Confirmation Procedure......................................................................................... 930 Wiring Diagram..................................................................................................... 931 Diagnostic Procedure............................................................................................... 932 DTC P0446 EVAPORATIVE EMISSION (EVAP) CANISTER VENT CONTROL VALVE (CIRCUIT)............................................ 935 Component Description.............................................................................................. 935 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 935 ECM Terminals and Reference Value.................................................................................. 935 On Board Diagnosis Logic........................................................................................... 935 Possible Cause..................................................................................................... 936 DTC Confirmation Procedure......................................................................................... 936 Wiring Diagram..................................................................................................... 937 Diagnostic Procedure............................................................................................... 938 DTC P0450 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM PRESSURE SENSOR................................................... 942 Component Description.............................................................................................. 942 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 942 ECM Terminals and Reference Value.................................................................................. 942 On Board Diagnosis Logic........................................................................................... 943 Possible Cause..................................................................................................... 943 DTC Confirmation Procedure......................................................................................... 943 Wiring Diagram..................................................................................................... 945 Diagnostic Procedure............................................................................................... 946 DTC P0455 EVAP CONTROL SYSTEM (GROSS LEAK)............................................................................. 955 On Board Diagnosis Logic........................................................................................... 955 Possible Cause..................................................................................................... 955 DTC Confirmation Procedure......................................................................................... 957 Diagnostic Procedure............................................................................................... 958 DTC P0460 FUEL LEVEL SENSOR FUNCTION (SLOSH)........................................................................... 968 Component Description.............................................................................................. 968 On Board Diagnostic Logic.......................................................................................... 968 Possible Cause..................................................................................................... 968 DTC Confirmation Procedure......................................................................................... 968 Wiring Diagram..................................................................................................... 969 Diagnostic Procedure............................................................................................... 970 DTC P0461 FUEL LEVEL SENSOR FUNCTION................................................................................... 972 Component Description.............................................................................................. 972 On Board Diagnostic Logic.......................................................................................... 972 Possible Cause..................................................................................................... 972 Overall Function Check............................................................................................. 972 DTC P0464 FUEL LEVEL SENSOR CIRCUIT.................................................................................... 974 Component Description.............................................................................................. 974 On Board Diagnostic Logic.......................................................................................... 974 Possible Cause..................................................................................................... 974 DTC Confirmation Procedure......................................................................................... 974 Wiring Diagram..................................................................................................... 975 Diagnostic Procedure............................................................................................... 976 DTC P0500 VEHICLE SPEED SENSOR (VSS)................................................................................... 978 Component Description.............................................................................................. 978 ECM Terminals and Reference Value.................................................................................. 978 On Board Diagnosis Logic........................................................................................... 978 Possible Cause..................................................................................................... 979 DTC Confirmation Procedure......................................................................................... 979 Overall Function Check............................................................................................. 980 Wiring Diagram..................................................................................................... 981 Diagnostic Procedure............................................................................................... 982 DTC P0505 IDLE AIR CONTROL VALVE (IACV) - AUXILIARY AIR CONTROL (AAC) VALVE............................................ 983 Description........................................................................................................ 983 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 984 ECM Terminals and Reference Value.................................................................................. 984 On Board Diagnosis Logic........................................................................................... 984 Possible Cause..................................................................................................... 984 DTC Confirmation Procedure......................................................................................... 984 Wiring Diagram..................................................................................................... 986 Diagnostic Procedure............................................................................................... 987 DTC P0510 CLOSED THROTTLE POSITION SWITCH.............................................................................. 992 Component Description.............................................................................................. 992 CONSULT-II Reference Value in Data Monitor Mode.................................................................... 992 ECM Terminals and Reference Value.................................................................................. 992 On Board Diagnosis Logic........................................................................................... 992 Possible Cause..................................................................................................... 992 DTC Confirmation Procedure......................................................................................... 993 Overall Function Check............................................................................................. 993 Wiring Diagram..................................................................................................... 995 Diagnostic Procedure............................................................................................... 996 DTC P0600 A/T COMMUNICATION LINE.......................................................................................1001 System Description.................................................................................................1001 ECM Terminals and Reference Value..................................................................................1001 On Board Diagnosis Logic...........................................................................................1001 Possible Cause.....................................................................................................1001 DTC Confirmation Procedure.........................................................................................1001 Wiring Diagram.....................................................................................................1003 Diagnostic Procedure...............................................................................................1004 DTC P0605 ECM..........................................................................................................1005 Component Description..............................................................................................1005 On Board Diagnosis Logic...........................................................................................1005 Possible Cause.....................................................................................................1005 DTC Confirmation Procedure.........................................................................................1005 Diagnostic Procedure...............................................................................................1006 DTC P1110 (RIGHT, -B1), P1135 (LEFT, -B2) INTAKE VALVE TIMING CONTROL..................................................1007 Description........................................................................................................1007 CONSULT-II Reference Value in Data Monitor Mode....................................................................1007 ECM Terminals and Reference Value..................................................................................1008 On Board Diagnosis Logic...........................................................................................1009 Possible Cause.....................................................................................................1009 DTC Confirmation Procedure.........................................................................................1010 DTC P1111 (RIGHT, -B1), P1136 (LEFT, -B2) INTAKE VALVE TIMING CONTROL SOLENOID VALVE (CIRCUIT).........................1012 Component Description..............................................................................................1012 CONSULT-II Reference Value in Data Monitor Mode....................................................................1012 ECM Terminals and Reference Value..................................................................................1012 On Board Diagnosis Logic...........................................................................................1013 Possible Cause.....................................................................................................1013 DTC Confirmation Procedure.........................................................................................1013 Wiring Diagram.....................................................................................................1014 Diagnostic Procedure...............................................................................................1016 DTC P1130 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE...................................................................1019 Description........................................................................................................1019 CONSULT-II Reference Value in Data Monitor Mode....................................................................1020 ECM Terminals and Reference Value..................................................................................1020 On Board Diagnosis Logic...........................................................................................1020 Possible Cause.....................................................................................................1021 DTC Confirmation Procedure.........................................................................................1021 Wiring Diagram.....................................................................................................1023 Diagnostic Procedure...............................................................................................1024 DTC P1140 (RIGHT, -B1), P1145 (LEFT, -B2) INTAKE VALVE TIMING CONTROL POSITION SENSOR (CIRCUIT)........................1043 Component Description..............................................................................................1043 CONSULT-II Reference Value in Data Monitor Mode....................................................................1043 ECM Terminals and Reference Value..................................................................................1044 On Board Diagnosis Logic...........................................................................................1044 Possible Cause.....................................................................................................1045 DTC Confirmation Procedure.........................................................................................1045 Wiring Diagram.....................................................................................................1046 Diagnostic Procedure...............................................................................................1048 DTC P1148 (RIGHT BANK, -B1), P1168 (LEFT BANK, -B2) CLOSED LOOP CONTROL................................................1052 On Board Diagnosis Logic...........................................................................................1052 Possible Cause.....................................................................................................1052 DTC Confirmation Procedure.........................................................................................1052 Overall Function Check.............................................................................................1053 Diagnostic Procedure...............................................................................................1053 DTC P1165 SWIRL CONTROL VALVE CONTROL VACUUM CHECK SWITCH..............................................................1054 Component Description..............................................................................................1054 CONSULT-II Reference Value in Data Monitor Mode....................................................................1054 ECM Terminals and Reference Value..................................................................................1054 On Board Diagnosis Logic...........................................................................................1055 Possible Cause.....................................................................................................1055 DTC Confirmation Procedure.........................................................................................1055 Wiring Diagram.....................................................................................................1056 Diagnostic Procedure...............................................................................................1057 DTC P1320 IGNITION SIGNAL..............................................................................................1060 Component Description..............................................................................................1060 ECM Terminals and Reference Value..................................................................................1060 On Board Diagnosis Logic...........................................................................................1060 Possible Cause.....................................................................................................1061 DTC Confirmation Procedure.........................................................................................1061 Wiring Diagram.....................................................................................................1062 Diagnostic Procedure...............................................................................................1065 DTC P1335 CRANKSHAFT POSITION SENSOR (CKPS) (REF)......................................................................1071 Component Description..............................................................................................1071 CONSULT-II Reference Value in Data Monitor Mode....................................................................1071 ECM Terminals and Reference Value..................................................................................1071 On Board Diagnosis Logic...........................................................................................1072 Possible Cause.....................................................................................................1072 DTC Confirmation Procedure.........................................................................................1072 Wiring Diagram.....................................................................................................1074 Diagnostic Procedure...............................................................................................1075 DTC P1336 CRANKSHAFT POSITION SENSOR (CKPS) (POS) (COG)................................................................1078 Component Description..............................................................................................1078 CONSULT-II Reference Value in Data Monitor Mode....................................................................1078 ECM Terminals and Reference Value..................................................................................1079 On Board Diagnosis Logic...........................................................................................1079 Possible Cause.....................................................................................................1079 DTC Confirmation Procedure.........................................................................................1080 Wiring Diagram.....................................................................................................1081 Diagnostic Procedure...............................................................................................1082 DTC P1441 EVAP CONTROL SYSTEM (VERY SMALL LEAK)........................................................................1087 On Board Diagnosis Logic...........................................................................................1087 Possible Cause.....................................................................................................1087 DTC Confirmation Procedure.........................................................................................1088 Diagnostic Procedure...............................................................................................1090 DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE............................................................1102 Description........................................................................................................1102 CONSULT-II Reference Value in Data Monitor Mode....................................................................1102 ECM Terminals and Reference Value..................................................................................1103 On Board Diagnosis Logic...........................................................................................1103 Possible Cause.....................................................................................................1103 DTC Confirmation Procedure.........................................................................................1104 Wiring Diagram.....................................................................................................1105 Diagnostic Procedure...............................................................................................1106 DTC P1446 EVAPORATIVE EMISSION (EVAP) CANISTER VENT CONTROL VALVE (CLOSE)..............................................1114 Component Description..............................................................................................1114 CONSULT-II Reference Value in Data Monitor Mode....................................................................1114 ECM Terminals and Reference Value..................................................................................1114 On Board Diagnosis Logic...........................................................................................1114 Possible Cause.....................................................................................................1115 DTC Confirmation Procedure.........................................................................................1115 Wiring Diagram.....................................................................................................1116 Diagnostic Procedure...............................................................................................1117 DTC P1447 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM PURGE FLOW MONITORING.............................................1122 System Description.................................................................................................1122 On Board Diagnosis Logic...........................................................................................1122 Possible Cause.....................................................................................................1122 DTC Confirmation Procedure.........................................................................................1123 Overall Function Check.............................................................................................1124 Diagnostic Procedure...............................................................................................1125 DTC P1448 EVAPORATIVE EMISSION (EVAP) CANISTER VENT CONTROL VALVE (OPEN)...............................................1134 Component Description..............................................................................................1134 CONSULT-II Reference Value in Data Monitor Mode....................................................................1134 ECM Terminals and Reference Value..................................................................................1134 On Board Diagnosis Logic...........................................................................................1134 Possible Cause.....................................................................................................1135 DTC Confirmation Procedure.........................................................................................1135 Overall Function Check.............................................................................................1136 Wiring Diagram.....................................................................................................1137 Diagnostic Procedure...............................................................................................1138 DTC P1464 FUEL LEVEL SENSOR CIRCUIT (GROUND SIGNAL)....................................................................1143 Component Description..............................................................................................1143 On Board Diagnostic Logic..........................................................................................1143 Possible Cause.....................................................................................................1143 DTC Confirmation Procedure.........................................................................................1143 Wiring Diagram.....................................................................................................1144 Diagnostic Procedure...............................................................................................1145 DTC P1490 VACUUM CUT VALVE BYPASS VALVE (CIRCUIT)......................................................................1146 Description........................................................................................................1146 CONSULT-II Reference Value in Data Monitor Mode....................................................................1146 ECM Terminals and Reference Value..................................................................................1146 On Board Diagnosis Logic...........................................................................................1147 Possible Cause.....................................................................................................1147 DTC Confirmation Procedure.........................................................................................1147 Wiring Diagram.....................................................................................................1148 Diagnostic Procedure...............................................................................................1149 DTC P1491 VACUUM CUT VALVE BYPASS VALVE................................................................................1152 Description........................................................................................................1152 CONSULT-II Reference Value in Data Monitor Mode....................................................................1152 ECM Terminals and Reference Value..................................................................................1152 On Board Diagnosis Logic...........................................................................................1153 Possible Cause.....................................................................................................1153 DTC Confirmation Procedure.........................................................................................1153 Overall Function Check.............................................................................................1154 Wiring Diagram.....................................................................................................1155 Diagnostic Procedure...............................................................................................1156 DTC P1605 A/T DIAGNOSIS COMMUNICATION LINE.............................................................................1164 Component Description..............................................................................................1164 On Board Diagnosis Logic...........................................................................................1164 Possible Cause.....................................................................................................1164 DTC Confirmation Procedure.........................................................................................1164 DTC P1706 PARK/NEUTRAL POSITION (PNP) SWITCH...........................................................................1165 Component Description..............................................................................................1165 CONSULT-II Reference Value in Data Monitor Mode....................................................................1165 ECM Terminals and Reference Value..................................................................................1165 On Board Diagnosis Logic...........................................................................................1165 Possible Cause.....................................................................................................1165 DTC Confirmation Procedure.........................................................................................1166 Overall Function Check.............................................................................................1167 Wiring Diagram.....................................................................................................1168 Diagnostic Procedure...............................................................................................1169 VARIABLE INDUCTION AIR CONTROL SYSTEM (VIAS)...........................................................................1172 Description........................................................................................................1172 ECM Terminals and Reference Value..................................................................................1173 Wiring Diagram.....................................................................................................1174 Diagnostic Procedure...............................................................................................1175 INJECTOR...............................................................................................................1178 Component Description..............................................................................................1178 CONSULT-II Reference Value in Data Monitor Mode....................................................................1178 ECM Terminals and Reference Value..................................................................................1178 Wiring Diagram.....................................................................................................1179 Diagnostic Procedure...............................................................................................1180 START SIGNAL...........................................................................................................1183 CONSULT-II Reference Value in Data Monitor Mode....................................................................1183 ECM Terminals and Reference Value..................................................................................1183 Wiring Diagram.....................................................................................................1184 Diagnostic Procedure...............................................................................................1185 FUEL PUMP..............................................................................................................1187 System Description.................................................................................................1187 Component Description..............................................................................................1187 CONSULT-II Reference Value in Data Monitor Mode....................................................................1187 ECM Terminals and Reference Value..................................................................................1188 Wiring Diagram.....................................................................................................1189 Diagnostic Procedure...............................................................................................1190 POWER STEERING OIL PRESSURE SWITCH.....................................................................................1196 Component Description..............................................................................................1196 CONSULT-II Reference Value in Data Monitor Mode....................................................................1196 ECM Terminals and Reference Value..................................................................................1196 Wiring Diagram.....................................................................................................1197 Diagnostic Procedure...............................................................................................1198 REFRIGERANT PRESSURE SENSOR............................................................................................1201 Description........................................................................................................1201 ECM Terminals and Reference Value..................................................................................1201 Wiring Diagram.....................................................................................................1202 Diagnostic Procedure...............................................................................................1203 ELECTRICAL LOAD SIGNAL.................................................................................................1205 ECM Terminals and Reference Value..................................................................................1205 Wiring Diagram.....................................................................................................1206 Diagnostic Procedure...............................................................................................1209 MIL & DATA LINK CONNECTORS.............................................................................................1212 Wiring Diagram.....................................................................................................1212 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1213 Fuel Pressure Regulator............................................................................................1213 Idle Speed and Ignition Timing.....................................................................................1213 Mass Air Flow Sensor...............................................................................................1213 Engine Coolant Temperature Sensor..................................................................................1213 Heated Oxygen Sensor 1 Heater (front)..............................................................................1213 Fuel Pump..........................................................................................................1213 IACV-AAC Valve.....................................................................................................1213 Injector...........................................................................................................1213 Resistor...........................................................................................................1213 Throttle Position Sensor...........................................................................................1214 Calculated Load Value..............................................................................................1214 Intake Air Temperature Sensor......................................................................................1214 Heated Oxygen Sensor 2 Heater (rear)...............................................................................1214 Crankshaft Position Sensor (REF)...................................................................................1214 Fuel Tank Temperature Sensor.......................................................................................1214 Camshaft Position Sensor (PHASE)...................................................................................1214 SUPER MULTIPLE JUNCTION (SMJ).......................................................................................... 0 FUSE BLOCK - JUNCTION BOX (J/B)........................................................................................ 2 FUSE AND FUSIBLE LINK BOX.............................................................................................. 3 ELECTRICAL UNITS....................................................................................................... 4 el.........................................................................................................................1216 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1216 PRECAUTIONS............................................................................................................1219 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................................1219 Wiring Diagrams and Trouble Diagnosis..............................................................................1219 HARNESS CONNECTOR......................................................................................................1220 Description........................................................................................................1220 STANDARDIZED RELAY.....................................................................................................1222 Description........................................................................................................1222 POWER SUPPLY ROUTING...................................................................................................1224 Schematic..........................................................................................................1224 Wiring Diagram - POWER -...........................................................................................1225 Inspection.........................................................................................................1231 GROUND.................................................................................................................1232 Ground Distribution................................................................................................1232 COMBINATION SWITCH.....................................................................................................1243 Check..............................................................................................................1243 Replacement........................................................................................................1245 STEERING SWITCH........................................................................................................1246 Check..............................................................................................................1246 HEADLAMP (FOR USA).....................................................................................................1247 Component Parts and Harness Connector Location.....................................................................1247 System Description.................................................................................................1247 Schematic..........................................................................................................1252 Wiring Diagram - H/LAMP -..........................................................................................1254 Trouble Diagnoses..................................................................................................1261 Bulb Replacement...................................................................................................1266 Aiming Adjustment..................................................................................................1266 HEADLAMP (FOR CANADA) - DAYTIME LIGHT SYSTEM -.........................................................................1268 Component Parts and Harness Connector Location.....................................................................1268 System Description.................................................................................................1268 Schematic..........................................................................................................1275 Wiring Diagram - DTRL -............................................................................................1277 Trouble Diagnoses..................................................................................................1287 Bulb Replacement...................................................................................................1290 Aiming Adjustment..................................................................................................1290 PARKING, LICENSE AND TAIL LAMPS........................................................................................1291 System Description.................................................................................................1291 Schematic..........................................................................................................1292 Wiring Diagram - TAIL/L -..........................................................................................1293 Trouble Diagnoses..................................................................................................1297 STOP LAMP..............................................................................................................1298 Wiring Diagram - STOP/L -..........................................................................................1298 BACK-UP LAMP...........................................................................................................1300 Wiring Diagram - BACK/L -..........................................................................................1300 FRONT FOG LAMP.........................................................................................................1301 System Description.................................................................................................1301 Wiring Diagram - F/FOG -...........................................................................................1304 Aiming Adjustment..................................................................................................1308 TURN SIGNAL AND HAZARD WARNING LAMPS...................................................................................1309 System Description.................................................................................................1309 Wiring Diagram - TURN -............................................................................................1311 Trouble Diagnoses..................................................................................................1313 Electrical Components Inspection...................................................................................1313 ILLUMINATION...........................................................................................................1314 System Description.................................................................................................1314 Schematic..........................................................................................................1316 Wiring Diagram - ILL -.............................................................................................1317 INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS...................................................................1323 System Description.................................................................................................1323 Schematic..........................................................................................................1325 Wiring Diagram - INT/L -...........................................................................................1326 METERS AND GAUGES......................................................................................................1329 Component Parts and Harness Connector Location.....................................................................1329 System Description.................................................................................................1329 Combination Meter..................................................................................................1331 Schematic..........................................................................................................1333 Wiring Diagram - METER -...........................................................................................1334 Meter/Gauge Operation and Odo/Trip Meter Segment Check in Diagnosis Mode...........................................1335 Trouble Diagnoses..................................................................................................1336 Electrical Components Inspection...................................................................................1343 COMPASS AND THERMOMETER................................................................................................1345 System Description.................................................................................................1345 Wiring Diagram - COMPAS -..........................................................................................1346 Trouble Diagnoses..................................................................................................1347 Calibration Procedure for Compass..................................................................................1348 WARNING LAMPS..........................................................................................................1349 Schematic..........................................................................................................1349 Wiring Diagram - WARN -............................................................................................1350 Fuel Warning Lamp Sensor Check.....................................................................................1358 Electrical Components Inspection...................................................................................1358 WARNING CHIME..........................................................................................................1359 Component Parts and Harness Connector Location.....................................................................1359 System Description.................................................................................................1359 Wiring Diagram - CHIME -...........................................................................................1361 Trouble Diagnoses..................................................................................................1363 FRONT WIPER AND WASHER.................................................................................................1370 System Description.................................................................................................1370 Wiring Diagram - WIPER -...........................................................................................1372 Removal and Installation...........................................................................................1373 Washer Nozzle Adjustment...........................................................................................1374 Washer Tube Layout.................................................................................................1374 REAR WIPER AND WASHER..................................................................................................1375 System Description.................................................................................................1375 Wiring Diagram - WIP/R -...........................................................................................1377 Trouble Diagnoses..................................................................................................1379 Removal and Installation...........................................................................................1379 Washer Nozzle Adjustment...........................................................................................1380 Washer Tube Layout.................................................................................................1380 Check Valve........................................................................................................1380 HORN...................................................................................................................1381 Wiring Diagram - HORN -............................................................................................1381 CIGARETTE LIGHTER......................................................................................................1382 Wiring Diagram - CIGAR -...........................................................................................1382 CLOCK..................................................................................................................1384 Wiring Diagram - CLOCK -...........................................................................................1384 REAR WINDOW DEFOGGER...................................................................................................1385 Component Parts and Harness Connector Location.....................................................................1385 System Description.................................................................................................1385 Wiring Diagram - DEF -.............................................................................................1387 Trouble Diagnoses..................................................................................................1389 Electrical Components Inspection...................................................................................1391 Filament Check.....................................................................................................1391 Filament Repair....................................................................................................1392 AUDIO..................................................................................................................1394 System Description.................................................................................................1394 Wiring Diagram - AUDIO -/Base System...............................................................................1395 Schematic/BOSE System..............................................................................................1397 Wiring Diagram - AUDIO -/BOSE System...............................................................................1398 Trouble Diagnoses..................................................................................................1403 Inspection.........................................................................................................1404 Audio Unit Removal and Installation................................................................................1404 Wiring Diagram - REMOTE -..........................................................................................1405 AUDIO ANTENNA..........................................................................................................1406 System Description.................................................................................................1406 Wiring Diagram - P/ANT -...........................................................................................1407 Trouble Diagnoses..................................................................................................1408 Location of Antenna................................................................................................1408 Antenna Rod Replacement............................................................................................1408 POWER SUNROOF..........................................................................................................1410 System Description.................................................................................................1410 Wiring Diagram - SROOF -...........................................................................................1411 Trouble Diagnoses..................................................................................................1413 DOOR MIRROR............................................................................................................1414 Wiring Diagram - MIRROR -..........................................................................................1414 POWER SEAT.............................................................................................................1415 Wiring Diagram - SEAT -............................................................................................1415 HEATED SEAT............................................................................................................1417 Wiring Diagram - HSEAT -...........................................................................................1417 Seatback Heating Unit..............................................................................................1418 AUTOMATIC DRIVE POSITIONER.............................................................................................1419 Component Parts and Harness Connector Location.....................................................................1419 System Description.................................................................................................1420 Schematic..........................................................................................................1423 Wiring Diagram - AUT/DP -..........................................................................................1424 On Board Diagnosis.................................................................................................1429 Trouble Diagnoses..................................................................................................1431 AUTOMATIC SPEED CONTROL DEVICE (ASCD)..................................................................................1454 Component Parts and Harness Connector Location.....................................................................1454 System Description.................................................................................................1455 Schematic..........................................................................................................1457 Wiring Diagram - ASCD -............................................................................................1458 Fail-safe System...................................................................................................1462 Trouble Diagnoses..................................................................................................1463 Electrical Component Inspection....................................................................................1472 ASCD Wire Adjustment...............................................................................................1473 POWER WINDOW...........................................................................................................1474 System Description.................................................................................................1474 Schematic..........................................................................................................1477 Wiring Diagram - WINDOW -..........................................................................................1478 Trouble Diagnoses..................................................................................................1483 POWER DOOR LOCK........................................................................................................1487 Component Parts and Harness Connector Location.....................................................................1487 System Description.................................................................................................1487 Schematic..........................................................................................................1488 Wiring Diagram - D/LOCK -..........................................................................................1489 Trouble Diagnoses..................................................................................................1494 MULTI-REMOTE CONTROL SYSTEM............................................................................................1503 Component Parts and Harness Connector Location.....................................................................1503 System Description.................................................................................................1503 Schematic..........................................................................................................1506 Wiring Diagram - MULTI -...........................................................................................1507 Trouble Diagnoses..................................................................................................1510 ID Code Entry Procedure............................................................................................1522 Remote Controller Battery Replacement..............................................................................1526 THEFT WARNING SYSTEM...................................................................................................1527 Component Parts and Harness Connector Location.....................................................................1527 System Description.................................................................................................1528 Schematic..........................................................................................................1531 Wiring Diagram - THEFT -...........................................................................................1535 Trouble Diagnoses..................................................................................................1543 SMART ENTRANCE CONTROL UNIT............................................................................................1558 Description........................................................................................................1558 Schematic..........................................................................................................1561 Smart Entrance Control Unit Inspection Table.......................................................................1563 INTEGRATED HOMELINK TRANSMITTER........................................................................................1564 Wiring Diagram - TRNSMT -..........................................................................................1564 Trouble Diagnoses..................................................................................................1565 NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM - NATS)........................................................................1567 Component Parts and Harness Connetor Location......................................................................1567 System Description.................................................................................................1568 System Composition.................................................................................................1568 Wiring Diagram - NATS -............................................................................................1569 CONSULT-II.........................................................................................................1570 Trouble Diagnoses..................................................................................................1573 How to Replace NVIS (NATS) IMMU....................................................................................1586 ELECTRICAL UNITS LOCATION..............................................................................................1587 Engine Compartment.................................................................................................1587 Passenger Compartment..............................................................................................1589 HARNESS LAYOUT.........................................................................................................1591 How to Read Harness Layout.........................................................................................1591 Outline............................................................................................................1592 Main Harness.......................................................................................................1593 Engine Room Harness................................................................................................1595 Engine Control Harness.............................................................................................1597 Body Harness LH....................................................................................................1599 Body Harness RH....................................................................................................1600 Back Door Harness..................................................................................................1601 Engine and Transmission Harness....................................................................................1602 Room Lamp Harness..................................................................................................1603 Air Bag Harness....................................................................................................1604 Front Door Harness.................................................................................................1605 Rear Door Harness..................................................................................................1606 BULB SPECIFICATIONS....................................................................................................1607 Headlamp...........................................................................................................1607 Exterior Lamp......................................................................................................1607 Interior Lamp......................................................................................................1607 WIRING DIAGRAM CODES (CELL CODES)......................................................................................1608 SUPER MULTIPLE JUNCTION (SMJ).......................................................................................... 0 FUSE BLOCK - JUNCTION BOX (J/B)........................................................................................ 2 FUSE AND FUSIBLE LINK BOX.............................................................................................. 3 ELECTRICAL UNITS....................................................................................................... 4 em.........................................................................................................................1610 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1610 PRECAUTIONS............................................................................................................1612 Parts Requiring Angular Tightening.................................................................................1612 Liquid Gasket Application Procedure................................................................................1612 PREPARATION............................................................................................................1613 Special Service Tools..............................................................................................1613 Commercial Service Tools...........................................................................................1615 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING...................................................................1617 NVH Troubleshooting - Engine Noise.................................................................................1618 OUTER COMPONENT PARTS..................................................................................................1619 Removal and Installation...........................................................................................1619 TIGHTENING PROCEDURES..........................................................................................1621 MEASUREMENT OF COMPRESSION PRESSURE....................................................................................1623 OIL PAN................................................................................................................1624 Components.........................................................................................................1624 Removal............................................................................................................1624 Installation.......................................................................................................1627 TIMING CHAIN...........................................................................................................1629 Components.........................................................................................................1629 POSITION FOR APPLYING LIQUID GASKET............................................................................1630 Removal............................................................................................................1632 Inspection.........................................................................................................1638 Installation.......................................................................................................1638 OIL SEAL...............................................................................................................1645 Replacement........................................................................................................1645 VALVE OIL SEAL.................................................................................................1645 OIL SEAL INSTALLATION DIRECTION................................................................................1646 FRONT OIL SEAL.................................................................................................1646 REAR OIL SEAL..................................................................................................1646 CYLINDER HEAD..........................................................................................................1648 Components.........................................................................................................1648 Removal............................................................................................................1649 Disassembly........................................................................................................1651 Inspection.........................................................................................................1652 CYLINDER HEAD DISTORTION.......................................................................................1652 CAMSHAFT VISUAL CHECK..........................................................................................1652 CAMSHAFT RUNOUT................................................................................................1652 CAMSHAFT CAM HEIGHT............................................................................................1652 CAMSHAFT JOURNAL CLEARANCE.....................................................................................1652 CAMSHAFT END PLAY..............................................................................................1653 CAMSHAFT SPROCKET RUNOUT.......................................................................................1653 VALVE GUIDE CLEARANCE..........................................................................................1653 VALVE GUIDE REPLACEMENT........................................................................................1654 VALVE SEATS....................................................................................................1655 REPLACING VALVE SEAT FOR SERVICE PARTS.........................................................................1655 VALVE DIMENSIONS...............................................................................................1656 VALVE SPRING...................................................................................................1656 VALVE LIFTER...................................................................................................1656 Assembly...........................................................................................................1657 Installation.......................................................................................................1657 Valve Clearance....................................................................................................1662 CHECKING.......................................................................................................1662 ADJUSTING......................................................................................................1664 ENGINE ASSEMBLY........................................................................................................1667 Removal and Installation...........................................................................................1667 REMOVAL........................................................................................................1668 INSTALLATION...................................................................................................1670 CYLINDER BLOCK.........................................................................................................1671 Components.........................................................................................................1671 CYLINDER BLOCK HEATER..........................................................................................1672 Removal and Installation...........................................................................................1672 Disassembly........................................................................................................1672 PISTON, CRANKSHAFT AND OIL JET.................................................................................1672 Inspection.........................................................................................................1673 PISTON AND PISTON PIN CLEARANCE................................................................................1673 PISTON RING SIDE CLEARANCE.....................................................................................1674 PISTON RING END GAP............................................................................................1674 CONNECTING ROD BEND AND TORSION................................................................................1675 CYLINDER BLOCK DISTORTION AND WEAR.............................................................................1675 PISTON-TO-BORE CLEARANCE.......................................................................................1676 CRANKSHAFT.....................................................................................................1677 BEARING CLEARANCE..............................................................................................1677 CONNECTING ROD BUSHING CLEARANCE (SMALL END)...................................................................1680 FLYWHEEL/DRIVE PLATE RUNOUT....................................................................................1680 Assembly...........................................................................................................1681 PISTON.........................................................................................................1681 OIL JET........................................................................................................1681 CRANKSHAFT.....................................................................................................1681 REPLACEMENT OF PILOT BUSHING (M/T) OR PILOT CONVERTER (A/T)....................................................1684 FLYWHEEL/DRIVE PLATE...........................................................................................1684 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1685 General Specifications.............................................................................................1685 Compression Pressure...............................................................................................1685 Cylinder Head......................................................................................................1685 Valve..............................................................................................................1686 VALVE..........................................................................................................1686 VALVE CLEARANCE................................................................................................1686 AVAILABLE SHIMS................................................................................................1686 VALVE SPRING...................................................................................................1688 VALVE LIFTER...................................................................................................1688 VALVE GUIDE....................................................................................................1689 Valve Seat.........................................................................................................1689 Camshaft and Camshaft Bearing......................................................................................1690 Cylinder Block.....................................................................................................1691 Piston, Piston Ring and Piston Pin.................................................................................1692 AVAILABLE PISTON...............................................................................................1692 PISTON RING....................................................................................................1693 PISTON PIN.....................................................................................................1693 Connecting Rod.....................................................................................................1693 Crankshaft.........................................................................................................1694 Available Main Bearing.............................................................................................1695 UNDERSIZE......................................................................................................1695 Available Connecting Rod Bearing...................................................................................1696 CONNECTING ROD BEARING.........................................................................................1696 UNDERSIZE......................................................................................................1696 Miscellaneous Components...........................................................................................1696 BEARING CLEARANCE..............................................................................................1696 fe.........................................................................................................................1698 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1698 PREPARATION............................................................................................................1699 Special Service Tool...............................................................................................1699 Commercial Service Tools...........................................................................................1699 ACCELERATOR CONTROL SYSTEM.............................................................................................1700 Removal and Installation...........................................................................................1700 Adjusting Accelerator Wire.........................................................................................1700 FUEL SYSTEM............................................................................................................1701 Removal and Installation...........................................................................................1701 FUEL TANK......................................................................................................1702 FUEL PUMP AND GAUGE............................................................................................1703 EXHAUST SYSTEM.........................................................................................................1705 Removal and Installation...........................................................................................1705 foldout....................................................................................................................1708 QUICK REFERENCE INDEX.................................................................................................. 0 SUPER MULTIPLE JUNCTION (SMJ)..........................................................................................1708 FUSE BLOCK - JUNCTION BOX (J/B)........................................................................................1710 FUSE AND FUSIBLE LINK BOX..............................................................................................1711 ELECTRICAL UNITS.......................................................................................................1712 QUICK REFERENCE CHART..................................................................................................1713 gi.........................................................................................................................1714 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1714 PRECAUTIONS............................................................................................................1716 Precautions........................................................................................................1716 PRECAUTIONS FOR SUPPLEMENTAL RESTRAINT SYSTEM (SRS) "AIR BAG" AND "SEAT BELT PRE-TENSIONER"....................1716 PRECAUTIONS FOR NVIS (NISSAN VEHICLE IMMOBILIZER SYSTEM - NATS)................................................1716 GENERAL PRECAUTIONS............................................................................................1717 PRECAUTIONS FOR MULTIPORT FUEL INJECTION SYSTEM OR ENGINE CONTROL SYSTEM.......................................1719 PRECAUTIONS FOR THREE WAY CATALYST.............................................................................1719 PRECAUTIONS FOR HOSES..........................................................................................1720 PRECAUTIONS FOR ENGINE OILS....................................................................................1720 PRECAUTIONS FOR FUEL...........................................................................................1721 PRECAUTIONS FOR AIR CONDITIONING...............................................................................1721 HOW TO USE THIS MANUAL.................................................................................................1722 HOW TO READ WIRING DIAGRAMS............................................................................................1724 Sample/Wiring Diagram - EXAMPL -...................................................................................1724 OPTIONAL SPLICE................................................................................................1725 Description........................................................................................................1726 CONNECTOR SYMBOLS..............................................................................................1728 HARNESS INDICATION.............................................................................................1729 COMPONENT INDICATION...........................................................................................1729 SWITCH POSITIONS...............................................................................................1729 DETECTABLE LINES AND NON-DETECTABLE LINES......................................................................1730 MULTIPLE SWITCH................................................................................................1731 REFERENCE AREA.................................................................................................1732 HOW TO CHECK TERMINAL..................................................................................................1734 Connector and Terminal Pin Kit.....................................................................................1734 How to Probe Connectors............................................................................................1734 PROBING FROM HARNESS SIDE......................................................................................1734 PROBING FROM TERMINAL SIDE.....................................................................................1734 How to Check Enlarged Contact Spring of Terminal...................................................................1735 Waterproof Connector Inspection....................................................................................1736 RUBBER SEAL INSPECTION.........................................................................................1736 WIRE SEAL INSPECTION...........................................................................................1736 Terminal Lock Inspection...........................................................................................1736 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT..........................................................1737 Work Flow..........................................................................................................1737 Incident Simulation Tests..........................................................................................1738 INTRODUCTION...................................................................................................1738 VEHICLE VIBRATION..............................................................................................1738 HEAT SENSITIVE.................................................................................................1739 FREEZING.......................................................................................................1739 WATER INTRUSION................................................................................................1740 ELECTRICAL LOAD................................................................................................1740 COLD OR HOT START UP...........................................................................................1740 Circuit Inspection.................................................................................................1740 INTRODUCTION...................................................................................................1740 TESTING FOR "OPENS" IN THE CIRCUIT.............................................................................1741 TESTING FOR "SHORTS" IN THE CIRCUIT............................................................................1742 GROUND INSPECTION..............................................................................................1743 VOLTAGE DROP TESTS.............................................................................................1743 CONTROL UNIT CIRCUIT TEST......................................................................................1745 HOW TO FOLLOW TROUBLE DIAGNOSES........................................................................................1747 How to Follow Test Groups in Trouble Diagnoses.....................................................................1748 Key to Symbols Signifying Measurements or Procedures...............................................................1749 CONSULT-II CHECKING SYSTEM.............................................................................................1751 Function and System Application....................................................................................1751 Nickel Metal Hydride Battery Replacement...........................................................................1751 Checking Equipment.................................................................................................1752 CONSULT-II Data Link Connector (DLC) Circuit.......................................................................1752 INSPECTION PROCEDURE...........................................................................................1752 IDENTIFICATION INFORMATION.............................................................................................1753 Model Variation....................................................................................................1753 2WD............................................................................................................1753 4WD............................................................................................................1753 PREFIX AND SUFFIX DESIGNATIONS.................................................................................1753 Identification Number..............................................................................................1754 VEHICLE IDENTIFICATION NUMBER ARRANGEMENT......................................................................1754 IDENTIFICATION PLATE...........................................................................................1755 ENGINE SERIAL NUMBER...........................................................................................1755 MANUAL TRANSMISSION NUMBER.....................................................................................1755 AUTOMATIC TRANSMISSION NUMBER..................................................................................1755 TRANSFER SERIAL NUMBER.........................................................................................1756 Dimensions.........................................................................................................1756 Wheels & Tires.....................................................................................................1756 LIFTING POINTS AND TOW TRUCK TOWING....................................................................................1757 Screw Jack.........................................................................................................1757 Garage Jack and Safety Stand.......................................................................................1758 2-pole Lift........................................................................................................1759 Tow Truck Towing...................................................................................................1759 2WD MODELS.....................................................................................................1760 PART TIME 4WD MODELS...........................................................................................1760 ALL-MODE 4WD MODELS............................................................................................1761 VEHICLE RECOVERY...............................................................................................1761 TIGHTENING TORQUE OF STANDARD BOLTS....................................................................................1762 SAE J1930 TERMINOLOGY LIST.............................................................................................1763 SAE J1930 Terminology List.........................................................................................1763 ha.........................................................................................................................1768 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1768 AUTO...................................................................................................................1770 PRECAUTIONS........................................................................................................1770 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"....................................1770 Precautions for Working with HFC-134a (R-134a).................................................................1770 General Refrigerant Precautions................................................................................1771 Precautions for Leak Detection Dye.............................................................................1771 Identification.................................................................................................1772 Precautions for Refrigerant Connection.........................................................................1772 Precautions for Servicing Compressor...........................................................................1774 Precautions for Service Equipment..............................................................................1775 Wiring Diagrams and Trouble Diagnoses..........................................................................1777 PREPARATION........................................................................................................1778 Special Service Tools..........................................................................................1778 HFC-134a (R-134a) Service Tools and Equipment..................................................................1779 DESCRIPTION........................................................................................................1782 Refrigeration System...........................................................................................1782 V-6 Variable Displacement Compressor...........................................................................1783 Component Layout...............................................................................................1787 Introduction...................................................................................................1788 Features.......................................................................................................1788 Overview of Control System.....................................................................................1791 Control Operation..............................................................................................1791 Discharge Air Flow.............................................................................................1793 System Description.............................................................................................1794 TROUBLE DIAGNOSES..................................................................................................1795 Component Location.............................................................................................1795 Circuit Diagram................................................................................................1797 Wiring Diagram - A/C, A -......................................................................................1798 Auto Amp. Terminals and Reference Value........................................................................1802 Self-diagnosis.................................................................................................1804 How to Perform Trouble Diagnoses for Quick and Accurate Repair.................................................1814 Operational Check..............................................................................................1815 A/C System.....................................................................................................1818 Mode Door Motor................................................................................................1820 Air Mix Door Motor.............................................................................................1826 Intake Door Motor..............................................................................................1830 Blower Motor...................................................................................................1837 Magnet Clutch..................................................................................................1845 Insufficient Cooling...........................................................................................1852 Insufficient Heating...........................................................................................1860 Noise..........................................................................................................1861 Self-diagnosis.................................................................................................1862 Memory Function................................................................................................1863 ECON (ECONOMY) Mode............................................................................................1864 Ambient Sensor Circuit.........................................................................................1864 In-vehicle Sensor Circuit......................................................................................1868 Sunload Sensor Circuit.........................................................................................1871 Intake Sensor Circuit..........................................................................................1875 Air Mix Door Motor PBR Circuit.................................................................................1877 SERVICE PROCEDURE..................................................................................................1878 HFC-134a (R-134a) Service Procedure............................................................................1878 Maintenance of Lubricant Quantity in Compressor................................................................1880 Compressor.....................................................................................................1883 Compressor Clutch..............................................................................................1883 Refrigerant Lines..............................................................................................1887 Belt...........................................................................................................1892 SERVICE DATA AND SPECIFICATIONS (SDS)..............................................................................1893 Auto...........................................................................................................1893 MANUAL.................................................................................................................1894 PRECAUTIONS........................................................................................................1894 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"....................................1894 Precautions for Working with HFC-134a (R-134a).................................................................1894 General Refrigerant Precautions................................................................................1895 Precautions for Leak Detection Dye.............................................................................1895 Identification.................................................................................................1896 Precautions for Refrigerant Connection.........................................................................1896 Precautions for Servicing Compressor...........................................................................1898 Precautions for Service Equipment..............................................................................1899 Wiring Diagrams and Trouble Diagnoses..........................................................................1901 PREPARATION........................................................................................................1902 Special Service Tools..........................................................................................1902 HFC-134a (R-134a) Service Tools and Equipment..................................................................1903 DESCRIPTION........................................................................................................1906 Refrigeration System...........................................................................................1906 V-6 Variable Displacement Compressor...........................................................................1907 Component Layout...............................................................................................1911 Control Operation..............................................................................................1912 Discharge Air Flow.............................................................................................1913 System Description.............................................................................................1914 TROUBLE DIAGNOSES..................................................................................................1915 Component Location.............................................................................................1915 Wiring Diagram - HEATER -......................................................................................1917 Circuit Diagram - Air Conditioner..............................................................................1918 Wiring Diagram - A/C, M -......................................................................................1919 How to Perform Trouble Diagnoses for Quick and Accurate Repair.................................................1922 Operational Check..............................................................................................1923 Intake Door....................................................................................................1925 Blower Motor...................................................................................................1932 Insufficient Cooling...........................................................................................1939 Insufficient Heating...........................................................................................1947 Air Outlet.....................................................................................................1949 Magnet Clutch..................................................................................................1951 Noise..........................................................................................................1958 SERVICE PROCEDURE..................................................................................................1959 HFC-134a (R-134a) Service Procedure............................................................................1959 Maintenance of Lubricant Quantity in Compressor................................................................1961 Compressor.....................................................................................................1964 Compressor Clutch..............................................................................................1964 Refrigerant Lines..............................................................................................1968 Belt...........................................................................................................1973 SERVICE DATA AND SPECIFICATIONS (SDS)..............................................................................1974 Manual.........................................................................................................1974 SUPER MULTIPLE JUNCTION (SMJ).......................................................................................... 0 FUSE BLOCK - JUNCTION BOX (J/B)........................................................................................ 2 FUSE AND FUSIBLE LINK BOX.............................................................................................. 3 ELECTRICAL UNITS....................................................................................................... 4 idx........................................................................................................................1976 QUICK REFERENCE INDEX.................................................................................................. 0 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 Transmission............................................................................................... 0 AT - Automatic Transmission............................................................................................ 0 TF - Transfer.......................................................................................................... 0 PD - Propeller Shaft & Differential Carrier............................................................................ 0 AX - Front & Rear Axle................................................................................................. 0 SU - Front & Rear Suspension........................................................................................... 0 BR - Brake System...................................................................................................... 0 ST - Steering System................................................................................................... 0 RS - Restraint System.................................................................................................. 0 BT - Body & Trim....................................................................................................... 0 HA - Heater & Air Conditioner.......................................................................................... 0 SC - Starting & Charging System........................................................................................ 0 EL - Electrical System................................................................................................. 0 lc.........................................................................................................................1986 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1986 ENGINE LUBRICATION SYSTEM..............................................................................................1987 Precautions........................................................................................................1987 LIQUID GASKET APPLICATION PROCEDURE............................................................................1987 Preparation........................................................................................................1987 SPECIAL SERVICE TOOLS..........................................................................................1987 COMMERCIAL SERVICE TOOL........................................................................................1988 Lubrication Circuit................................................................................................1988 Oil Pressure Check.................................................................................................1990 Oil Pump...........................................................................................................1991 REMOVAL AND INSTALLATION.......................................................................................1991 DISASSEMBLY AND ASSEMBLY.......................................................................................1991 OIL PUMP INSPECTION............................................................................................1992 REGULATOR VALVE INSPECTION.....................................................................................1992 OIL FILTER.....................................................................................................1993 Oil Cooler.........................................................................................................1993 REMOVAL AND INSTALLATION.......................................................................................1993 INSPECTION.....................................................................................................1994 Service Data and Specifications (SDS)..............................................................................1994 OIL PRESSURE...................................................................................................1994 REGULATOR VALVE................................................................................................1994 OIL PUMP.......................................................................................................1994 ENGINE COOLING SYSTEM..................................................................................................1995 Precautions........................................................................................................1995 LIQUID GASKET APPLICATION PROCEDURE............................................................................1995 Preparation........................................................................................................1995 SPECIAL SERVICE TOOLS..........................................................................................1995 Cooling Circuit....................................................................................................1996 System Check.......................................................................................................1997 CHECKING COOLING SYSTEM HOSES..................................................................................1997 CHECKING RADIATOR..............................................................................................1997 CHECKING RADIATOR CAP..........................................................................................1997 CHECKING COOLING SYSTEM FOR LEAKS..............................................................................1998 Water Pump.........................................................................................................1998 REMOVAL AND INSTALLATION.......................................................................................1998 REMOVAL........................................................................................................1998 INSPECTION.....................................................................................................2000 INSTALLATION...................................................................................................2000 Thermostat.........................................................................................................2002 REMOVAL AND INSTALLATION.......................................................................................2002 INSPECTION.....................................................................................................2002 Water Control Valve................................................................................................2003 REMOVAL AND INSTALLATION.......................................................................................2003 INSPECTION.....................................................................................................2004 Radiator...........................................................................................................2005 REMOVAL AND INSTALLATION.......................................................................................2005 Cooling Fan (Crankshaft driven)....................................................................................2006 REMOVAL AND INSTALLATION.......................................................................................2006 INSPECTION.....................................................................................................2006 Refilling Engine Coolant...........................................................................................2006 Radiator (Aluminum type)...........................................................................................2007 PREPARATION....................................................................................................2007 DISASSEMBLY....................................................................................................2007 ASSEMBLY.......................................................................................................2008 INSPECTION.....................................................................................................2009 Overheating Cause Analysis.........................................................................................2010 Service Data and Specifications (SDS)..............................................................................2011 THERMOSTAT.....................................................................................................2011 WATER CONTROL VALVE............................................................................................2011 RADIATOR.......................................................................................................2011 ma.........................................................................................................................2012 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................2012 PRECAUTIONS............................................................................................................2014 Precautions for Supplemental Restraint System (SRS) "AIR BAG"......................................................2014 PREPARATION............................................................................................................2015 Special Service Tool...............................................................................................2015 Commercial Service Tool............................................................................................2015 GENERAL MAINTENANCE....................................................................................................2016 PERIODIC MAINTENANCE...................................................................................................2018 Schedule 1.........................................................................................................2019 EMISSION CONTROL SYSTEM MAINTENANCE............................................................................2019 CHASSIS AND BODY MAINTENANCE...................................................................................2020 Schedule 2.........................................................................................................2021 EMISSION CONTROL SYSTEM MAINTENANCE............................................................................2021 CHASSIS AND BODY MAINTENANCE...................................................................................2022 RECOMMENDED FLUIDS AND LUBRICANTS......................................................................................2023 Fluids and Lubricants..............................................................................................2023 SAE Viscosity Number...............................................................................................2024 GASOLINE ENGINE OIL............................................................................................2024 GEAR OIL.......................................................................................................2024 Anti-freeze Coolant Mixture Ratio..................................................................................2024 ENGINE MAINTENANCE.....................................................................................................2025 Checking Drive Belts...............................................................................................2025 Changing Engine Coolant............................................................................................2026 -DRAINING ENGINE COOLANT-......................................................................................2026 -REFILLING ENGINE COOLANT-.....................................................................................2027 -FLUSHING COOLING SYSTEM-......................................................................................2028 Checking Fuel Lines................................................................................................2028 Changing Fuel Filter...............................................................................................2028 WITH CONSULT-II................................................................................................2028 WITHOUT CONSULT-II.............................................................................................2029 Changing Air Cleaner Filter........................................................................................2029 VISCOUS PAPER TYPE.............................................................................................2029 Changing Engine Oil................................................................................................2030 Changing Oil Filter................................................................................................2030 Changing Spark Plugs...............................................................................................2031 Checking EVAP Vapor Lines..........................................................................................2032 CHASSIS AND BODY MAINTENANCE...........................................................................................2033 Checking Exhaust System............................................................................................2033 Checking Clutch Fluid Level and Leaks..............................................................................2033 Checking M/T Oil...................................................................................................2033 Changing M/T Oil...................................................................................................2033 Checking Water Entry - For 4WD models with M/T.....................................................................2034 Checking A/T Fluid.................................................................................................2034 Changing A/T Fluid.................................................................................................2034 Checking Part Time 4WD Transfer Fluid..............................................................................2035 Changing Part Time 4WD Transfer Fluid..............................................................................2035 Checking All-mode 4WD Transfer Fluid...............................................................................2035 Changing All-mode 4WD Transfer Fluid...............................................................................2036 Checking Propeller Shaft...........................................................................................2036 Greasing Propeller Shaft...........................................................................................2036 Checking Differential Gear Oil.....................................................................................2037 Changing Differential Gear Oil.....................................................................................2037 LIMITED-SLIP DIFFERENTIAL GEAR.................................................................................2037 Balancing Wheels...................................................................................................2037 Tire Rotation......................................................................................................2038 Checking Brake Fluid Level and Leaks...............................................................................2038 Checking Brake Lines and Cables....................................................................................2038 Checking Disc Brake................................................................................................2038 ROTOR..........................................................................................................2038 CALIPER........................................................................................................2038 PAD............................................................................................................2039 Checking Drum Brake................................................................................................2039 WHEEL CYLINDER.................................................................................................2039 DRUM...........................................................................................................2039 LINING.........................................................................................................2039 TEMPORARY METHOD FOR CHECKING LINING WEAR......................................................................2039 Checking Steering Gear, Linkage and Transfer Gear..................................................................2039 STEERING GEAR..................................................................................................2039 STEERING LINKAGE...............................................................................................2039 STEERING TRANSFER GEAR.........................................................................................2040 Checking Power Steering Fluid and Lines............................................................................2040 CHECKING FLUID LEVEL...........................................................................................2040 CHECKING LINES.................................................................................................2040 Lubricating Locks, Hinges and Hood Latches.........................................................................2040 Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters....................................................2041 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................2042 Engine Maintenance.................................................................................................2042 DRIVE BELT DEFLECTION..........................................................................................2042 DRIVE BELT TENSION.............................................................................................2042 SPARK PLUG TYPE................................................................................................2042 Chassis and Body Maintenance.......................................................................................2042 WHEEL BALANCE..................................................................................................2042 mt.........................................................................................................................2044 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................2044 PREPARATION............................................................................................................2045 Special Service Tools..............................................................................................2045 Commercial Service Tool............................................................................................2047 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING...................................................................2048 NVH Troubleshooting Chart..........................................................................................2048 MANUAL TRANSMISSION............................................................................................2048 ON-VEHICLE SERVICE.....................................................................................................2049 Replacing Rear Oil Seal - 2WD Model................................................................................2049 REMOVAL........................................................................................................2049 INSTALLATION...................................................................................................2049 Position Switch Check - 2WD Model..................................................................................2049 Position Switch Check - 4WD Model..................................................................................2050 DESCRIPTION............................................................................................................2051 Cross-sectional View - 2WD Model...................................................................................2051 Cross-sectional View - 4WD Model...................................................................................2052 REMOVAL AND INSTALLATION...............................................................................................2053 Removal............................................................................................................2053 2WD MODEL......................................................................................................2053 4WD MODEL......................................................................................................2054 Installation.......................................................................................................2055 OVERHAUL...............................................................................................................2057 Case Components....................................................................................................2057 Gear Components....................................................................................................2058 Shift Control Components...........................................................................................2060 DISASSEMBLY............................................................................................................2061 Case Components....................................................................................................2061 DISASSEMBLY....................................................................................................2061 Shift Control Components...........................................................................................2062 DISASSEMBLY....................................................................................................2062 Gear Components....................................................................................................2063 DISASSEMBLY....................................................................................................2063 INSPECTION.............................................................................................................2067 Shift Control Components...........................................................................................2067 INSPECTION.....................................................................................................2067 Gear Components....................................................................................................2067 INSPECTION.....................................................................................................2067 ASSEMBLY...............................................................................................................2069 Gear Components....................................................................................................2069 ASSEMBLY.......................................................................................................2069 Shift Control Components...........................................................................................2077 ASSEMBLY.......................................................................................................2077 Case Components....................................................................................................2078 ASSEMBLY.......................................................................................................2078 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................2080 General Specifications.............................................................................................2080 Gear End Play......................................................................................................2080 Clearance Between Baulk Ring and Gear..............................................................................2080 1ST, 2ND AND 3RD BAULK RING....................................................................................2081 Distance Between Rear Surface of Reverse Cone and Reverse Baulk Ring...............................................2081 Available Snap Ring................................................................................................2081 MAIN DRIVE GEAR SNAP RING......................................................................................2081 MAINSHAFT FRONT SNAP RING......................................................................................2081 COUNTER GEAR REAR SNAP RING....................................................................................2082 Available C-ring...................................................................................................2082 MAINSHAFT C-RING...............................................................................................2082 Available Shim and Washer..........................................................................................2083 TABLE FOR SELECTING PROPER COUNTER GEAR FRONT BEARING THRUST WASHER............................................2083 REVERSE IDLER REAR THRUST WASHER...............................................................................2083 pd.........................................................................................................................2084 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................2084 PROPELLER SHAFT........................................................................................................2086 Preparation........................................................................................................2086 SPECIAL SERVICE TOOLS..........................................................................................2086 Noise, Vibration and Harshness (NVH) Troubleshooting...............................................................2087 NVH TROUBLESHOOTING CHART......................................................................................2087 Components.........................................................................................................2088 FRONT PROPELLER SHAFT..........................................................................................2088 REAR PROPELLER SHAFT...........................................................................................2089 On-vehicle Service.................................................................................................2091 PROPELLER SHAFT VIBRATION......................................................................................2091 APPEARANCE CHECKING............................................................................................2091 Removal and Installation...........................................................................................2091 Inspection.........................................................................................................2092 Disassembly........................................................................................................2092 CENTER BEARING - 2WD -.........................................................................................2092 JOURNAL (71H AND 80B)..........................................................................................2093 Assembly...........................................................................................................2094 CENTER BEARING - 2WD -.........................................................................................2094 JOURNAL (71H AND 80B)..........................................................................................2094 Service Data and Specifications (SDS)..............................................................................2095 GENERAL SPECIFICATIONS.........................................................................................2095 SERVICE DATA...................................................................................................2096 SNAP RING (80B)................................................................................................2096 SNAP RING (71H)................................................................................................2096 SNAP RING (1310)...............................................................................................2096 R200A..................................................................................................................2097 FRONT FINAL DRIVE..................................................................................................2097 Preparation....................................................................................................2097 SPECIAL SERVICE TOOLS......................................................................................2097 Noise, Vibration and Harshness (NVH) Troubleshooting...........................................................2099 On-vehicle Service.............................................................................................2099 FRONT OIL SEAL REPLACEMENT.................................................................................2099 REAR COVER GASKET REPLACEMENT..............................................................................2100 Components.....................................................................................................2101 Removal and Installation.......................................................................................2102 REMOVAL....................................................................................................2102 INSTALLATION...............................................................................................2102 Disassembly....................................................................................................2102 PRE-INSPECTION.............................................................................................2102 FINAL DRIVE HOUSING........................................................................................2103 DIFFERENTIAL CASE..........................................................................................2105 DIFFERENTIAL SIDE SHAFT....................................................................................2106 Inspection.....................................................................................................2107 RING GEAR AND DRIVE PINION.................................................................................2107 DIFFERENTIAL CASE ASSEMBLY.................................................................................2107 BEARING....................................................................................................2107 Adjustment.....................................................................................................2108 SIDE BEARING PRELOAD.......................................................................................2108 PINION GEAR HEIGHT AND PINION BEARING PRELOAD..............................................................2109 TOOTH CONTACT..............................................................................................2113 Assembly.......................................................................................................2114 DIFFERENTIAL SIDE SHAFT....................................................................................2114 DIFFERENTIAL CASE..........................................................................................2115 FINAL DRIVE HOUSING........................................................................................2116 Service Data and Specifications (SDS)..........................................................................2120 R200A......................................................................................................2120 H233B..................................................................................................................2122 REAR FINAL DRIVE...................................................................................................2122 Preparation....................................................................................................2122 SPECIAL SERVICE TOOLS......................................................................................2122 Noise, Vibration and Harshness (NVH) Troubleshooting...........................................................2124 On-vehicle Service.............................................................................................2124 FRONT OIL SEAL REPLACEMENT.................................................................................2124 Components.....................................................................................................2126 Removal and Installation.......................................................................................2127 REMOVAL....................................................................................................2127 INSTALLATION...............................................................................................2127 Disassembly....................................................................................................2127 PRE-INSPECTION.............................................................................................2127 DIFFERENTIAL CARRIER.......................................................................................2128 DIFFERENTIAL CASE..........................................................................................2130 Inspection.....................................................................................................2131 RING GEAR AND DRIVE PINION.................................................................................2131 DIFFERENTIAL CASE ASSEMBLY.................................................................................2131 BEARING....................................................................................................2131 Limited Slip Differential......................................................................................2131 PREPARATION FOR DISASSEMBLY................................................................................2131 DISASSEMBLY................................................................................................2132 INSPECTION.................................................................................................2133 ADJUSTMENT.................................................................................................2134 ASSEMBLY...................................................................................................2135 Adjustment.....................................................................................................2137 PINION GEAR HEIGHT.........................................................................................2137 TOOTH CONTACT..............................................................................................2140 Assembly.......................................................................................................2141 DIFFERENTIAL CASE..........................................................................................2141 DIFFERENTIAL CARRIER.......................................................................................2142 Service Data and Specifications (SDS)..........................................................................2145 H233B......................................................................................................2145 rs.........................................................................................................................2150 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................2150 SEAT BELTS.............................................................................................................2152 Precautions........................................................................................................2152 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) "AIR BAG" AND "SEAT BELT PRE-TENSIONER"....................................2152 PRECAUTION FOR SEAT BELT SERVICE...............................................................................2152 Front Seat Belt....................................................................................................2153 REMOVAL AND INSTALLATION.......................................................................................2153 Rear Seat Belt.....................................................................................................2154 REMOVAL AND INSTALLATION.......................................................................................2154 Seat Belt Inspection...............................................................................................2156 AFTER A COLLISION..............................................................................................2156 PRELIMINARY CHECKS.............................................................................................2156 SEAT BELT RETRACTOR ON-VEHICLE CHECK...........................................................................2157 SEAT BELT RETRACTOR OFF-VEHICLE CHECK..........................................................................2157 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)....................................................................................2159 Precautions........................................................................................................2159 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) "AIR BAG" AND "SEAT BELT PRE-TENSIONER"....................................2159 PRECAUTIONS FOR SRS "AIR BAG" AND "SEAT BELT PRE-TENSIONER" SERVICE............................................2159 WIRING DIAGRAMS AND TROUBLE DIAGNOSIS..........................................................................2159 Preparation........................................................................................................2160 SPECIAL SERVICE TOOLS..........................................................................................2160 Description........................................................................................................2161 Seat Belt Pre-tensioner with Load Limiter..........................................................................2161 Built-in Type Side Air Bag.........................................................................................2162 SRS Component Parts Location.......................................................................................2162 Maintenance Items..................................................................................................2163 Diagnosis Sensor Unit..............................................................................................2164 REMOVAL AND INSTALLATION.......................................................................................2164 Seat Belt Pre-tensioner............................................................................................2164 REMOVAL AND INSTALLATION.......................................................................................2164 Satellite Sensor...................................................................................................2165 REMOVAL AND INSTALLATION.......................................................................................2165 Driver Air Bag Module and Spiral Cable.............................................................................2166 REMOVAL AND INSTALLATION.......................................................................................2166 REMOVAL........................................................................................................2166 INSTALLATION...................................................................................................2167 Front Passenger Air Bag Module.....................................................................................2168 REMOVAL........................................................................................................2168 INSTALLATION...................................................................................................2169 Side Air Bag Module................................................................................................2170 REMOVAL........................................................................................................2170 INSTALLATION...................................................................................................2171 Disposal of Air Bag Module and Seat Belt Pre-tensioner.............................................................2171 CHECKING DEPLOYMENT TOOL.......................................................................................2172 DEPLOYMENT PROCEDURES FOR AIR BAG MODULE (OUTSIDE OF VEHICLE)..................................................2173 DEPLOYMENT PROCEDURES FOR SEAT BELT PRE-TENSIONER (OUTSIDE OF VEHICLE).........................................2176 DEPLOYMENT OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER WHILE MOUNTED IN VEHICLE..............................2176 DISPOSING OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER........................................................2177 Trouble Diagnoses Introduction.....................................................................................2178 DIAGNOSIS FUNCTION.............................................................................................2178 DIAGNOSIS MODE FOR CONSULT-II..................................................................................2178 HOW TO CHANGE SELF-DIAGNOSIS MODE WITH CONSULT-II..............................................................2179 HOW TO CHANGE SELF-DIAGNOSIS MODE WITHOUT CONSULT-II...........................................................2179 HOW TO ERASE SELF-DIAGNOSIS RESULTS............................................................................2179 How to Perform Trouble Diagnoses for Quick and Accurate Repair.....................................................2181 INFORMATION FROM CUSTOMER......................................................................................2181 PRELIMINARY CHECK..............................................................................................2181 WORK FLOW......................................................................................................2182 Schematic..........................................................................................................2183 Wiring Diagram - SRS -.............................................................................................2184 SRS Operation Check................................................................................................2187 DIAGNOSTIC PROCEDURE 1.........................................................................................2187 Trouble Diagnoses with CONSULT-II..................................................................................2188 DIAGNOSTIC PROCEDURE 2.........................................................................................2188 DIAGNOSTIC PROCEDURE 3.........................................................................................2191 DIAGNOSTIC PROCEDURE 4 (CONTINUED FROM DIAGNOSTIC PROCEDURE 2).................................................2193 DIAGNOSTIC PROCEDURE 5.........................................................................................2193 Trouble Diagnoses without CONSULT-II...............................................................................2197 DIAGNOSTIC PROCEDURE 6.........................................................................................2197 DIAGNOSTIC PROCEDURE 7.........................................................................................2202 DIAGNOSTIC PROCEDURE 8 (CONTINUED FROM DIAGNOSTIC PROCEDURE 6).................................................2204 Trouble Diagnoses: "AIR BAG" Warning Lamp Does Not Turn Off........................................................2205 DIAGNOSTIC PROCEDURE 9.........................................................................................2205 Collision Diagnosis................................................................................................2208 FOR FRONTAL COLLISION..........................................................................................2208 FOR SIDE COLLISION.............................................................................................2210 Trouble Diagnoses: "AIR BAG" Warning Lamp Does Not Turn On.........................................................2207 DIAGNOSTIC PROCEDURE 10........................................................................................2207 SUPER MULTIPLE JUNCTION (SMJ).......................................................................................... 0 FUSE BLOCK - JUNCTION BOX (J/B)........................................................................................ 2 FUSE AND FUSIBLE LINK BOX.............................................................................................. 3 ELECTRICAL UNITS....................................................................................................... 4 sc.........................................................................................................................2212 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................2212 PRECAUTIONS............................................................................................................2213 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................................2213 Wiring Diagrams and Trouble Diagnosis..............................................................................2213 PREPARATION............................................................................................................2214 Special Service Tool...............................................................................................2214 BATTERY................................................................................................................2215 How to Handle Battery..............................................................................................2215 METHODS OF PREVENTING OVER-DISCHARGE...........................................................................2215 CHECKING ELECTROLYTE LEVEL.....................................................................................2215 SPECIFIC GRAVITY CHECK.........................................................................................2216 CHARGING THE BATTERY...........................................................................................2217 Trouble Diagnoses with Battery/Starting/Charging System Tester.....................................................2218 DIAGNOSTIC RESULT ITEM CHART...................................................................................2220 STARTING SYSTEM........................................................................................................2221 System Description.................................................................................................2221 WITH M/T.......................................................................................................2221 WITH A/T.......................................................................................................2221 Wiring Diagram - START -/With M/T..................................................................................2222 Wiring Diagram - START -/With A/T..................................................................................2223 Trouble Diagnoses with Battery/Starting/Charging System Tester.....................................................2224 DIAGNOSTIC RESULT ITEM CHART...................................................................................2225 WORK FLOW......................................................................................................2226 DIAGNOSTIC PROCEDURE 1.........................................................................................2227 DIAGNOSTIC PROCEDURE 2.........................................................................................2229 MINIMUM SPECIFICATION OF CRANKING VOLTAGE REFERENCING COOLANT TEMPERATURE......................................2229 Construction.......................................................................................................2230 Removal and Installation...........................................................................................2230 Pinion/Clutch Check................................................................................................2230 CHARGING SYSTEM........................................................................................................2231 System Description.................................................................................................2231 Wiring Diagram - CHARGE -..........................................................................................2232 Trouble Diagnoses with Battery/Starting/Charging System Tester.....................................................2233 DIAGNOSTIC RESULT ITEM CHART...................................................................................2235 WORK FLOW......................................................................................................2236 DIAGNOSTIC PROCEDURE 1.........................................................................................2237 DIAGNOSTIC PROCEDURE 2.........................................................................................2238 DIAGNOSTIC PROCEDURE 3.........................................................................................2239 MALFUNCTION INDICATOR..........................................................................................2239 Construction.......................................................................................................2240 Removal and Installation...........................................................................................2240 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................2241 Battery............................................................................................................2241 Starter............................................................................................................2241 Alternator.........................................................................................................2241 SUPER MULTIPLE JUNCTION (SMJ).......................................................................................... 0 FUSE BLOCK - JUNCTION BOX (J/B)........................................................................................ 2 FUSE AND FUSIBLE LINK BOX.............................................................................................. 3 ELECTRICAL UNITS....................................................................................................... 4 st.........................................................................................................................2242 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................2242 PRECAUTIONS............................................................................................................2243 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"........................................2243 Precautions for Steering System....................................................................................2243 PREPARATION............................................................................................................2244 Special Service Tools..............................................................................................2244 Commercial Service Tools...........................................................................................2246 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING...................................................................2247 NVH Troubleshooting Chart..........................................................................................2247 ON-VEHICLE SERVICE.....................................................................................................2248 Checking Steering Wheel Play.......................................................................................2248 Checking Neutral Position on Steering Wheel........................................................................2248 PRE-CHECKING...................................................................................................2248 CHECKING.......................................................................................................2248 Front Wheel Turning Angle..........................................................................................2248 Checking Gear Housing Movement.....................................................................................2249 Adjusting Rack Retainer............................................................................................2249 Checking and Adjusting Drive Belts.................................................................................2249 Checking Fluid Level...............................................................................................2249 Checking Fluid Leakage.............................................................................................2249 Bleeding Hydraulic System..........................................................................................2250 Checking Steering Wheel Turning Force..............................................................................2250 Checking Hydraulic System..........................................................................................2251 STEERING WHEEL AND STEERING COLUMN.....................................................................................2252 Components.........................................................................................................2252 Removal and Installation...........................................................................................2252 STEERING WHEEL.................................................................................................2252 STEERING COLUMN................................................................................................2253 Disassembly and Assembly...........................................................................................2254 Inspection.........................................................................................................2255 TILT MECHANISM.................................................................................................2255 STEERING TRANSFER GEAR.................................................................................................2256 Removal............................................................................................................2256 Installation.......................................................................................................2257 Inspection.........................................................................................................2257 POWER STEERING GEAR AND LINKAGE........................................................................................2258 Components.........................................................................................................2258 Removal and Installation...........................................................................................2259 Disassembly........................................................................................................2260 Inspection.........................................................................................................2261 BOOT...........................................................................................................2261 RACK...........................................................................................................2261 PINION ASSEMBLY................................................................................................2261 GEAR HOUSING CYLINDER..........................................................................................2261 TIE-ROD OUTER AND INNER SOCKETS................................................................................2262 Assembly...........................................................................................................2262 Adjustment.........................................................................................................2265 POWER STEERING OIL PUMP................................................................................................2268 Components.........................................................................................................2268 Pre-disassembly Inspection.........................................................................................2268 Disassembly........................................................................................................2269 Inspection.........................................................................................................2270 Assembly...........................................................................................................2270 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................2273 General Specifications.............................................................................................2273 Steering Wheel.....................................................................................................2273 Steering Column....................................................................................................2273 Steering Transfer Gear.............................................................................................2273 Steering Gear and Linkage..........................................................................................2274 Power Steering.....................................................................................................2274 su.........................................................................................................................2276 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................2276 FRONT SUSPENSION.......................................................................................................2277 Precautions........................................................................................................2277 PRECAUTIONS....................................................................................................2277 Preparation........................................................................................................2277 SPECIAL SERVICE TOOLS..........................................................................................2277 COMMERCIAL SERVICE TOOLS.......................................................................................2277 Noise, Vibration and Harshness (NVH) Troubleshooting...............................................................2278 NVH TROUBLESHOOTING CHART......................................................................................2278 Components.........................................................................................................2279 2WD............................................................................................................2279 4WD............................................................................................................2280 On-vehicle Service.................................................................................................2281 FRONT SUSPENSION PARTS.........................................................................................2281 FRONT WHEEL ALIGNMENT..........................................................................................2282 Coil Spring and Strut Assembly.....................................................................................2284 COMPONENTS.....................................................................................................2284 REMOVAL........................................................................................................2286 DISASSEMBLY....................................................................................................2286 INSPECTION.....................................................................................................2286 ASSEMBLY.......................................................................................................2287 Stabilizer Bar.....................................................................................................2287 REMOVAL AND INSTALLATION.......................................................................................2287 INSPECTION.....................................................................................................2288 Transverse Link and Lower Ball Joint...............................................................................2288 REMOVAL AND INSTALLATION.......................................................................................2288 INSPECTION.....................................................................................................2289 Service Data and Specifications (SDS)..............................................................................2289 GENERAL SPECIFICATIONS (FRONT).................................................................................2289 WHEEL ALIGNMENT (UNLADEN*1)....................................................................................2289 LOWER BALL JOINT...............................................................................................2290 WHEELARCH HEIGHT (UNLADEN*)....................................................................................2291 WHEEL RUNOUT AVERAGE*..........................................................................................2291 REAR SUSPENSION........................................................................................................2292 Precautions........................................................................................................2292 PRECAUTIONS....................................................................................................2292 Preparation........................................................................................................2292 COMMERCIAL SERVICE TOOLS.......................................................................................2292 Noise, Vibration and Harshness (NVH) Troubleshooting...............................................................2292 Components.........................................................................................................2293 On-vehicle Service.................................................................................................2293 REAR SUSPENSION PARTS..........................................................................................2293 Removal and Installation...........................................................................................2294 Coil Spring and Shock Absorber.....................................................................................2295 COMPONENTS.....................................................................................................2295 REMOVAL AND INSTALLATION.......................................................................................2296 INSPECTION.....................................................................................................2296 Upper Link, Lower Link and Panhard Rod.............................................................................2296 INSPECTION.....................................................................................................2296 BUSHING REPLACEMENT............................................................................................2296 INSTALLATION...................................................................................................2297 Stabilizer Bar.....................................................................................................2297 REMOVAL AND INSTALLATION.......................................................................................2297 Service Data and Specifications (SDS)..............................................................................2297 GENERAL SPECIFICATIONS (REAR)..................................................................................2297 tf.........................................................................................................................2298 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................2298 PREPARATION............................................................................................................2301 Special Service Tools..............................................................................................2301 Commercial Service Tools...........................................................................................2306 TX10A..................................................................................................................2307 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING...............................................................2307 NVH Troubleshooting Chart......................................................................................2307 TRANSFER...................................................................................................2307 DESCRIPTION........................................................................................................2308 Cross-sectional View...........................................................................................2308 ON-VEHICLE SERVICE.................................................................................................2309 Replacing Oil Seal.............................................................................................2309 CENTER CASE OIL SEAL.......................................................................................2309 SHIFT SHAFT OIL SEAL.......................................................................................2309 REAR OIL SEAL..............................................................................................2310 Position Switch Check..........................................................................................2310 REMOVAL AND INSTALLATION...........................................................................................2311 Removal........................................................................................................2311 Installation...................................................................................................2311 M/T MODEL..................................................................................................2311 A/T MODEL..................................................................................................2311 OVERHAUL...........................................................................................................2312 Transfer Gear Control..........................................................................................2312 Case Components................................................................................................2313 Gear Components................................................................................................2314 Shift Control Components.......................................................................................2315 DISASSEMBLY........................................................................................................2316 REPAIR FOR COMPONENT PARTS.........................................................................................2320 Mainshaft......................................................................................................2320 DISASSEMBLY................................................................................................2320 INSPECTION.................................................................................................2321 ASSEMBLY...................................................................................................2321 Front Drive Shaft..............................................................................................2322 DISASSEMBLY................................................................................................2322 INSPECTION.................................................................................................2322 ASSEMBLY...................................................................................................2322 Counter Gear...................................................................................................2322 DISASSEMBLY................................................................................................2322 INSPECTION.................................................................................................2323 ASSEMBLY...................................................................................................2323 Main Gear......................................................................................................2323 DISASSEMBLY................................................................................................2323 INSPECTION.................................................................................................2324 ASSEMBLY...................................................................................................2324 Front Case.....................................................................................................2324 REMOVAL....................................................................................................2324 INSTALLATION...............................................................................................2325 Front Case Cover...............................................................................................2325 REMOVAL....................................................................................................2325 INSTALLATION...............................................................................................2325 Bearing Retainer...............................................................................................2325 REMOVAL....................................................................................................2325 INSTALLATION...............................................................................................2325 Center Case....................................................................................................2326 REMOVAL....................................................................................................2326 INSTALLATION...............................................................................................2326 Rear Case......................................................................................................2326 REMOVAL....................................................................................................2326 INSTALLATION...............................................................................................2326 Shift Control Components.......................................................................................2327 INSPECTION.................................................................................................2327 ASSEMBLY...........................................................................................................2328 SERVICE DATA AND SPECIFICATIONS (SDS)..............................................................................2335 General Specifications.........................................................................................2335 Gear End Play..................................................................................................2335 Available Snap Ring............................................................................................2335 MAINSHAFT FRONT BEARING....................................................................................2335 MAINSHAFT REAR BEARING.....................................................................................2335 MAIN GEAR BEARING..........................................................................................2335 Available Shim.................................................................................................2336 COUNTER GEAR REAR BEARING..................................................................................2336 ATX14A.................................................................................................................2337 PRECAUTIONS........................................................................................................2337 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"....................................2337 Precautions....................................................................................................2337 Service Notice.................................................................................................2338 Wiring Diagrams and Trouble Diagnosis..........................................................................2338 ALL-MODE 4WD SYSTEM................................................................................................2339 Cross-sectional View...........................................................................................2339 Control System.................................................................................................2340 ALL-MODE 4WD TRANSFER BASIC CONTROL........................................................................2341 HYDRAULIC CONTROL CIRCUITS.................................................................................2341 OUTLINE....................................................................................................2341 CONTROL SYSTEM DIAGRAM.....................................................................................2342 INDICATIONS OF 4WD WARNING LAMP............................................................................2342 Location of Electrical Parts...................................................................................2343 Description of Electrical Parts................................................................................2344 TRANSFER MOTOR.............................................................................................2344 WAIT DETECTION SWITCH......................................................................................2344 2-4WD SHIFT SOLENOID VALVE.................................................................................2345 LINE PRESSURE SWITCH.......................................................................................2345 Circuit Diagram for Quick Pinpoint Check.......................................................................2346 Wiring Diagram - TF -..........................................................................................2347 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION.............................................................................2356 Trouble Diagnosis without CONSULT-II...........................................................................2356 DESCRIPTION................................................................................................2356 SELF-DIAGNOSTIC PROCEDURE..................................................................................2357 INDICATIONS OF 4WD WARNING LAMP............................................................................2358 Trouble Diagnosis with CONSULT-II..............................................................................2359 SELF-DIAGNOSIS.............................................................................................2359 SELF-DIAGNOSTIC ITEMS......................................................................................2360 DATA MONITOR...............................................................................................2362 DATA MONITOR ITEMS.........................................................................................2363 REFERENCE VALUE IN DATA MONITOR MODE.......................................................................2365 WORK SUPPORT...............................................................................................2367 CLUTCH FORCE RELEASE LIMIT ADJUSTMENT......................................................................2368 TROUBLE DIAGNOSIS - INTRODUCTION...................................................................................2370 Introduction...................................................................................................2370 DESCRIPTION................................................................................................2370 DIAGNOSTIC WORKSHEET.......................................................................................2370 Work Flow......................................................................................................2372 HOW TO PERFORM TROUBLE DIAGNOSES FOR QUICK AND ACCURATE REPAIR.............................................2372 TROUBLE DIAGNOSIS - BASIC INSPECTION...............................................................................2373 Listen to Customer Complaints..................................................................................2373 Transfer Fluid Check...........................................................................................2373 Road Test......................................................................................................2373 PREPARATION FOR ROAD TEST..................................................................................2373 1. CHECK BEFORE ENGINE IS STARTED..........................................................................2374 2. CHECK AT IDLE...........................................................................................2375 3. CRUISE TEST.............................................................................................2379 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION............................................................................2382 Transfer Control Unit Terminals and Reference Value............................................................2382 REMOVAL AND INSTALLATION OF TRANSFER CONTROL UNIT..........................................................2382 INSPECTION OF TRANSFER CONTROL UNIT........................................................................2382 TRANSFER CONTROL UNIT INSPECTION TABLE.....................................................................2383 VEHICLE SPEED SENSOR (FRONT REVOLUTION SENSOR).....................................................................2389 Diagnostic Procedure...........................................................................................2389 4WD SOLENOID VALVE.................................................................................................2392 Diagnostic Procedure...........................................................................................2392 2-4WD SHIFT SOLENOID VALVE AND 4WD SHIFT SWITCH....................................................................2394 Diagnostic Procedure...........................................................................................2394 TRANSFER MOTOR AND TRANSFER MOTOR RELAY............................................................................2398 Diagnostic Procedure...........................................................................................2398 TRANSFER FLUID TEMPERATURE SENSOR..................................................................................2401 Diagnostic Procedure...........................................................................................2401 ATP SWITCH, WAIT DETECTION SWITCH AND NEUTRAL-4LO SWITCH...........................................................2404 Diagnostic Procedure...........................................................................................2404 CLUTCH PRESSURE SWITCH.............................................................................................2408 Diagnostic Procedure...........................................................................................2408 LINE PRESSURE SWITCH...............................................................................................2411 Diagnostic Procedure...........................................................................................2411 ABS OPERATION SIGNAL...............................................................................................2414 Diagnostic Procedure...........................................................................................2414 DATA ERASE/DISPLAY.................................................................................................2416 Diagnostic Procedure...........................................................................................2416 SHIFT ACTUATOR.....................................................................................................2417 Diagnostic Procedure...........................................................................................2417 SHIFT ACTUATOR POSITION SWITCH.....................................................................................2420 Diagnostic Procedure...........................................................................................2420 SHIFT ACTUATOR CIRCUIT.............................................................................................2422 Diagnostic Procedure...........................................................................................2422 TROUBLE DIAGNOSES FOR SYMPTOMS.....................................................................................2426 Symptom 1. 4WD Shift Indicator Lamp Does Not Turn ON...........................................................2426 Symptom 2. 4WD Warning Lamp Does Not Turn ON...................................................................2428 Symptom 3. 4WD Shift Indicator Lamp Does Not Turn OFF..........................................................2430 Symptom 4. ATP Warning Lamp Does Not Turn ON...................................................................2430 Symptom 5. 4LO Indicator Lamp Does Not Turn ON.................................................................2432 Symptom 6. 4WD Shift Indicator Lamp Does Not Indicate "4H".....................................................2434 Symptom 7. 4WD Shift Indicator Lamp Repeats Flickering.........................................................2435 Symptom 8. Tight Corner Braking Symptom........................................................................2436 Symptom 9. 4WD System Does Not Operate.........................................................................2437 COMPONENT INSPECTION...............................................................................................2439 4WD Shift Switch...............................................................................................2439 2-4WD Shift Solenoid Valve and Transfer Fluid Temperature Sensor...............................................2439 4WD Solenoid Valve, Clutch Pressure Switch and Line Pressure Switch............................................2439 Front Revolution Sensor........................................................................................2440 Transfer Dropping Resistor.....................................................................................2440 ATP Switch, Neutral-4LO Switch and Wait Detection Switch.......................................................2440 Transfer Motor.................................................................................................2441 Transfer Motor Relay...........................................................................................2441 Transfer Sub-harness...........................................................................................2441 FRONT REVOLUTION SENSOR SUB-HARNESS CONNECTOR..............................................................2441 TRANSFER SWITCH ASSEMBLY SUB-HARNESS CONNECTOR.............................................................2442 TRANSFER TERMINAL CORD ASSEMBLY SUB-HARNESS CONNECTOR......................................................2442 Transfer Shift Relay (High & low)..............................................................................2442 Actuator & Actuator Position Switch............................................................................2443 ACTUATOR...................................................................................................2443 ACTUATOR POSITION SWITCH...................................................................................2443 ON-VEHICLE SERVICE.................................................................................................2444 Replacing Oil Seal.............................................................................................2444 FRONT CASE OIL SEAL........................................................................................2444 SHIFT SHAFT OIL SEAL.......................................................................................2445 REAR OIL SEAL..............................................................................................2445 Transfer Motor.................................................................................................2445 REMOVAL....................................................................................................2445 INSTALLATION...............................................................................................2445 Transfer Oil Filter............................................................................................2446 REMOVAL....................................................................................................2446 INSTALLATION...............................................................................................2446 REMOVAL AND INSTALLATION...........................................................................................2447 Removal........................................................................................................2447 Installation...................................................................................................2447 OVERHAUL...........................................................................................................2448 Transfer Gear Control..........................................................................................2448 Transfer Components............................................................................................2449 DISASSEMBLY........................................................................................................2451 Rear Case......................................................................................................2451 DISASSEMBLY................................................................................................2451 Center Case....................................................................................................2451 DISASSEMBLY................................................................................................2451 Front Case.....................................................................................................2461 DISASSEMBLY................................................................................................2461 REPAIR FOR COMPONENT PARTS.........................................................................................2465 Front Case.....................................................................................................2465 INSPECTION.................................................................................................2465 Center Case....................................................................................................2466 INSPECTION.................................................................................................2466 ASSEMBLY...........................................................................................................2469 Front Case.....................................................................................................2469 ASSEMBLY...................................................................................................2469 Center Case....................................................................................................2473 ASSEMBLY...................................................................................................2473 Final Assembly.................................................................................................2481 SERVICE DATA AND SPECIFICATIONS (SDS)..............................................................................2485 General Specifications.........................................................................................2485 Inner Gear and Outer Gear......................................................................................2485 SUB-OIL PUMP...............................................................................................2485 MAIN OIL PUMP..............................................................................................2485 Control Valve..................................................................................................2485 VALVE......................................................................................................2485 SPRING.....................................................................................................2485 Clutch.........................................................................................................2486 DRIVE PLATE................................................................................................2486 DRIVEN PLATE...............................................................................................2486 RETURN SPRING..............................................................................................2486 RETAINING PLATE............................................................................................2486 Seal Ring (Mainshaft side).....................................................................................2487 Bearing Race (Thrust needle bearing side)......................................................................2487 Snap Ring (Sun gear side)......................................................................................2487 SUPER MULTIPLE JUNCTION (SMJ).......................................................................................... 0 FUSE BLOCK - JUNCTION BOX (J/B)........................................................................................ 2 FUSE AND FUSIBLE LINK BOX.............................................................................................. 3 ELECTRICAL UNITS....................................................................................................... 4
DESCRIPTION:
2001 NISSAN PATHFINDER R50 Series Service Manual PDF DOWNLOAD
FOREWORD
- This manual contains maintenance and repair procedures for the 2001 Nissan PATHFINDER.
- 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 completely satisfy himself that neither his safety nor the vehicle’s safety will be jeopardized by the service method selected .
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PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
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