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1994 INFINITI J30 Y32 Series Service Manual PDF DOWNLOAD
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Description
1994 INFINITI J30 Y32 Series Service Manual PDF DOWNLOAD
FILE DETAILS:
1994 INFINITI J30 Y32 Series Service Manual PDF DOWNLOAD
Language : English
Pages : 1161
Downloadable : Yes
File Type : PDF
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DESCRIPTION:
1994 INFINITI J30 Y32 Series Service Manual PDF DOWNLOAD
FOREWORD
- This manual contains maintenance and repair procedures for the 1994 INFINITI J30.
- 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 INFINITI must first be completely satisfied that neither personal safety nor the vehicle’s safety will be jeopardized by the service method selected.
TABLE OF CONTENTS:
1994 INFINITI J30 Y32 Series Service Manual PDF DOWNLOAD
fwd................................................................................................. 1 Model Selection................................................................................. 0 QUICK REFERENCE INDEX........................................................................... 1 FOREWORD........................................................................................ 2 GI - General Information........................................................................ 0 MA - Maintenance................................................................................ 0 EM - Engine Mechanical.......................................................................... 0 LC - Engine Lubrication & Cooling Systems....................................................... 0 EF & EC - Engine Fuel & Emission Control System................................................. 0 FE - Accelerator Control, Fuel & Exhaust Systems................................................ 0 AT - Automatic Transmission..................................................................... 0 PD - Propeller Shaft & Differential Carrier..................................................... 0 FA - Front Axle & Front Suspension.............................................................. 0 RA - Rear Axle & Rear Suspension................................................................ 0 BR - Brake System............................................................................... 0 ST - Steering System............................................................................ 0 BF - Body....................................................................................... 0 HA - Heater & Air Conditioner................................................................... 0 EL - Electrical System.......................................................................... 0 IDX - Alphabetical Index........................................................................ 1 Inch to Metric Conversion....................................................................... 3 QUICK REFERENCE CHART........................................................................... 4 at.................................................................................................. 5 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS............................................................................... 5 PREPARATION AND PRECAUTIONS..................................................................... 6 Service Notice.............................................................................. 7 Precautions for Supplemental Restraint System "AIR BAG" and "SEAT BELT PRE-TENSIONER"....... 8 DESCRIPTION..................................................................................... 9 Cross-sectional View........................................................................ 9 Hydraulic Control Circuits.................................................................. 10 Shift Mechanism............................................................................. 11 Control System.............................................................................. 13 TROUBLE DIAGNOSES............................................................................... 15 Contents.................................................................................... 15 TROUBLE DIAGNOSES - A/T Shift Lock System....................................................... 93 Contents.................................................................................... 93 ON-VEHICLE SERVICE.............................................................................. 104 Control Valve Assembly and Accumulators Inspection.......................................... 104 Revolution Sensor Replacement............................................................... 104 Rear Oil Seal Replacement................................................................... 105 Parking Components Inspection............................................................... 105 Inhibitor Switch Adjustment................................................................. 106 Manual Control Linkage Adjustment........................................................... 106 Kickdown Switch Adjustment.................................................................. 106 REMOVAL AND INSTALLATION........................................................................ 108 Removal..................................................................................... 108 Installation................................................................................ 108 MAJOR OVERHAUL.................................................................................. 110 Oil Channel................................................................................. 112 Locations of Needle Bearings, Thrust Washers and Snap Rings................................. 113 DISASSEMBLY..................................................................................... 114 Disassembly................................................................................. 114 REPAIR FOR COMPONENT PARTS...................................................................... 125 Oil Pump.................................................................................... 125 Control Valve Assembly...................................................................... 129 Control Valve Upper Body.................................................................... 135 Control Valve Lower Body.................................................................... 140 Reverse Clutch.............................................................................. 142 High Clutch................................................................................. 146 Forward and Overrun Clutches................................................................ 148 Low & Reverse Brake......................................................................... 152 Forward Clutch Drum Assembly................................................................ 156 Rear Internal Gear and Forward Clutch Hub................................................... 159 Band Servo Piston Assembly.................................................................. 162 Parking Pawl Components..................................................................... 166 ASSEMBLY........................................................................................ 168 Assembly.................................................................................... 168 Adjustment.................................................................................. 173 Assembly.................................................................................... 177 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................... 187 General Specifications...................................................................... 187 Specifications and Adjustment............................................................... 187 bf.................................................................................................. 191 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS............................................................................... 191 GENERAL SERVICING............................................................................... 192 Precautions................................................................................. 192 Supplemental Restraint System "AIR BAG" and "SEAT BELT PRE-TENSIONER"....................... 192 Circuit Breaker Inspection.................................................................. 192 Clip and Fastener........................................................................... 193 BODY END........................................................................................ 195 Body Front End.............................................................................. 195 Body Rear End and Opener.................................................................... 197 DOOR............................................................................................ 200 Front Door.................................................................................. 200 Rear Door................................................................................... 201 DOOR - Power Window............................................................................. 202 Power window................................................................................ 202 DOOR - Trouble Diagnoses for Power Window....................................................... 204 Contents.................................................................................... 204 DOOR - Power Door Lock.......................................................................... 212 Power Door Lock............................................................................. 212 MULTI-REMOTE CONTROL SYSTEM..................................................................... 218 Wiring Diagram.............................................................................. 218 Circuit Diagram for Quick Pinpoint Check.................................................... 220 Trouble Diagnoses Preliminary Inspection.................................................... 221 Trouble Diagnoses........................................................................... 222 Replacing Remote Controller or Control Unit................................................. 228 INSTRUMENT PANEL................................................................................ 229 INTERIOR AND EXTERIOR........................................................................... 231 Interior.................................................................................... 231 Exterior.................................................................................... 237 SEAT............................................................................................ 242 Front Seat.................................................................................. 242 Rear Seat................................................................................... 248 SUN ROOF........................................................................................ 249 Wiring Diagram.............................................................................. 250 WINDSHIELD AND WINDOWS.......................................................................... 251 Windshield and Rear Window.................................................................. 251 MIRROR.......................................................................................... 252 Door Mirror................................................................................. 252 REAR AIR SPOILER................................................................................ 254 BODY ALIGNMENT.................................................................................. 255 Engine Compartment.......................................................................... 255 Underbody................................................................................... 257 SUPPLEMENTAL RESTRAINT SYSTEM (SDS)............................................................. 259 Precautions for SRS "Air Bag" and "Seat Belt Pre-tensioner" Service......................... 259 Special Service Tools....................................................................... 259 Commercial Service Tools.................................................................... 259 Description................................................................................. 260 Caution Labels and SRS Component Parts Location............................................. 261 Maintenance Items........................................................................... 264 Removal and Installation - Diagnosis (Control) Unit, Sensors and Seat Belt Pre-tensioner.... 265 Removal - Air Bag Module and Spiral Cable................................................... 266 Removal - Front Passenger Air Bag Module.................................................... 267 Installation - Air Bag Module and Spiral Cable.............................................. 268 Installation - Front Passenger Air Bag Module............................................... 270 Scrapping Air Bag and Seat Belt Pre-tensioners.............................................. 270 TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)......................................... 273 Contents.................................................................................... 273 br.................................................................................................. 285 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS............................................................................... 285 PRECAUTIONS AND PREPARATION..................................................................... 287 Precautions................................................................................. 287 Special Service Tools....................................................................... 287 Comemrcial Service Tools.................................................................... 287 CHECK AND ADJUSTMENT............................................................................ 288 Checking Brake Fluid Level.................................................................. 288 Checking Brake Line......................................................................... 288 Changing Brake Fluid........................................................................ 288 Bleeding Brake System....................................................................... 288 BRAKE HYDRAULIC LINE............................................................................ 290 Removal..................................................................................... 290 Inspection.................................................................................. 290 Installation................................................................................ 290 CONTROL VALVE................................................................................... 291 Proportioning Valve......................................................................... 291 BRAKE PEDAL AND BRACKET......................................................................... 292 Removal and Installation.................................................................... 292 Inspection.................................................................................. 292 Adjustment.................................................................................. 292 MASTER CYLINDER................................................................................. 294 Removal..................................................................................... 294 Disassembly................................................................................. 294 Inspection.................................................................................. 295 Assembly.................................................................................... 295 Installation................................................................................ 296 BRAKE BOOSTER................................................................................... 297 On-vehicle Service.......................................................................... 297 Removal..................................................................................... 297 Inspection.................................................................................. 298 Installation................................................................................ 298 VACUUM HOSE..................................................................................... 299 Removal and Installation.................................................................... 299 Inspection.................................................................................. 299 FRONT DISC BRAKE................................................................................ 300 Pad Replacement............................................................................. 300 Removal..................................................................................... 302 Disassembly................................................................................. 302 Inspection - Caliper........................................................................ 302 Inspection - Rotor.......................................................................... 303 Assembly.................................................................................... 303 Installation................................................................................ 303 REAR DISC BRAKE................................................................................. 304 Pad Replacement............................................................................. 304 Removal..................................................................................... 305 Disassembly................................................................................. 306 Inspection - Caliper........................................................................ 306 Inspection - Rotor.......................................................................... 306 Assembly.................................................................................... 307 Installation................................................................................ 307 REAR DISC BRAKE - Parking Drum Brake............................................................ 308 Removal..................................................................................... 308 Inspection - Drum........................................................................... 309 Inspection - Lining......................................................................... 309 Installation................................................................................ 310 Shoe Clearance Adjustment................................................................... 310 Breaking in Drum and Lining................................................................. 311 PARKING BRAKE CONTROL........................................................................... 312 Removal and Installation.................................................................... 312 Inspection.................................................................................. 313 Adjustment.................................................................................. 313 ANTI-LOCK BRAKE SYSTEM.......................................................................... 314 Wiring Diagram.............................................................................. 315 Removal and Installation.................................................................... 316 TROUBLE DIAGNOSES............................................................................... 318 Contents.................................................................................... 318 How to Perform Trouble Diagnoses for Quick and Accurate Repair.............................. 319 Self-diagnoses.............................................................................. 320 Component Parts and Harness Connector Location.............................................. 323 Preliminary Check........................................................................... 324 Ground Circuit Check........................................................................ 325 Circuit Diagram for Quick Pinpoint Check.................................................... 325 Diagnostic Procedure 1 (Not self-diagnostic item)........................................... 326 Diagnostic Procedure 2 (Not self-diagnostic item)........................................... 327 Diagnostic Procedure 3 ..................................................................... 328 Diagnostic Procedure 4...................................................................... 329 Diagnostic Procedure 5...................................................................... 331 Diagnostic Procedure 6...................................................................... 333 Diagnostic Procedure 7...................................................................... 334 Diagnostic Procedure 8...................................................................... 334 Diagnostic Procedure 9...................................................................... 334 Electrical Components Inspection............................................................ 335 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................... 336 General Specifications...................................................................... 336 Inspection and Adjustment................................................................... 336 ec.................................................................................................. 337 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS............................................................................... 337 PRECAUTIONS..................................................................................... 339 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER.................. 339 Engine Fuel & Emission Control System....................................................... 340 PREPARATION..................................................................................... 341 ENGINE AND EMISSION CONTROL OVERALL SYSTEM...................................................... 342 ECCS Component Parts Location............................................................... 342 System Diagram.............................................................................. 344 System Chart................................................................................ 345 Vacuum Hose Drawing......................................................................... 346 Circuit Diagram............................................................................. 347 ENGINE AND EMISSION CONTROL PARTS DESCRIPTION................................................... 348 Engine Control Module (ECM)-ECCS Control Module............................................. 348 Camshaft Position Sensor (CMPS)............................................................. 348 Mass Air Flow Sensor (MAFS)................................................................. 348 Engine Coolant Temperature Sensor (ECTS).................................................... 349 Throttle Position Sensor (TPS) & Soft/Hard Closed Throttle Position (CTP) Switch............ 349 Fuel Injector............................................................................... 350 Fuel Pressure Regulator..................................................................... 350 Heated Oxygen Sensor (HO2S)................................................................. 350 Fuel Pump................................................................................... 350 Fuel Damper................................................................................. 351 Power Transistor Unit & Ignition Coil....................................................... 351 Idle Air Control Valve (IAVC)-Air Regulator................................................. 351 Idle Air Control Valve (IACV) Unit.......................................................... 352 Idle Air Control Valve (IACV)-Auxiliary Air Control (AAC) Valve............................. 352 Power Steering Oil Pressure Switch.......................................................... 352 Vehicle Speed Sensor (VSS).................................................................. 352 Knock Sensor (KS)........................................................................... 352 Exhaust Gas Recirculation (EGR) Valve....................................................... 353 EGR Control (EGRC)-Solenoid Valve........................................................... 353 Pressure Regulator Vacuum Relief (PRVR) Control Solenoid Valve.............................. 353 Fuel Filter................................................................................. 353 Data Link Connector For CONSULT............................................................. 353 EGR Temperature Sensor...................................................................... 354 Valve Timing Control Solenoid Valve......................................................... 354 Carbon Canister............................................................................. 354 Fuel Temperature Sensor..................................................................... 354 ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION.................................................. 355 Multiport Fuel Injection (MFI) System....................................................... 355 Electronic Ignition System (EI)............................................................. 357 Idle Air Control (IAC) System............................................................... 359 Fuel Pump Control........................................................................... 360 Exhaust Gas Recirculation (EGR) System...................................................... 361 Fuel Pressure Regulator Control............................................................. 361 Acceleration Cut Control.................................................................... 362 Valve Timing Control........................................................................ 362 Cooling Fan Control......................................................................... 364 Fail-safe System............................................................................ 365 Direct Ignition System...................................................................... 367 IDLE SPEED/IGNITION TIMING/IDLE MIXTURE RATIO INSPECTION........................................ 369 TROUBLE DIAGNOSES............................................................................... 376 Contents.................................................................................... 376 MULTIPORT FUEL INJECTION SYSTEM INSPECTION...................................................... 566 Releasing Fuel Pressure..................................................................... 566 Fuel Pressure Check......................................................................... 566 Injector Removal and Installation........................................................... 567 EVAPORATIVE EMISSION SYSTEM..................................................................... 568 Description................................................................................. 568 Inspection.................................................................................. 568 CRANKCASE EMISSION CONTROL SYSTEM............................................................... 570 Description................................................................................. 570 Inspection.................................................................................. 570 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................... 571 General Specifications...................................................................... 571 Inspection and Adjustment................................................................... 571 el.................................................................................................. 572 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS............................................................................... 572 PRECAUTIONS..................................................................................... 574 Supplemental Restraint System "AIR BAG" and "SEAT BELT PRE-TENSIONER"....................... 574 HARNESS CONNECTOR............................................................................... 575 Description................................................................................. 575 STANDARDIZED RELAY.............................................................................. 576 Description................................................................................. 576 POWER SUPPLY ROUTING............................................................................ 580 Wiring Diagram.............................................................................. 580 Fuse........................................................................................ 583 Fusible Link................................................................................ 583 HYBRID ELECTRIC CONTROL UNIT (HEC).............................................................. 584 Construction and Terminal Arrangement....................................................... 584 Internal Circuit............................................................................ 585 BATTERY......................................................................................... 586 How to Handle Battery....................................................................... 586 Battery Test and Charging Chart............................................................. 589 Service Data and Specifications (SDS)....................................................... 593 STARTING SYSTEM................................................................................. 594 Wiring Diagram.............................................................................. 594 Construction................................................................................ 595 Service Data and Specifications (SDS)....................................................... 595 CHARGING SYSTEM................................................................................. 596 Wiring Diagram.............................................................................. 596 Trouble-shooting............................................................................ 597 Construction................................................................................ 598 Diode Check................................................................................. 599 Assembly.................................................................................... 600 Service Data and Specifications (SDS)....................................................... 601 COMBINATION SWITCH.............................................................................. 602 Combination Switch/Check.................................................................... 602 Combination Switch/Replacement.............................................................. 603 Steering Switch/Check....................................................................... 604 HEADLAMP........................................................................................ 605 Wiring Diagram.............................................................................. 605 Operation (Daytime light system for Canada)................................................. 606 Schematic................................................................................... 606 Wiring Diagram.............................................................................. 607 Bulb Replacement............................................................................ 608 Aiming Adjustment........................................................................... 608 EXTERIOR LAMP................................................................................... 610 Clearance, License, Tail and Stop Lamps/Wiring Diagram...................................... 610 Back-up Lamp/Wiring Diagram................................................................. 611 Turn Signal and Hazard Warning Lamps/Wiring Diagram......................................... 612 Combination Flasher Unit Check.............................................................. 613 Bulb Specifications......................................................................... 613 INTERIOR LAMP................................................................................... 614 Illumination/Wiring Diagram................................................................. 614 Interior and Trunk Room Lamps/Wiring diagram................................................ 615 METERS AND GAUGES............................................................................... 616 Combination Meter........................................................................... 616 Speedometer, Tachometer, Temp. and Fuel Gauges/Wiring Diagram............................... 617 Inspection/Fuel Gauge and Water Temperature Gauge........................................... 618 Fuel Tank Gauge Unit Check.................................................................. 619 Fuel Warning Lamp Sensor Check.............................................................. 619 Thermal Transmitter Check................................................................... 619 Oil Pressure Switch Check................................................................... 619 Vehicle Speed Sensor Signal Check........................................................... 620 WARNING LAMPS AND CHIME......................................................................... 621 Warning Lamps/Schematic..................................................................... 621 Diode Check................................................................................. 622 Warning Lamps/Wiring Diagram................................................................ 623 TIME CONTROL SYSTEM............................................................................. 624 Description................................................................................. 624 Wiring Diagram.............................................................................. 625 Trouble Diagnoses........................................................................... 627 WIPER AND WASHER................................................................................ 640 Wiper and Washer/Wiring Diagram............................................................. 640 Installation................................................................................ 641 Washer Nozzle Adjustment.................................................................... 642 HORN, CIGARETTE LIGHTER, CLOCK.................................................................. 643 Wiring Diagram.............................................................................. 643 REAR WINDOW DEFOGGER............................................................................ 644 Wiring Diagram.............................................................................. 644 Filament Check.............................................................................. 645 Filament Repair............................................................................. 646 AUDIO AND POWER ANTENNA......................................................................... 647 Audio /Wiring Diagram....................................................................... 647 Power Antenna/Wiring Diagram................................................................ 648 Location of Antenna......................................................................... 649 Radio Fuse Check............................................................................ 649 Antenna Rod Replacement..................................................................... 650 Window Antenna Repair....................................................................... 651 TELEPHONE....................................................................................... 652 Telephone/Wiring Diagram.................................................................... 652 AUTOMATIC SPEED CONTROL DEVICE (ASCD)........................................................... 654 Component Parts and Harness Connector Location.............................................. 654 Wiring Diagram.............................................................................. 655 Trouble Diagnoses........................................................................... 657 ASCD Wire Adjustment........................................................................ 674 THEFT WARNING SYSTEM............................................................................ 676 Component Parts and Harness Connector Location.............................................. 676 Wiring Diagram.............................................................................. 677 Trouble Diagnoses........................................................................... 679 LOCATION OF ELECTRICAL UNITS.................................................................... 696 Engine Compartment.......................................................................... 696 Passenger Compartment....................................................................... 697 Luggage Compartment......................................................................... 698 HARNESS LAYOUT.................................................................................. 699 Outline..................................................................................... 699 Engine Room Harness......................................................................... 700 Main Harness................................................................................ 703 Body Harness and Tail Harness............................................................... 705 Engine Control Harness and Engine Harness................................................... 707 Room Lamp Harness........................................................................... 709 Air Bag Harness............................................................................. 710 Door Harness (LH side)...................................................................... 711 Door Harness (RH side)...................................................................... 712 SUPER MULTIPLE JUNCTION (SMJ)................................................................... 0 Terminal Arrangement........................................................................ 1 em.................................................................................................. 713 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS............................................................................... 713 PRECAUTIONS..................................................................................... 714 Supplemental Restraint System "AIR BAG" and "SEAT BELT PRE-TENSIONER"....................... 714 Parts Requiring Angular Tightening.......................................................... 714 Liquid Gasket Application Procedure......................................................... 715 PREPARATION..................................................................................... 716 OUTER COMPONENT PARTS........................................................................... 719 COMPRESSION PRESSURE............................................................................ 721 Measurement of Compression Pressure......................................................... 721 OIL PAN......................................................................................... 722 Removal..................................................................................... 722 Installation................................................................................ 724 TIMING BELT..................................................................................... 726 Removal..................................................................................... 727 Inspection.................................................................................. 729 Installation................................................................................ 730 OIL SEAL REPLACEMENT............................................................................ 734 THROTTLE BODIES................................................................................. 736 Precaution.................................................................................. 736 Installation................................................................................ 736 CYLINDER HEAD................................................................................... 738 Removal..................................................................................... 739 Disassembly................................................................................. 740 Inspection.................................................................................. 741 Assembly.................................................................................... 746 Installation................................................................................ 747 ENGINE REMOVAL.................................................................................. 749 CYLINDER BLOCK.................................................................................. 751 Disassembly................................................................................. 752 Inspection.................................................................................. 752 Assembly.................................................................................... 760 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................... 764 General Specifications...................................................................... 764 Inspection and Adjustment................................................................... 765 fa.................................................................................................. 771 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS............................................................................... 771 PRECAUTIONS AND PREPARATION..................................................................... 772 Precautions................................................................................. 772 Preparation................................................................................. 772 FRONT AXLE AND FRONT SUSPENSION................................................................. 774 ON-VEHICLE SERVICE.............................................................................. 775 Front Axle and Front Suspension Parts....................................................... 775 Front Wheel Bearing......................................................................... 776 Front Wheel Alignment....................................................................... 777 FRONT AXLE...................................................................................... 780 Removal..................................................................................... 780 Inspection.................................................................................. 781 Installation................................................................................ 781 FRONT SUSPENSION................................................................................ 784 FRONT SUSPENSION - Coil Spring and Strut Assembly............................................... 785 Removal and Installation.................................................................... 785 Disassembly................................................................................. 786 Inspection.................................................................................. 787 Assembly.................................................................................... 787 FRONT SUSPENSION - Tension Rod and Stabilizer Bar............................................... 790 Removal and Installation.................................................................... 790 FRONT SUSPENSION - Transverse Link Assembly..................................................... 791 Removal and Installation.................................................................... 791 Inspection.................................................................................. 791 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................... 792 General Specifications...................................................................... 792 Inspection and Adjustment................................................................... 792 fe.................................................................................................. 793 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS............................................................................... 793 ACCELERATOR CONTROL SYSTEM...................................................................... 794 Adjusting Accelerator Wire.................................................................. 794 FUEL SYSTEM..................................................................................... 795 Fuel Tank................................................................................... 795 Fuel Pump and Gauge......................................................................... 797 EXHAUST SYSTEM.................................................................................. 798 foldout............................................................................................. 799 QUICK REFERENCE INDEX........................................................................... 0 ELECTRICAL SYSTEM............................................................................... 1 SUPER MULTIPLE JUNCTION (SMJ)................................................................... 799 Terminal Arrangement........................................................................ 800 gi.................................................................................................. 811 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS............................................................................... 811 PRECAUTIONS..................................................................................... 812 Precautions for Supplemental Restraint System "AIR BAG"..................................... 812 General Precautions......................................................................... 812 Precautions for Multiport Fuel Injection System or ECCS Engine.............................. 814 Precautions for Three Way Catalyst.......................................................... 814 Engine Oils................................................................................. 814 Precautions for Fuel........................................................................ 815 HOW TO USE THIS MANUAL.......................................................................... 816 HOW TO READ WIRING DIAGRAMS..................................................................... 818 HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES................................................... 822 CONSULT CHECKING SYSTEM......................................................................... 825 System Application and Function............................................................. 825 Lithium Battery Replacement................................................................. 825 Checking Equipment.......................................................................... 826 IDENTIFICATION INFORMATION...................................................................... 827 Model Variation............................................................................. 827 Identification Number....................................................................... 828 Dimensions.................................................................................. 830 Wheels and Tires............................................................................ 830 LIFTING POINTS AND TOW TRUCK TOWING............................................................. 831 Garage Jack and Safety Stand................................................................ 831 2-pole Lift................................................................................. 832 Tow Truck Towing............................................................................ 832 TIGHTENING TORQUE OF STANDARD BOLTS............................................................. 834 SAE J1930 TERMINOLOGY LIST...................................................................... 835 ha.................................................................................................. 839 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS............................................................................... 839 PRECAUTIONS..................................................................................... 840 Supplemental Restraint System "AIR BAG" and "SEAT BELT PRE-TENSIONER"...................... 840 Precautions for Working with HFC0134a (R-134a).............................................. 841 General Refrigerant Precautions............................................................. 841 Precautions for Refrigerant Connection...................................................... 842 Precautions for Servicing Compressor........................................................ 843 DESCRIPTION - Overall System.................................................................... 844 Introduction................................................................................ 844 Features.................................................................................... 844 Control Operation........................................................................... 846 Component Layout............................................................................ 848 Air Flow.................................................................................... 849 DESCRIPTION - Refrigeration System.............................................................. 850 Refrigeration Cycle......................................................................... 850 V-6 Variable Displacement Compressor........................................................ 851 Cooling Fan Motor Operation System.......................................................... 855 PREPARATION..................................................................................... 856 HFC-134a (R-134a) Service Tools and Equipment............................................... 856 Precautions for Service Equipment........................................................... 858 SERVICE PROCEDURES.............................................................................. 860 HFC-134a (R-134a) Service Procedure......................................................... 860 Refrigeration Lines......................................................................... 862 Compressor Mounting......................................................................... 863 Belt Tension................................................................................ 863 Fast Idle Control Device (FICD)............................................................. 863 LUBRICATION OIL - Checking and Adjusting........................................................ 864 Lubrication Oil............................................................................. 864 Maintenance of Oil Quantity in Compressor................................................... 864 Checking and Adjusting...................................................................... 864 DIAGNOSES - Overall System...................................................................... 866 How to Perform Trouble Diagnoses for Quick and Accurate Repair.............................. 866 Operational Check........................................................................... 867 Performance Chart........................................................................... 870 Performance Test Diagnoses.................................................................. 871 TROUBLE DIAGNOSES............................................................................... 876 Table of Contents........................................................................... 876 SYSTEM DESCRIPTION.............................................................................. 945 Overview of Control System.................................................................. 945 Control System Input components............................................................. 945 Control System Automatic Amplifier (Auto amp.).............................................. 949 Control System Output Components............................................................ 951 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................... 966 General Specifications...................................................................... 966 Inspection and Adjustment................................................................... 966 idx................................................................................................. 967 QUICK REFERENCE INDEX........................................................................... 0 lc.................................................................................................. 973 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS............................................................................... 973 PREPARATION..................................................................................... 974 PRECAUTIONS..................................................................................... 975 Supplemental Restraint System "AIR BAG" and "SEAT BELT PRE-TENSIONER"....................... 975 Liquid Gasket Application Procedure......................................................... 975 ENGINE LUBRICATION SYSTEM....................................................................... 976 Lubrication Circuit......................................................................... 976 Oil Pressure Check.......................................................................... 977 Oil Pump.................................................................................... 977 ENGINE COOLING SYSTEM........................................................................... 980 Cooling Circuit............................................................................. 980 System Check................................................................................ 981 Water Pump.................................................................................. 981 Thermostat.................................................................................. 983 Cooling Fan (Crankshaft driven)............................................................. 984 Radiator.................................................................................... 985 Cooling Fan (Motor driven).................................................................. 985 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................... 986 Engine Lubrication System................................................................... 986 Engine Cooling System....................................................................... 986 ma.................................................................................................. 987 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS............................................................................... 987 PRECAUTIONS..................................................................................... 988 Supplemental Restraint System "AIR BAG" and "SEAT BELT PRE-TENSIONER"....................... 988 GENERAL MAINTENANCE............................................................................. 989 PERIODIC MAINTENANCE............................................................................ 991 Schedule 1.................................................................................. 992 Schedule 2.................................................................................. 993 RECOMMENDED FLUIDS AND LUBRICANTS............................................................... 994 Fluids and Lubricants....................................................................... 994 SAE Viscosity Number........................................................................ 994 ENGINE MAINTENANCE.............................................................................. 995 Checking Drive Belts........................................................................ 995 Changing Engine Coolant..................................................................... 996 Checking Fuel Lines......................................................................... 997 Changing Fuel Filter........................................................................ 998 Changing Air Cleaner Filter................................................................. 998 Changing Engine Oil......................................................................... 998 Changing Oil Filter......................................................................... 999 Changing Spark Plugs........................................................................1000 Checking Vapor Lines........................................................................1000 CHASSIS AND BODY MAINTENANCE....................................................................1001 Checking A/T Fluid..........................................................................1001 Changing A/T Fluid..........................................................................1001 Checking Differential Gear Oil..............................................................1002 Changing Differential Gear Oil..............................................................1002 Checking Brake Fluid Level and Leaks........................................................1002 Checking Brake Lines and Cables.............................................................1003 Checking Disc Brake.........................................................................1003 Balancing Wheels............................................................................1003 Tire Rotation...............................................................................1004 Checking Steering Gear and Linkage..........................................................1004 Checking Power Steering Fluid and Lines.....................................................1004 Checking SUPER HICAS Linkage (With SUPER HICAS system)......................................1005 Checking Exhaust System.....................................................................1005 Lubricating Locks, Hinges and Hood Latches..................................................1006 Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters.............................1006 SERVICE DATA AND SPECIFICATIONS (SDS)...........................................................1007 Engine Maintenance..........................................................................1007 Chassis and Body Maintenance................................................................1008 pd..................................................................................................1009 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS...............................................................................1009 PREPARATION.....................................................................................1010 PROPELLER SHAFT.................................................................................1013 On-vehicle Service..........................................................................1013 Removal.....................................................................................1013 Installation................................................................................1014 Inspection..................................................................................1015 Disassembly.................................................................................1015 Assembly....................................................................................1016 ON-VEHICLE SERVICE/REMOVAL AND INSTALLATION.....................................................1017 Front Oil Seal Replacement..................................................................1017 Side Oil Seal Replacement...................................................................1017 Removal.....................................................................................1018 Installation................................................................................1018 FINAL DRIVE.....................................................................................1019 DISASSEMBLY.....................................................................................1020 Pre-inspection..............................................................................1020 Differential Carrier........................................................................1020 Differential Case...........................................................................1022 INSPECTION......................................................................................1024 Contact Surfaces............................................................................1024 Bearing.....................................................................................1024 ADJUSTMENT......................................................................................1025 Differential Case...........................................................................1025 Side Bearing Preload........................................................................1026 Pinion Gear Height and Pinion Bearing Preload...............................................1027 Tooth Contact...............................................................................1032 ASSEMBLY........................................................................................1033 SERVICE DATA AND SPECIFICATIONS (SDS)...........................................................1037 Propeller Shaft.............................................................................1037 Final Drive.................................................................................1037 ra..................................................................................................1039 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS...............................................................................1039 PRECAUTIONS AND PREPARATION.....................................................................1040 Precautions.................................................................................1040 Preparation.................................................................................1040 REAR AXLE AND REAR SUSPENSION...................................................................1042 ON-VEHICLE SERVICE..............................................................................1043 Rear Axle and Rear Suspension Parts.........................................................1043 Rear Wheel Bearing..........................................................................1044 Rear Wheel Alignment........................................................................1044 Drive shaft.................................................................................1045 REAR AXLE.......................................................................................1046 Removal.....................................................................................1047 REAR AXLE - Wheel Hub and Axle Housing..........................................................1048 Installation................................................................................1048 Disassembly.................................................................................1048 Inspection..................................................................................1050 Assembly....................................................................................1050 REAR AXLE - Drive Shaft.........................................................................1053 Removal.....................................................................................1053 Installation................................................................................1053 Components..................................................................................1054 Disassembly.................................................................................1054 Inspection..................................................................................1055 Assembly....................................................................................1055 REAR SUSPENSION.................................................................................1058 Removal and Installation....................................................................1059 REAR SUSPENSION - Coil Spring and Shock Absorber................................................1060 Removal.....................................................................................1060 Disassembly.................................................................................1060 Inspection..................................................................................1060 Assembly....................................................................................1061 REAR SUSPENSION - Multi-link and Lower Ball Joint...............................................1062 Removal and Installation....................................................................1062 Inspection..................................................................................1063 REAR SUSPENSION - Stabilizer Bar................................................................1065 Removal.....................................................................................1065 Inspection..................................................................................1065 Installation................................................................................1065 SUPER HICAS.....................................................................................1066 Rear Wheel Alignment........................................................................1066 Rear Axle Housing Ball Joint................................................................1067 SERVICE DATA AND SPECIFICATIONS (SDS)...........................................................1068 General Specifications......................................................................1068 Inspection and Adjustment...................................................................1069 st..................................................................................................1070 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS...............................................................................1070 PRECAUTIONS AND PREPARATION.....................................................................1071 Supplemental Restraint System "AIR BAG" and "SEAT BELT PRE-TENSIONER".......................1071 Preparation.................................................................................1071 ON-VEHICLE SERVICE..............................................................................1074 Checking Steering Wheel Play................................................................1074 Checking Neutral Position on Steering Wheel.................................................1074 Front Wheel Turning Angle...................................................................1074 Checking Gear Housing Movement..............................................................1075 Adjusting Rack Retainer.....................................................................1075 Checking and Adjusting Drive Belts (For power steering).....................................1075 Checking Fluid Level........................................................................1075 Checking Fluid Leakage......................................................................1076 Bleeding Hydraulic System...................................................................1076 Checking Steering Wheel Turning Force (For power steering)..................................1077 Checking Hydraulic System...................................................................1077 STEERING WHEEL AND STEERING COLUMN..............................................................1079 Removal.....................................................................................1079 Installation................................................................................1080 Disassembly and Assembly....................................................................1081 Inspection..................................................................................1082 POWER STEERING GEAR AND LINKAGE.................................................................1083 Removal and Installation....................................................................1083 Disassembly.................................................................................1086 Inspection..................................................................................1086 Assembly....................................................................................1088 Adjustment..................................................................................1093 POWER STEERING OIL PUMP.........................................................................1095 Pre-disassembly Inspection..................................................................1095 Disassembly.................................................................................1095 Inspection..................................................................................1096 Assembly....................................................................................1096 TWIN ORIFICE POWER STEERING SYSTEM..............................................................1098 Hydraulic Circit............................................................................1098 Schematic...................................................................................1098 Wiring Diagram..............................................................................1099 TWIN ORIFICE POWER STEERING SYSTEM - Trouble Diagnoses..........................................1100 Precautions.................................................................................1100 Diagnostic Procedure 1......................................................................1101 Diagnostic Procedure 2......................................................................1108 Control Unit Inspection Table...............................................................1110 Performance of Controller...................................................................1110 SUPER HICAS SYSTEM..............................................................................1111 HICAS Component Parts Location..............................................................1111 System Diagram..............................................................................1111 SUPER HICAS SYSTEM - On-vehicle Service.........................................................1112 Checking Fluid Level........................................................................1112 Checking Fluid Leakage......................................................................1112 Measuring Rear Toe-in.......................................................................1112 Inspection of HICAS System Operation........................................................1113 Bleeding Hydrauli System....................................................................1115 SUPER HICAS SYSTEM - Repair of Component Parts..................................................1116 Power Cylinder..............................................................................1116 Oil Pump....................................................................................1121 HICAS Solenoid and Fail-safe Valve..........................................................1125 Steering Angle Sensor.......................................................................1125 Steering Wheel..............................................................................1126 SUPER HICAS SYSTEM - Trouble Diagnoses..........................................................1127 Contents....................................................................................1127 SERVICE DATA AND SPECIFICATIONS (SDS)...........................................................1160 General Specifications......................................................................1160 Inspection and Adjustment...................................................................1160
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