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1995 INFINITI J30 Y32 Series Service Manual PDF DOWNLOAD
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Description
1995 INFINITI J30 Y32 Series Service Manual PDF DOWNLOAD
FILE DETAILS:
1995 INFINITI J30 Y32 Series Service Manual PDF DOWNLOAD
Language : English
Pages : 1130
Downloadable : Yes
File Type : PDF
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DESCRIPTION:
1995 INFINITI J30 Y32 Series Service Manual PDF DOWNLOAD
FOREWORD
- This manual contains maintenance and repair procedures for the 1995 INFINITI J30.
- In order to assure your safety and the efficient functioning of the vehicle, this manual should be read thoroughly.
- II 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 al 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:
1995 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 RS - Restraint System................................................................... 0 BT - Body & Trim........................................................................ 0 HA - Heater & Air Conditoner............................................................ 0 EL - Electrical System.................................................................. 0 IDX - Alphabetical Index................................................................ 1 Foldout................................................................................. 1 Quick Reference Chart................................................................... 4 at.......................................................................................... 5 QUICK REFERENCE INDEX................................................................... 0 TABLE OF CONTENTS....................................................................... 5 PREPARATION AND PRECAUTIONS............................................................. 6 Special Service Tools............................................................... 6 Service Notice...................................................................... 7 Supplemental Restraint System (SRS) "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 A/T Electrical Parts Location....................................................... 36 Wiring Diagram...................................................................... 38 TROUBLE DIAGNOSES - A/T Shift Lock System............................................... 93 Contents............................................................................ 93 Shift Lock System Electrical Parts Location......................................... 95 Wiring Diagram...................................................................... 97 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 Location 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 br.......................................................................................... 191 QUICK REFERENCE INDEX................................................................... 0 TABLE OF CONTENTS....................................................................... 191 PRECAUTIONS AND PREPARATION............................................................. 193 Precautions......................................................................... 193 Commercial Service Tools............................................................ 193 CHECK AND ADJUSTMENT.................................................................... 194 Checking Brake Fluid Level.......................................................... 194 Checking Brake Line................................................................. 194 Changing Brake Fluid................................................................ 194 Bleeding Brake System............................................................... 194 BRAKE HYDRAULIC LINE.................................................................... 196 Removal............................................................................. 196 Inspection.......................................................................... 196 Installation........................................................................ 196 CONTROL VALVE........................................................................... 197 Proportioning Valve................................................................. 197 BRAKE PEDAL AND BRACKET................................................................. 198 Removal and Installation............................................................ 198 Inspection.......................................................................... 198 Adjsutment.......................................................................... 198 MASTER CYLINDER......................................................................... 200 Removal............................................................................. 200 Disassembly......................................................................... 200 Inspection.......................................................................... 201 Assembly............................................................................ 201 Installation........................................................................ 202 BRAKE BOOSTER....................................................................... 203 On-vehicle Service.............................................................. 203 Removal......................................................................... 203 Inspection...................................................................... 204 Installation.................................................................... 204 VACUUM HOSE............................................................................. 205 Removal and Installation............................................................ 205 Inspection.......................................................................... 205 FRONT DISC BRAKE........................................................................ 206 Pad Replacement..................................................................... 206 Removal............................................................................. 208 Disassembly......................................................................... 208 Inspection - Caliper................................................................ 208 Inspection - Rotor.................................................................. 209 Assembly............................................................................ 209 Installation........................................................................ 209 REAR DISC BRAKE......................................................................... 210 Pad Replacement..................................................................... 210 Removal............................................................................. 211 Disassembly......................................................................... 212 Inspection - Caliper................................................................ 212 Inspection - Rotor.................................................................. 212 Assembly............................................................................ 213 Installation........................................................................ 213 REAR DISC BRAKE - Parking Drum Brake.................................................... 214 Removal............................................................................. 214 Inspection - Drum................................................................... 215 Inspection - Lining................................................................. 215 Installation........................................................................ 216 Shoe Clearance Adjustment........................................................... 216 Breaking in Drum and Lining......................................................... 217 PARKING BRAKE CONTROL................................................................... 218 Removal and Installation............................................................ 218 Inspection.......................................................................... 219 Adjustment.......................................................................... 219 ANTI-LOCK BRAKE SYSTEM.................................................................. 220 Wiring Diagram...................................................................... 221 Removal and Installation............................................................ 222 TROUBLE DIAGNOSES....................................................................... 224 Contents............................................................................ 224 Component Parts and Harness Connector Location...................................... 229 SERVICE DATA AND SPECIFICATIONS (SDS)................................................... 247 General Specifications.............................................................. 247 Inspection and Adjustment........................................................... 247 bt.......................................................................................... 248 QUICK REFERENCE INDEX................................................................... 0 TABLE OF CONTENTS....................................................................... 248 GENERAL SERVICING....................................................................... 249 Precautions......................................................................... 249 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"......... 249 Clip and Fastener................................................................... 250 BODY END................................................................................ 252 Body Front End...................................................................... 252 Body Rear End and Opener............................................................ 254 DOOR.................................................................................... 256 Front Door.......................................................................... 256 Rear Door........................................................................... 257 INSTRUMENT PANEL........................................................................ 258 INTERIOR TRIM........................................................................... 260 Side and Floor Trim................................................................. 260 Door Trim........................................................................... 262 Roof Trim........................................................................... 263 Trunk Room Trim..................................................................... 265 EXTERIOR TRIM........................................................................... 266 SEAT.................................................................................... 271 Front Seat.......................................................................... 271 Rear Seat........................................................................... 274 SUN ROOF................................................................................ 275 WINDSHIELD AND WINDOWS.................................................................. 276 Windshield and Rear Window.......................................................... 276 MIRROR.................................................................................. 277 Door Mirror......................................................................... 277 REAR AIR SPOILER........................................................................ 278 BODY ALIGNMENT.......................................................................... 279 Engine Compartment.................................................................. 279 Underbody........................................................................... 281 ec.......................................................................................... 283 QUICK REFERENCE INDEX................................................................... 0 TABLE OF CONTENTS....................................................................... 283 PRECAUTIONS............................................................................. 285 Supplemental Restraint System "AIR BAG" and "SEAT BELT PRE-TENSIONER"............... 285 Engine Fuel & Emission Control System............................................... 286 PREPARATION............................................................................. 287 ENGINE AND EMISSION CONTROL OVERALL SYSTEM.............................................. 288 ECCS Component Parts Location....................................................... 288 System Diagram...................................................................... 290 System Chart........................................................................ 291 Vacuum Hose Drawing................................................................. 292 Circuit Diagram..................................................................... 293 ENGINE AND EMISSION CONTROL PARTS DESCRIPTION........................................... 294 Engine Control Module (ECM)-ECCS Control Module..................................... 294 Camshaft Position Sensor (CMPS)..................................................... 294 Mass Air Flow Sensor (MAFS)......................................................... 294 Engine Coolant Temperature Sensor (ECTS)............................................ 295 Throttle Position Sensor (TPS) & Soft/Hard Closed Throttle Position (CTP) Switch.... 295 Fuel Injector....................................................................... 296 Fuel Pressure Regulator............................................................. 296 Heated Oxygen Sensor (HO2S)......................................................... 296 Fuel Pump........................................................................... 296 Fuel Damper......................................................................... 297 Power Transistor Unit & Ignition Coil............................................... 297 Idle Air Control Valve (IACV)-Air Regulator......................................... 297 Idle Air Control Valve (IACV) Unit.................................................. 298 Idle Air Control Valve (IACV)-Auxiliary Air Control (AAC) Valve..................... 298 Power Steering Oil Pressure Switch.................................................. 298 Vehicle Speed Sensor (VSS).......................................................... 298 Knock Sensor (KS)................................................................... 298 Exhaust Gas Recirculation (EGR) Valve............................................... 299 EGR Control (EGRC)-Solenoid Valve................................................... 299 Fuel Filter......................................................................... 299 Data Link Connector for CONSULT..................................................... 299 EGR Temperature Sensor.............................................................. 299 Valve Timing Control Solenoid Valve................................................. 300 Activated Carbon Canister........................................................... 300 ENGINE AND EMISSION CONTROL SYTEM DESCRIPTION........................................... 301 Multiport Fuel Injection (MFI) System............................................... 301 Electronic Ignition System (EI)..................................................... 304 Idle Air Control (IAC) System....................................................... 306 Fuel Pump Control................................................................... 307 Exhaust Gas Recirculation (EGR) System.............................................. 308 Acceleration Cut Control............................................................ 308 Valve Timing Control................................................................ 309 Cooling Fan Control................................................................. 311 Fail-safe System.................................................................... 312 Direct Ignition System.............................................................. 314 IDLE SPEED/IGNITION TIMING/IDLE MIXTURE RATIO INSPECTION................................ 316 TROUBLE DIAGNOSES....................................................................... 323 Contents............................................................................ 323 MULTIPORT FUEL INJECTION SYSTEM INSPECTION.............................................. 505 Releasing Fuel Pressure............................................................. 505 Fuel Pressure Check................................................................. 505 Injector Removal and Installation................................................... 506 EVAPORATIVE EMISSION SYSTEM............................................................. 507 Description......................................................................... 507 Inspection.......................................................................... 507 CRANKCASE EMISSION CONTROL SYSTEM....................................................... 509 Description......................................................................... 509 Inspection.......................................................................... 509 SERVICE DATA AND SPECIFICATIONS (SDS)................................................... 510 General Specifications.............................................................. 510 Inspection and Adjustment........................................................... 510 el.......................................................................................... 511 QUICK REFERENCE INDEX................................................................... 0 TABLE OF CONTENTS....................................................................... 511 PRECAUTIONS............................................................................. 513 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"......... 513 HARNESS CONNECTOR....................................................................... 514 Description......................................................................... 514 STANDARDIZED RELAY...................................................................... 515 Description......................................................................... 515 POWER SUPPLY ROUTING.................................................................... 519 Wiring Diagram...................................................................... 519 Fuse................................................................................ 522 Fusible Link........................................................................ 522 HYBRID ELECTRIC CONTROL UNIT (HEC)...................................................... 523 Construction and Terminal Arrangement............................................... 523 Internal Circuit.................................................................... 524 BATTERY................................................................................. 525 How to Handle Battery............................................................... 525 Battery Test and Charging Chart..................................................... 528 Service Data and Specifications (SDS)............................................... 532 STARTING SYSTEM......................................................................... 533 Wiring Diagram...................................................................... 533 Construction........................................................................ 534 Service Data and Specifications (SDS)............................................... 534 CHARGING SYSTEM......................................................................... 535 Wiring Diagram...................................................................... 535 Trouble-shooting.................................................................... 536 Construction........................................................................ 537 Diode Check......................................................................... 539 Assembly............................................................................ 540 Service Data and Specifications (SDS)............................................... 541 COMBINATION SWITCH...................................................................... 542 Combination Switch/Check............................................................ 542 Combination Switch/Replacement...................................................... 543 Steering Switch/Check............................................................... 544 HEADLAMP................................................................................ 545 Wiring Diagram...................................................................... 545 Operation (Daytime light system for Canada)......................................... 546 Schematic........................................................................... 546 Wiring Diagram...................................................................... 547 Bulb Replacement.................................................................... 548 Aiming Adjustment................................................................... 548 EXTERIOR LAMP........................................................................... 550 Clearance, License, Tail and Stop Lamps/Wiring Diagram.............................. 550 Back-up Lamp/Wiring Diagram......................................................... 551 Turn Signal and Hazard Warning Lamps/Wiring Diagram................................. 552 Combination Flasher Unit Check...................................................... 553 Bulb Specifications................................................................. 553 INTERIOR LAMP........................................................................... 554 Illumination/Wiring Diagram......................................................... 554 Interior and Trunk Room Lamps/Wiring Diagram........................................ 555 METERS AND GAUGES....................................................................... 556 Combination Meter................................................................... 556 Speedometer, Tachometer, Temp. and Fuel Gauges/Wiring Diagram....................... 557 Inspection/Fuel Gauge and Water Temperature Gauge................................... 558 Fuel Tank Gauge Unit Check.......................................................... 559 Fuel Warning Lamp Sensor Check...................................................... 559 Thermal Transmitter Check........................................................... 559 Oil Pressure Switch Check........................................................... 559 Vehicle Speed Sensor Signal Check................................................... 560 WARNING LAMPS AND CHIME................................................................. 561 Warning Lamps/Schematic............................................................. 561 Diode Check......................................................................... 562 Warning Lamps/Wiring Diagram........................................................ 563 TIME CONTROL SYSTEM..................................................................... 564 Description......................................................................... 564 Wiring Diagram...................................................................... 566 Trouble Diagnoses................................................................... 568 WIPER AND WASHER........................................................................ 580 Wiper and Washer/Wiring Diagram..................................................... 580 Installation........................................................................ 581 Washer Nozzle Adjustment............................................................ 582 POWER WINDOW............................................................................ 584 Wiring Diagram...................................................................... 584 Trouble Diagnoses................................................................... 586 POWER DOOR LOCK......................................................................... 594 Wiring Diagram...................................................................... 594 Trouble Diagnoses................................................................... 596 POWER DOOR MIRROR....................................................................... 600 Wiring Diagram...................................................................... 600 INSIDE MIRROR........................................................................... 601 Auto Anti-dazzling Inside Mirror/Wiring Diagram..................................... 601 ELECTRIC SUN ROOF....................................................................... 602 Wiring Diagram...................................................................... 602 TRUNK LID AND FUEL FILLER LID OPENER.................................................... 603 Wiring Diagram...................................................................... 603 HORN, CIGARETTE LIGHTER, CLOCK.......................................................... 604 Wiring Diagram...................................................................... 604 REAR WINDOW DEFOGGER.................................................................... 605 Wiring Diagram...................................................................... 605 Filament Check...................................................................... 606 Filament Repair..................................................................... 607 AUDIO AND POWER ANTENNA................................................................. 608 Audio/Wiring Diagram................................................................ 608 Power Antenna/Wiring Diagram........................................................ 609 Location of Antenna................................................................. 610 Radio Fuse Check.................................................................... 610 Antenna Rod Replacement............................................................. 611 Window Antenna Repair............................................................... 612 TELEPHONE............................................................................... 613 Telephone/Wiring Diagram............................................................ 613 POWER SEAT.............................................................................. 614 Wiring Diagram...................................................................... 614 HEATED SEAT............................................................................. 616 Wiring Diagram...................................................................... 616 MULTI-REMOTE CONTROL SYSTEM............................................................. 618 Wiring Diagram...................................................................... 618 Circuit Diagram for Quick Pinpoint Check............................................ 620 Trouble Diagnoses Preliminary Inspection............................................ 621 Trouble Diagnoses................................................................... 622 Replacing Remote Controller or Control Unit......................................... 628 AUTOMATIC SPEED CONTROL DEVICE (ASCD)................................................... 629 Component Parts and Harness Connector Location...................................... 629 Wiring Diagram...................................................................... 630 Trouble Diagnoses................................................................... 632 ASCD Wire Adjustment................................................................ 649 THEFT WARNING SYSTEM.................................................................... 651 Component Parts and Harness Connector Location...................................... 651 Wiring Diagram...................................................................... 652 Trouble Diagnoses................................................................... 654 LOCATION OF ELECTRICAL PARTS............................................................ 672 Engine Compartment.................................................................. 672 Passenger Compartment............................................................... 673 Luggage Compartment................................................................. 674 HARNESS LAYOUT.......................................................................... 675 Outline............................................................................. 675 Engine Room Harness................................................................. 676 Room Lamp Harness................................................................... 679 Main Harness ....................................................................... 680 Body Harness and Tail Harness....................................................... 682 Engine Control Harness and Engine Harness........................................... 684 Air Bag Harness..................................................................... 686 Door Harness (LH side).............................................................. 687 Door Harness (RH side).............................................................. 688 SUPER MULTIPLE JUNCTION (SMJ)........................................................... 0 Terminal Arrangement................................................................ 1 em.......................................................................................... 689 QUICK REFERENCE INDEX................................................................... 0 TABLE OF CONTENTS....................................................................... 689 PRECAUTIONS............................................................................. 690 Parts Requiring Angular Tightening.................................................. 690 Liquid Gasket Application Procedure................................................. 690 PREPARATION............................................................................. 691 OUTER COMPONENT PARTS................................................................... 694 COMPRESSION PRESSURE.................................................................... 696 Measurement of Compression Pressure................................................. 696 OIL PAN................................................................................. 697 Removal............................................................................. 697 Installation........................................................................ 699 TIMING BELT............................................................................. 701 Removal............................................................................. 702 Inspection.......................................................................... 704 Installation........................................................................ 705 OIL SEAL REPLACEMENT.................................................................... 709 THROTTLE BODIES......................................................................... 711 Precaution.......................................................................... 711 Installation........................................................................ 711 CYLINDER HEAD........................................................................... 713 Removal............................................................................. 714 Disassembly......................................................................... 715 Inspection.......................................................................... 716 Assembly............................................................................ 721 Installation........................................................................ 722 ENGINE REMOVAL.......................................................................... 724 CYLINDER BLOCK.......................................................................... 726 Disassembly......................................................................... 727 Inspection.......................................................................... 727 Assembly............................................................................ 735 SERVICE DATA AND SPECIFICATIONS (SDS)................................................... 738 General Specifictions............................................................... 738 Inspection and Adjustment........................................................... 739 fa.......................................................................................... 745 QUICK REFERENCE INDEX................................................................... 0 TABLE OF CONTENTS....................................................................... 745 PRECAUTIONS AND PREPARATION............................................................. 746 Precautions......................................................................... 746 Preparation......................................................................... 746 FRONT AXLE AND FRONT SUSPENSION......................................................... 748 ON-VEHICLE SERVICE...................................................................... 749 Front Axle and Front Suspension Parts............................................... 749 Front Wheel Bearing................................................................. 750 Front Wheel Alignment............................................................... 751 FRONT AXLE.............................................................................. 754 Removal............................................................................. 754 Inspection.......................................................................... 755 Installation........................................................................ 755 FRONT SUSPENSION........................................................................ 758 FRONT SUSPENSION - Coil Spring and Strut Assembly....................................... 759 Removal and Installation............................................................ 759 Disassembly......................................................................... 760 Inspection.......................................................................... 761 Assembly............................................................................ 761 FRONT SUSPENSION - Tension Rod and Stabilizer Bar....................................... 764 Removal and Installation............................................................ 764 FRONT SUSPENSION - Transverse Link Assembly............................................. 765 Removal and Installation............................................................ 765 Inspection.......................................................................... 765 SERVICE DATA AND SPECIFICATIONS (SDS)................................................... 766 General Specifications.............................................................. 766 Inspection and Adjustment........................................................... 766 fe.......................................................................................... 767 QUICK REFERENCE INDEX................................................................... 0 TABLE OF CONTENTS....................................................................... 767 ACCELERATOR CONTROL SYSTEM.............................................................. 768 Adjusting Accelerator Wre........................................................... 768 FUEL SYSTEM............................................................................. 769 Fuel Tank........................................................................... 769 Fuel Pump and Gauge................................................................. 771 EXHAUST SYSTEM.......................................................................... 772 foldout..................................................................................... 773 QUICK REFERENCE INDEX................................................................... 0 ELECTRICAL SYSTEM....................................................................... 1 SUPER MULTIPLE JUNCTION (SMJ)........................................................... 773 Terminal Arrangement................................................................ 774 gi.......................................................................................... 786 QUICK REFERENCE INDEX................................................................... 0 TABLE OF CONTENTS....................................................................... 786 PRECAUTIONS............................................................................. 787 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"......... 787 General Precautions................................................................. 787 Precautions for Multiport Fuel Injection System or ECCS Engine...................... 789 Precautions for Three Way Catalyst.................................................. 789 Engine Oils......................................................................... 789 Precautions for Fuel................................................................ 790 HOW TO USE THIS MANUAL.................................................................. 791 HOW TO READ WIRING DIAGRAMS............................................................. 793 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT........................... 797 Work Flow........................................................................... 797 Incident Simulation Tests........................................................... 798 Circuit Inspection.................................................................. 802 HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES........................................... 808 CONSULT CHECKING SYSTEM................................................................. 811 System Application and Function..................................................... 811 Lithium Battery Replacement......................................................... 811 Checking Equipment.................................................................. 811 IDENTIFICATION INFORMATION.............................................................. 812 Model Variation..................................................................... 812 Identification Number............................................................... 813 Dimensions.......................................................................... 815 Wheels and Tires.................................................................... 815 LIFTING POINTS AND TOW TRUCK TOWING..................................................... 816 Preparation......................................................................... 816 Board-on Lift....................................................................... 816 Garage Jack and Safety Stand........................................................ 817 2-pole Lift......................................................................... 818 Tow Truck Towing.................................................................... 818 TIGHTENING TORQUE OF STANDARD BOLTS..................................................... 820 SAE J1930 TERMINOLOGY LIST.............................................................. 821 ha.......................................................................................... 825 QUICK REFERENCE INDEX................................................................... 0 TABLE OF CONTENTS....................................................................... 825 PRECAUTIONS AND PREPARATION............................................................. 826 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"......... 826 Precautions for Working with HFC-134a (R134a)....................................... 827 General Refrigerant Precautions..................................................... 827 Precautions for Refrigerant Connection.............................................. 828 Precautions for Servicing Compressor................................................ 829 Special Service Tools............................................................... 829 HFC-134a (R-134a) Service Tools and Equipment....................................... 830 Precautions for Service Equipment................................................... 832 DESCRIPTION............................................................................. 834 Refrigeration Cycle................................................................. 834 V-6 Variable Displacement Compressor................................................ 835 Component Layout.................................................................... 839 Discharge Air Flow.................................................................. 840 Introduction........................................................................ 841 Features............................................................................ 841 Control Operation................................................................... 842 TROUBLE DIAGNOSES....................................................................... 845 Contents............................................................................ 845 Wiring Diagram...................................................................... 894 SYSTEM DESCRIPTION...................................................................... 924 Overview of Control System.......................................................... 924 Control System Input Components..................................................... 924 Control System Automatic Amplifier (Auto amp.)...................................... 928 Control System Output Components.................................................... 930 SERVICE PROCEDURES...................................................................... 945 HFC-134a (R-134a) Service Procedure................................................. 945 Maintenance of Oil Quantity In Compressor........................................... 947 Refrigerant Lines................................................................... 949 Compressor Mounting................................................................. 950 Belt Tenstion....................................................................... 950 Fast Idle Control Device (FICD)..................................................... 950 Compressor - Model V-6 (CALSONIC make).............................................. 951 Compressor Clutch................................................................... 951 SERVICE DATA AND SPECIFICATIONS (SDS)................................................... 954 General Specifications.............................................................. 954 Inspection and Adjustment........................................................... 954 idx......................................................................................... 955 QUICK REFERENCE INDEX................................................................... 3 lc.......................................................................................... 962 QUICK REFERENCE INDEX................................................................... 0 TABLE OF CONTENTS....................................................................... 962 PREPARATION............................................................................. 963 PRECAUTIONS............................................................................. 964 Liquid Gasket Application Procedure................................................. 964 ENGINE LUBRICATION SYSTEM............................................................... 965 Lubrication Circuit................................................................. 965 Oil Pressure Check.................................................................. 966 Oil Pump............................................................................ 966 ENGINE COOLING SYSTEM................................................................... 969 Cooling Circuit..................................................................... 969 System Check........................................................................ 970 Water Pump.......................................................................... 970 Thermostat.......................................................................... 972 Cooling Fan (Crankshaft driven)..................................................... 973 Radiator............................................................................ 974 Cooling Fan (Motor driven).......................................................... 974 SERVICE DATA AND SPECIFICATIONS (SDS)................................................... 975 Engine Lubrication System........................................................... 975 Engine Cooling System............................................................... 975 ma.......................................................................................... 976 QUICK REFERENCE INDEX................................................................... 0 TABLE OF CONTENTS....................................................................... 976 PRECAUTIONS............................................................................. 977 Supplemental Restraing System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"......... 977 GENERAL MAINTENANCE..................................................................... 978 PERIODIC MAINTENANCE.................................................................... 980 Schedule 1.......................................................................... 981 Schedule 2.......................................................................... 982 RECOMMENDED FLUIDS AND LUBRICANTS....................................................... 983 Fluids and Lubricants............................................................... 983 SAE Viscosity Number................................................................ 983 Anti-freeze Coolant Mixture Ratio................................................... 984 ENGINE MAINTENANCE...................................................................... 985 Checking Drive Belts................................................................ 985 Changing Engine Coolant............................................................. 986 Checking Fuel Lines................................................................. 987 Changing Fuel Filter................................................................ 988 Changing Air Cleaner Filter......................................................... 988 Changing Engine Oil................................................................. 988 Changing Oil Filter................................................................. 989 Changing Spark Plugs................................................................ 990 Checking Vapor Lines................................................................ 990 CHASSIS AND BODY MAINTENANCE............................................................ 991 Checking A/T Fluid.................................................................. 991 Changing A/T Fluid.................................................................. 991 Checking Differential Gear Oil...................................................... 992 Changing Differential Gear Oil...................................................... 992 Checking Brake Fluid Level and Leaks................................................ 992 Checking Brake Likes and Cables..................................................... 993 Checking Disc Brake................................................................. 993 Balancing Wheels.................................................................... 993 Tire Rotation....................................................................... 994 Checking Steering Gear and Linkage.................................................. 994 Checking Power Steering Fluid and Lines............................................. 994 Checking Exhaust System............................................................. 994 Lubricating Locks, Hinges and Hood Latches.......................................... 995 Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters..................... 995 SERVICE DATA AND SPECIFICATIONS (SDS)................................................... 996 Engine Maintenance.................................................................. 996 Chassis and Body Maintenance........................................................ 996 pd.......................................................................................... 997 QUICK REFERENCE INDEX................................................................... 0 TABLE OF CONTENTS....................................................................... 997 PREPARATION............................................................................. 998 PROPELLER SHAFT.........................................................................1001 On-vehicle Service..................................................................1001 Removal.............................................................................1001 Installation........................................................................1002 Inspection..........................................................................1003 Disassembly.........................................................................1003 Assembly............................................................................1004 ON-VEHICLE SERVICE/REMOVAL AND INSTALLATION.............................................1005 Front Oil Seal Replacement..........................................................1005 Side Oil Seal Replacement...........................................................1005 Removal.............................................................................1006 Installation........................................................................1006 FINAL DRIVE.............................................................................1007 DISASSEMBLY.............................................................................1008 Pre-inspection......................................................................1008 Differential Carrier................................................................1008 Differential Case...................................................................1010 INSPECTION..............................................................................1012 Contact Surfaces....................................................................1012 Bearing.............................................................................1012 ADJUSTMENT..............................................................................1013 Differential Case...................................................................1013 Side Bearing Preload................................................................1014 Pinion Gear Height and Pinion Bearing Preload.......................................1015 Tooth Contact.......................................................................1020 ASSEMBLY................................................................................1021 SERVICE DATA AND SPECIFICATIONS (SDS)...................................................1025 Propeller Shaft.....................................................................1025 Final Drive.........................................................................1025 ra..........................................................................................1027 QUICK REFERENCE INDEX................................................................... 0 TABLE OF CONTENTS.......................................................................1027 PRECAUTIONS AND PREPARATION.............................................................1028 Precautions.........................................................................1028 Preparation.........................................................................1028 REAR AXLE AND REAR SUSPENSION...........................................................1030 ON-VEHICLE SERVICE......................................................................1031 Rear Axle and Rear Suspension Parts.................................................1031 Rear Whel Bearing...................................................................1032 Rear Wheel Alignment................................................................1032 Drive Shaft.........................................................................1033 REAR AXLE...............................................................................1034 Removal.............................................................................1035 REAR AXLE - Wheel Hub and Axle Housing..................................................1036 Installation........................................................................1036 Disassembly.........................................................................1036 Inspection..........................................................................1038 Assembly............................................................................1038 REAR AXLE - Drive Shaft.................................................................1041 Removal.............................................................................1041 Installation........................................................................1041 Components..........................................................................1042 Disassembly.........................................................................1042 Inspection..........................................................................1043 Assembly............................................................................1044 REAR SUSPENSION.........................................................................1047 Removal and Installation............................................................1048 REAR SUSPENSION - Coil Sprint and Shock Absorber........................................1049 Removal.............................................................................1049 Disassembly.........................................................................1049 Inspection..........................................................................1049 Assembly............................................................................1050 REAR SUSPENSION - Multi-link and Lower Ball Joint.......................................1051 Removal and Installation............................................................1051 Inspection..........................................................................1052 REAR SUSPENSION - Stabilizer Bar........................................................1054 Removal.............................................................................1054 Inspection..........................................................................1054 Installation........................................................................1054 SERVICE DATA AND SPECIFICATIONS (SDS)...................................................1055 General Specifications..............................................................1055 Inspection and Adjustment...........................................................1056 rs..........................................................................................1057 QUICK REFERENCE INDEX................................................................... 0 TABLE OF CONTENTS.......................................................................1057 PRECAUTION..............................................................................1058 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER".........1058 SEAT BELTS..............................................................................1059 Front Seat Belt.....................................................................1059 Rear Seat Belt......................................................................1060 SUPPLEMENTAL RESTRAINT SYSTEM (SRS).....................................................1061 Precautions for SRS "Air Bag" and "Seat Belt Pre-tensioner" Service.................1061 Special Service Tools...............................................................1061 Description.........................................................................1062 SRS Component Parts Location........................................................1062 Maintenance Items...................................................................1063 Removal and Installation - Diagnosis Sensor Unit and Seat Belt Pre-tensioner........1064 Removal - Air Bag Module and Spiral Cable...........................................1065 Removal - Front Passenger Air Bag Module............................................1066 Installation - Air Bag Module and Spiral Cable......................................1067 Installation - Front Passenger Air Bag Module.......................................1068 Disposal of Air Bag Module and Seat Belt Pre-tensioner..............................1069 TROUBLE DIAGNOSES - Supplemental Restraint System (SRS).................................1074 Wiring Diagram......................................................................1074 Schematic...........................................................................1075 Self-diagnosis......................................................................1076 Trouble Diagnoses for Air Bag.......................................................1083 Trouble Diagnosis for Seat Belt Pre-tensioner.......................................1085 Collision Diagnosis.................................................................1087 st..........................................................................................1088 QUICK REFERENCE INDEX................................................................... 0 TABLE OF CONTENTS.......................................................................1088 PRECAUTIONS AND PREPARATION.............................................................1089 Supplemental Restraing System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER".........1089 Preparation.........................................................................1089 ON-VEHICLE SERVICE......................................................................1092 Checking Steering Wheel Play........................................................1092 Checking Neutral Position on Steering Wheel.........................................1092 Front Wheel Turning Angle...........................................................1092 Checking Gear Housing Movement......................................................1093 Adjusting Rack Retainer.............................................................1093 Checking and Adjusting Drive Belts (For power steering).............................1093 Checking Fluid Level................................................................1093 Checking Fluid Leakage..............................................................1094 Bleeding Hydraulic System...........................................................1094 Checking Steering Wheel Turning Force (For power steering)..........................1095 Checking Hydraulic System...........................................................1095 STEERING WHEEL AND STEERING COLUMN......................................................1097 Removal.............................................................................1097 Installation........................................................................1098 Disassembly and Assembly............................................................1099 Inspection..........................................................................1100 POWER STEERING GEAR AND LINKAGE.........................................................1101 Removal and Installation............................................................1101 Disassembly.........................................................................1104 Inspection..........................................................................1104 Assembly............................................................................1106 Adjustment..........................................................................1111 POWER STEERING OIL PUMP.................................................................1113 Pre-disassembly Inspection..........................................................1113 Disassembly.........................................................................1113 Inspection..........................................................................1114 Assembly............................................................................1114 TWIN ORIFICE POWER STEERING SYSTEM......................................................1116 Hydraulic Circuit...................................................................1116 Schematic...........................................................................1116 Wiring Diagram......................................................................1117 TWIN ORIFICE POWER STEERING SYSTEM - Trouble Diagnoses..................................1118 Precautions.........................................................................1118 Diagnostic Procedure 1..............................................................1119 Diagnostic Procedure 2..............................................................1126 Control Unit Inspection Table.......................................................1128 Performance of Controller...........................................................1128 SERVICE DATA AND SPECIFICATIONS (SDS)...................................................1129 General Specifications..............................................................1129 Inspection and Adjustment...........................................................1129
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