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1997 NISSAN TRUCK D21 Series Service Manual PDF DOWNLOAD
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Description
1997 NISSAN TRUCK D21 Series Service Manual PDF DOWNLOAD
FILE DETAILS:
1997 NISSAN TRUCK D21 Series Service Manual PDF DOWNLOAD
Language : English
Pages : 2472
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
1997 NISSAN TRUCK D21 Series Service Manual PDF DOWNLOAD
fwd..................................................................................................... 1 QUICK REFERENCE INDEX............................................................................... 1 FOREWORD............................................................................................ 2 GI - General Information............................................................................ 0 MA - Maintenance.................................................................................... 0 EM - Engine Mechanical.............................................................................. 0 LC - Engine Lubrication & Cooling Systems........................................................... 0 EC - Engine Control System.......................................................................... 0 FE - Accelerator Control, Fuel & Exhaust Systems.................................................... 0 CL - Clutch......................................................................................... 0 MT - Manual Transmission............................................................................ 0 AT - Automatic Transmission......................................................................... 0 TF - Transfer....................................................................................... 0 PD - Propeller Shaft & Differential Carrier......................................................... 0 FA - Front Axle & Front Suspension.................................................................. 0 RA - Rear Axle & Rear Suspension.................................................................... 0 BR - Brake System................................................................................... 0 ST - Steering System................................................................................ 0 RS - Restraint System............................................................................... 0 BT - Body Trim...................................................................................... 0 HA - Heater & Air Conditioner....................................................................... 0 EL - Electrical System.............................................................................. 0 IDX - Alphabetical Index............................................................................ 1 FOLD OUT............................................................................................ 0 COMMENT SHEET....................................................................................... 3 QUICK REFERENCE CHART............................................................................... 4 GST Mode 6 - Test Value & Test Limit Chart.......................................................... 5 at...................................................................................................... 6 QUICK REFERENCE INDEX............................................................................... 0 TABLE OF CONTENTS................................................................................... 6 PREPARATION AND PRECAUTIONS......................................................................... 8 Special Service Tools........................................................................... 8 Precautions For Supplemental Restraint System (SRS) "AIR BAG"................................... 10 Precautions..................................................................................... 10 OVERALL SYSTEM...................................................................................... 11 Circuit Diagram................................................................................. 11 Wiring Diagram ................................................................................. 12 Cross-Sectional View............................................................................ 14 Hydraulic Control Circuits...................................................................... 15 Shift Mechanism................................................................................. 16 TROUBLE DIAGNOSIS - Basic Inspection................................................................ 18 Remarks......................................................................................... 18 A/T Fluid Check................................................................................. 18 Road Test....................................................................................... 18 Shift Schedule.................................................................................. 20 TROUBLE DIAGNOSIS - General Description............................................................. 22 Symptom Chart................................................................................... 22 TROUBLE DIAGNOSIS FOR DTC P1550..................................................................... 26 Torque Converter Clutch Solenoid Valve.......................................................... 26 TROUBLE DIAGNOSES................................................................................... 28 Component Inspection............................................................................ 28 Final Check..................................................................................... 31 TROUBLE DIAGNOSES - A/T Shift Lock System........................................................... 36 Description..................................................................................... 36 Shift Lock System Electrical Parts Location..................................................... 36 Wiring Diagram.................................................................................. 37 Diagnostic Procedure............................................................................ 38 Key Interlock Cable............................................................................. 40 Component Check................................................................................. 41 ON-VEHICLE SERVICE.................................................................................. 43 Control Valve Assembly and Accumulators Inspection.............................................. 43 Rear Oil Seal Replacement....................................................................... 43 Parking Components Inspection................................................................... 44 Governor Valve.................................................................................. 44 Throttle Wire Adjustment........................................................................ 44 Inhibitor Switch Adjustment..................................................................... 45 Manual Control Linkage Adjustment............................................................... 45 REMOVAL AND INSTALLATION............................................................................ 46 Removal......................................................................................... 46 Installation.................................................................................... 47 MAJOR OVERHAUL...................................................................................... 48 Oil Channel..................................................................................... 50 Locations of Needle Bearings, Thrust Washers and Snap Rings..................................... 51 DISASSEMBLY......................................................................................... 52 Disassembly..................................................................................... 52 REPAIR FOR COMPONENT PARTS.......................................................................... 63 Oil Pump........................................................................................ 63 Control Valve Assembly.......................................................................... 67 Control Valve Upper Body........................................................................ 72 Control Valve Lower Body........................................................................ 76 Governor Valve Assembly......................................................................... 78 Parking Gear.................................................................................... 78 Reverse Clutch.................................................................................. 79 High Clutch..................................................................................... 83 Forward and Overrun Clutches.................................................................... 85 Low & Reverse Brake............................................................................. 89 Forward Clutch Drum Assembly.................................................................... 92 Rear Internal Gear and Forward Clutch Hub....................................................... 94 Band Servo Piston Assembly...................................................................... 96 Parking Pawl Components......................................................................... 100 ASSEMBLY............................................................................................ 102 Assembly (1).................................................................................... 102 Adjustment...................................................................................... 110 Assembly (2).................................................................................... 112 SERVICE DATA AND SPECIFICATIONS (SDS)............................................................... 119 General Specifications.......................................................................... 119 Specifications and Adjustment................................................................... 119 Vehicle Speed When Shifting Gears........................................................... 119 Vehicle Speed When Performing and Releasing Lock-Up......................................... 119 Stall Revolution............................................................................ 119 Line Pressure............................................................................... 119 Return Spring............................................................................... 120 Accumulator O-Ring.......................................................................... 120 Clutches And Brakes......................................................................... 121 Oil Pump And Low One-Way Clutch............................................................. 122 Total End Play.............................................................................. 122 Parking Gear................................................................................ 122 Reverse Clutch Drum End Play................................................................ 122 Removal and Installation.................................................................... 122 br...................................................................................................... 123 QUICK REFERENCE INDEX............................................................................... 0 TABLE OF CONTENTS................................................................................... 123 PRECAUTIONS AND PREPARATION......................................................................... 124 Supplemental Restraint System (SRS) "AIR BAG"................................................... 124 Commercial Service Tools........................................................................ 125 CHECK ADJUSTMENT.................................................................................... 126 Checking Brake Fluid Level...................................................................... 126 Checking Brake Line............................................................................. 126 Changing Brake Fluid............................................................................ 126 AIR BLEEDING........................................................................................ 127 Bleeding Procedure.............................................................................. 127 BRAKE HYDRAULIC LINE................................................................................ 128 CONTROL VALVE....................................................................................... 130 Proportioning Valve (4WD)....................................................................... 130 Load Sensing Valve (2WD)........................................................................ 131 BRAKE PEDAL AND BRACKET............................................................................. 133 Adjustment...................................................................................... 134 MASTER CYLINDER..................................................................................... 135 BRAKE BOOSTER....................................................................................... 138 On-vehicle Service.............................................................................. 138 VACUUM HOSE......................................................................................... 140 FRONT DISC BRAKE.................................................................................... 141 Pad Replacement................................................................................. 141 REAR DRUM BRAKE..................................................................................... 146 PARKING BRAKE CONTROL............................................................................... 150 Adjustment...................................................................................... 151 REAR WHEEL ANTI-LOCK BRAKE SYSTEM................................................................... 152 Purpose......................................................................................... 152 Operation....................................................................................... 152 System Description.............................................................................. 152 System Components............................................................................... 153 Hydraulic Circuit............................................................................... 153 Removal and Installation........................................................................ 154 TROUBLE DIAGNOSIS................................................................................... 155 How to Perform Trouble Diagnoses for Quick and Accurate Repair.................................. 155 Symptom Chart................................................................................... 156 Preliminary Check 1............................................................................. 157 Self-diagnosis.................................................................................. 158 Component Parts and Harness Connector Location.................................................. 159 Circuit Diagram................................................................................. 160 Wiring Diagram - ABS -.......................................................................... 161 Diagnostic Procedures........................................................................... 163 Electrical Components Inspection................................................................ 171 SERVICE DATA AND SPECIFICATIONS (SDS)............................................................... 172 General Specifications.......................................................................... 172 Inspection and Adjustment....................................................................... 173 bt...................................................................................................... 174 QUICK REFERENCE INDEX............................................................................... 0 TABLE OF CONTENTS................................................................................... 174 PRECAUTIONS......................................................................................... 175 Supplemental Restraint System (SRS) "AIR BAG"................................................... 175 GENERAL SERVICING................................................................................... 176 Clip and Fastener............................................................................... 176 BODY END............................................................................................ 179 Front End....................................................................................... 179 Rear End........................................................................................ 180 Step Bumper..................................................................................... 181 DOOR................................................................................................ 182 Front Door...................................................................................... 182 INSTRUMENT PANEL.................................................................................... 183 INTERIOR TRIM....................................................................................... 186 Side and Floor Trim - Passenger room............................................................ 186 Roof Trim....................................................................................... 188 EXTERIOR............................................................................................ 190 SEAT................................................................................................ 196 Front Seat...................................................................................... 196 Jump Seat - King Cab Model...................................................................... 197 SUNROOF............................................................................................. 198 Service Procedure............................................................................... 198 WINDSHIELD AND WINDOWS.............................................................................. 199 Windshield...................................................................................... 200 Back Window..................................................................................... 201 Rear Side Window................................................................................ 202 MIRROR.............................................................................................. 203 Door Mirror..................................................................................... 203 Rearview Mirror................................................................................. 204 CAB AND REAR BODY................................................................................... 205 Removal......................................................................................... 205 Cab Body.................................................................................... 205 Rear Body................................................................................... 205 Body Mounting................................................................................... 206 BODY ALIGNMENT...................................................................................... 207 Engine Compartment.............................................................................. 208 Underbody....................................................................................... 209 cl...................................................................................................... 216 QUICK REFERENCE INDEX............................................................................... 0 TABLE OF CONTENTS................................................................................... 216 PRECAUTIONS AND PREPARATION......................................................................... 217 Precautions..................................................................................... 217 Special Service Tools........................................................................... 217 Commercial Service Tools........................................................................ 217 CLUTCH SYSTEM....................................................................................... 218 Clutch Pedal.................................................................................... 219 INSPECTION AND ADJUSTMENT........................................................................... 220 Adjusting Clutch Pedal.......................................................................... 220 Bleeding Procedure.............................................................................. 221 HYDRAULIC CLUTCH CONTROL............................................................................ 222 Clutch Master Cylinder.......................................................................... 222 Operating Cylinder.............................................................................. 223 Clutch Damper................................................................................... 224 CLUTCH RELEASE MECHANISM............................................................................ 225 CLUTCH DISC AND CLUTCH COVER........................................................................ 227 Clutch Disc..................................................................................... 227 Clutch Cover and Flywheel....................................................................... 228 SERVICE DATA AND SPECIFICATIONS (SDS)............................................................... 229 General Specifications.......................................................................... 229 Inspection and Adjustment....................................................................... 229 d21_truck_1997.......................................................................................... 230 Forward.pdf......................................................................................... 230 QUICK REFERENCE INDEX........................................................................... 230 FOREWORD........................................................................................ 231 GI - General Information........................................................................ 0 MA - Maintenance................................................................................ 0 EM - Engine Mechanical.......................................................................... 0 LC - Engine Lubrication & Cooling Systems....................................................... 0 EC - Engine Control System...................................................................... 0 FE - Accelerator Control, Fuel & Exhaust Systems................................................ 0 CL - Clutch..................................................................................... 0 MT - Manual Transmission........................................................................ 0 AT - Automatic Transmission..................................................................... 0 TF - Transfer................................................................................... 0 PD - Propeller Shaft & Differential Carrier..................................................... 0 FA - Front Axle & Front Suspension.............................................................. 0 RA - Rear Axle & Rear Suspension................................................................ 0 BR - Brake System............................................................................... 0 ST - Steering System............................................................................ 0 RS - Restraint System........................................................................... 0 BT - Body Trim.................................................................................. 0 HA - Heater & Air Conditioner................................................................... 0 EL - Electrical System.......................................................................... 0 IDX - Alphabetical Index........................................................................ 1 FOLD OUT........................................................................................ 0 COMMENT SHEET................................................................................... 232 QUICK REFERENCE CHART........................................................................... 233 GST Mode 6 - Test Value & Test Limit Chart...................................................... 234 MA - Maintenance.pdf................................................................................ 235 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS............................................................................... 235 PRECAUTIONS AND PREPARATION..................................................................... 236 Supplemental Restraint System (SRS) "AIR BAG"............................................... 236 Special Service Tool........................................................................ 236 GENERAL MAINTENANCE............................................................................. 237 PERIODIC MAINTENANCE............................................................................ 239 Schecule 1.................................................................................. 240 Schedule 2.................................................................................. 241 RECOMMENDED FLUIDS AND LUBRICANTS............................................................... 242 Fluids and Lubricants....................................................................... 242 SAE Viscosity Number........................................................................ 243 Antifreeze Coolant Mixture Ratio............................................................ 243 ENGINE MAINTENANCE.............................................................................. 244 Checking Drive Belts........................................................................ 244 Changing Engine Coolant..................................................................... 245 Checking Fuel Lines......................................................................... 246 Changing Fuel Filter........................................................................ 246 Changing Air Cleaner Filter................................................................. 246 Changing Engine Oil......................................................................... 247 Changing Oil Filter......................................................................... 247 Changing Spark Plugs........................................................................ 248 Checking EVAP Vapor Purge Lines............................................................. 249 Changing Positive Crankcase Ventillation (PCV) Filter....................................... 249 CHASSIS AND BODY MAINTENANCE.................................................................... 250 Checking Exhaust System..................................................................... 250 Checking Clutch Fluid Level and Leaks....................................................... 250 Checking M/T Oil............................................................................ 250 Changing M/T Oil............................................................................ 250 Checking Water Entry - For 4WD models....................................................... 250 Checking A/T Fluid.......................................................................... 250 Changint A/T Fluid.......................................................................... 251 Checking Transfer Fluid..................................................................... 251 Changing Transfer Fluid..................................................................... 252 Checking Propeller Shaft.................................................................... 252 Checking Differential Gear Oil.............................................................. 252 Changing Differential Gear Oil.............................................................. 253 Balancing Wheels............................................................................ 253 Tire Roataion............................................................................... 253 Checking Brake Fluid Level and Leaks........................................................ 254 Checking Brake System....................................................................... 254 Checking Disc Brake......................................................................... 254 Checking Drum Brake......................................................................... 254 Checking Steering Gear and Linkage.......................................................... 255 Checking Power Steering Fluid and Lines..................................................... 255 Checking Steering Gear Oil Level and Leaks.................................................. 255 Lubricating Hood Latches, Locks and Hinges.................................................. 256 Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters............................. 257 SERVICE DATA AND SPECIFICATIONS (SDS............................................................ 258 Engine Maintenance.......................................................................... 258 Chassis and Body Maintenance................................................................ 258 EM - Engine Mechanical.pdf.......................................................................... 259 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS............................................................................... 259 PRECAUTIONS..................................................................................... 260 Supplemental Restraint System (SRS) "AIR BAG"............................................... 260 Parts Requiring Angular Tightening.......................................................... 260 Liquid Gasket Application Procedure......................................................... 260 PREPARATION..................................................................................... 261 Special Service Tools....................................................................... 261 Commercial Service Tools.................................................................... 263 OUTER COMPONENT PARTS........................................................................... 264 COMPRESSION PRESSURE............................................................................ 265 Measurement of Compression Pressure......................................................... 265 OIL PAN......................................................................................... 266 Removal..................................................................................... 266 Installation................................................................................ 266 TIMING CHAIN.................................................................................... 268 Removal..................................................................................... 268 Inspection.................................................................................. 269 Installation................................................................................ 270 OIL SEAL REPLACEMENT............................................................................ 272 Valve Oil Seal.............................................................................. 272 Front Oil Seal.............................................................................. 272 Rear Oil Seal............................................................................... 273 CYLINDER HEAD................................................................................... 274 Removal..................................................................................... 275 Disassembly................................................................................. 277 Inspection.................................................................................. 277 Assembly.................................................................................... 283 Installation................................................................................ 284 ENGINE REMOVAL.................................................................................. 287 Removal..................................................................................... 288 Installation................................................................................ 289 CYLINDER BLOCK.................................................................................. 290 Disassembly................................................................................. 291 Inspection.................................................................................. 291 Assembly.................................................................................... 297 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................... 300 General Specifications...................................................................... 300 Inspection and Adjusement................................................................... 300 GI - General Information.pdf........................................................................ 307 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS............................................................................... 307 PRECAUTIONS..................................................................................... 308 Precautions for Supplemental Restraint System (SRS) "AIR BAG"............................... 308 General Precautions......................................................................... 309 Precautions for Engine Oils................................................................. 311 Precautions for Multiport Fuel Injection System or ECCS Engine.............................. 312 Precautions for Three Way Catalyst.......................................................... 312 Precautions for Fuel........................................................................ 312 Precautions for Air Conditioning............................................................ 312 HOW TO USE THIS MANUAL.......................................................................... 313 HOW TO READ WIRING DIAGRAMS..................................................................... 315 Sample/Wiring Diagram - EXAMPL -............................................................ 315 Description................................................................................. 317 Connector Symbols....................................................................... 319 Switch Positions........................................................................ 320 Detectable Lines And Non-Detectable Lines............................................... 321 Multiple Switch......................................................................... 321 Foldout Page............................................................................ 322 Wiring Diagram Codes (Cell Codes)........................................................... 323 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT................................... 324 Work Flow................................................................................... 324 Incident Simulation Tests................................................................... 325 Circuit Inspection.......................................................................... 329 Introduction............................................................................ 329 Testing for "Opens" In The Circuit...................................................... 330 Testing for "Shorts" In The Circuit..................................................... 331 Ground Inspection....................................................................... 332 Voltage Drop Tests...................................................................... 333 HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES................................................... 336 CONSULT CHECKING SYSTEM......................................................................... 339 IDENTIFICATION INFORMATION...................................................................... 340 Model Variation............................................................................. 340 Identification Number....................................................................... 342 Dimensions.................................................................................. 344 Wheels & Tires.............................................................................. 344 LIFTING POINTS AND TWO TRUCK TOWING............................................................. 345 Pantograph Jack............................................................................. 345 Screw Jack.................................................................................. 345 Garage Jack and Safety Stand................................................................ 346 2-pole Lift................................................................................. 347 Tow Truck Towing............................................................................ 348 Towing Point................................................................................ 349 TIGHTENING TORQUE OF STANDARD BOLTS............................................................. 350 SAE J1930 TERMINOLOGY LIST...................................................................... 351 LC - Engine Lubrication & Cooling Systems.pdf....................................................... 355 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS............................................................................... 355 PRECAUTIONS AND PREPARATION..................................................................... 356 Supplemental Restraint System (SRS) "AIR BAG".............................................. 356 Liquid Gasket Application Procedure......................................................... 356 Special Service Tools....................................................................... 357 ENGINE LUBRICATION SYSTEM....................................................................... 358 Lubrication Circuit......................................................................... 358 Oil Pressure Check.......................................................................... 359 Oil Pump.................................................................................... 359 ENGINE COOLING SYSTEM........................................................................... 361 Cooling Circuit............................................................................. 361 System Check................................................................................ 361 Water Pump.................................................................................. 362 Thermostat.................................................................................. 363 Radiator.................................................................................... 365 Cooling Fan................................................................................. 366 Overheating Cause Analysis.................................................................. 367 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................... 368 Engine Lubrication System................................................................... 368 Engine Cooling System....................................................................... 368 EC - Engine Control System.pdf...................................................................... 369 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS............................................................................... 369 DIAGNOSTIC TROUBLE CODE INDEX................................................................... 371 Alphabetical & P No. Index for DTC.......................................................... 371 PRECAUTIONS AND PREPARATION..................................................................... 373 ENGINE AND EMISSION CONTROL OVERALL SYSTEM...................................................... 378 Circuit Diagram............................................................................. 378 System Diagram.............................................................................. 379 ECCS Component Parts Location............................................................... 380 Vacuum Hose Drawing......................................................................... 382 System Chart................................................................................ 383 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION............................................ 384 Multiport Fuel Injection (MFI) System....................................................... 384 Distributor Ignition (DI) System............................................................ 386 Air Conditioning Cut Control................................................................ 387 Fuel Cut control (at no load & high engine speed............................................ 388 EVAPORATIVE EMISSION SYSTEM..................................................................... 389 Description................................................................................. 389 Inspection.................................................................................. 389 Evaporative Emission Line Drawing........................................................... 391 POSITIVE CRANKCASE VENTILATION.................................................................. 393 Description................................................................................. 393 Inspection.................................................................................. 393 BASIC SERVICE PROCEDURE......................................................................... 394 Fuel Pressure Release....................................................................... 394 Fuel Pressure Check......................................................................... 394 Injector Removal and Installation........................................................... 395 Fast Idle Cam (FIC) Inspection and Adjustment............................................... 396 Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment.................................... 397 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION.......................................................... 403 Introduction................................................................................ 403 Two Trip Detection Logic.................................................................... 403 Emission-related Diagnostic Information..................................................... 404 Malfunction Indicator Lamp (MIL)............................................................ 414 OBD System Operation Chart.................................................................. 417 CONSULT..................................................................................... 422 Generic Scan Tool (GST)..................................................................... 435 TROUBLE DIAGNOSIS – Introduction................................................................ 437 Introduction................................................................................ 437 Diagnostic Worksheet........................................................................ 437 TROUBLE DIAGNOSIS - Work Flow................................................................... 439 Work Flow................................................................................... 439 Description for Work Flow................................................................... 440 TROUBLE DIAGNOSIS - Basic Inspection............................................................ 441 Basic Inspection............................................................................ 441 TROUBLE DIAGNOSIS - General Description......................................................... 444 Diagnostic Trouble Code (DTC) Inspection Priority Chart..................................... 444 Fail-Safe Chart............................................................................. 445 Symptom Matrix Chart........................................................................ 446 CONSULT Reference Value in Data Monitor Mode................................................ 448 Major Sensor Reference Graph in Data Monitor Mode........................................... 450 ECM Terminals and Reference Value........................................................... 452 TROUBLE DIAGNOSIS FOR POWER SUPPLY.............................................................. 458 Main Power Supply and Ground Circuit........................................................ 458 DTC P0100, Mass Air Flow Sensor (MAFS).......................................................... 462 DTC P0105, Absolute Pressure Sensor............................................................. 469 DTC P0110, Intake Air Temperature Sensor........................................................ 476 DTC P0115, Engine Coolant Temperature Sensor (ECTS)............................................. 482 DTC P0120, Throttle Position Sensor............................................................. 487 DTC P0125, Engine Coolant Temperature (ECT) Sensor.............................................. 493 DTC P0130, Front Heated Oxygen Sensor (Front HO2S).............................................. 498 DTC P0130, Closed Loop Control.................................................................. 503 DTC P0135, Front Heated Oxygen Sensor Heater.................................................... 504 DTC P0136, Rear Heated Oxygen Sensor (Rear (HO2S)............................................... 508 DTC P0141, Rear Heated Oxygen Sensor Heater..................................................... 512 DTC P0171, Fuel Injection System Function (Lean side)........................................... 517 DTC P0172, Fuel Injection system Function (Rich side)........................................... 522 DTC P0180, Tank Fuel Temperature Sensor......................................................... 527 DTC P0300 - P0304, No. 4 - 1 Cylinder Misfire, Multiple Cylinder Misfire........................ 531 DTC P0335, Crankshaft Position Sensor (CKPS) (OBD).............................................. 535 DTC P0340, Camshaft Position Sensor (CMPS)...................................................... 540 DTC P0400, EGR Function......................................................................... 545 DTC P0402, EGRC-BPT Valve Function.............................................................. 553 DTC P0420, Three Way Catalyst Function.......................................................... 555 DTC P0440, Evaporative Emission (EVAP) Control System (Small Leak).............................. 558 DTC P0443, Evaporative Emission (EVAP) Canister Purge Control Valve/Solenoid Valve.............. 568 DTC P0446, Evaporative Emission (EVAP) Canister Vent Control Valve.............................. 576 DTC P0450, Evaporative Emission (EVAP) Control System Pressure Sensor........................... 581 DTC P0500, Vehicle Speed Sensor (VSS)........................................................... 586 DTC P0505, Idle Air Control Valve (IACV) - Auxiliary Air Control (AAC) Valve.................... 590 DTC P0510, Closed Throttle Position Switch...................................................... 595 DTC P0605, Engine Control Module (ECM)-ECCS Control Module...................................... 599 DTC P0705, Park/Neutral Position Switch......................................................... 601 DTC P1105, Manifold Absolute Pressure (MAP)/Barometric Pressure (BARO) Switch Solenoid Valve.... 606 DTC P1130, Swirl Control Valve Control Solenoid Valve........................................... 612 DTC P1165, Swirl Control Valve Vacuum Check Switch.............................................. 620 DTC P1320, Ignition Signal...................................................................... 625 DTC P1336, Crankshaft Position Sensor (CKPS) (OBD) (COG)........................................ 631 DTC P1400, EGRC-Solenoid Valve.................................................................. 636 DTC P1401, EGR Temperature Sensor............................................................... 640 DTC P1441, Vacuum Cut Valve Bypass Valve........................................................ 645 DTC P1445, Evaporative Emission (EVAP) Canister Purge Volume Control Valve...................... 650 DTC P1447, Evaporative Emission (EVAP) Control System Purge Flow Monitoring..................... 657 DTC P1550, Torque Converter Clutch Solenoid Valve............................................... 664 DTC P1900, Overheat............................................................................. 669 TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS...................................................... 672 Injector.................................................................................... 672 Start Signal................................................................................ 675 Fuel Pump................................................................................... 678 Power Steering Oil Pressure Switch.......................................................... 682 IACV-FICD Solenoid Valve.................................................................... 686 MIL & Data Link Connectors.................................................................. 690 SERVICE DATA AND SPECIFICATIONS................................................................. 692 General Specfications....................................................................... 692 Inspection and Adjustment................................................................... 692 FE - Accelerator Control, Fuel & Exhaust Systems.pdf................................................ 694 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS............................................................................... 694 ACCELERATOR CONTROL SYSTEM...................................................................... 695 Adjusting Accelerator Wire.................................................................. 695 FUEL SYSTEM..................................................................................... 696 Fuel Tank................................................................................... 696 Fuel Pump and Gauge......................................................................... 699 EXHAUST SYSTEM.................................................................................. 700 CL - Clutch.pdf..................................................................................... 702 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS............................................................................... 702 PRECAUTIONS AND PREPARATION..................................................................... 703 Precautions................................................................................. 703 Special Service Tools....................................................................... 703 Commercial Service Tools.................................................................... 703 CLUTCH SYSTEM................................................................................... 704 Clutch Pedal................................................................................ 705 INSPECTION AND ADJUSTMENT....................................................................... 706 Adjusting Clutch Pedal...................................................................... 706 Bleeding Procedure.......................................................................... 707 HYDRAULIC CLUTCH CONTROL........................................................................ 708 Clutch Master Cylinder...................................................................... 708 Operating Cylinder.......................................................................... 709 Clutch Damper............................................................................... 710 CLUTCH RELEASE MECHANISM........................................................................ 711 CLUTCH DISC AND CLUTCH COVER.................................................................... 713 Clutch Disc................................................................................. 713 Clutch Cover and Flywheel................................................................... 714 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................... 715 General Specifications...................................................................... 715 Inspection and Adjustment................................................................... 715 MT - Manual Transmission.pdf........................................................................ 716 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS............................................................................... 716 PREPARATION..................................................................................... 717 Special Service Tools....................................................................... 717 Commercial Service Tools.................................................................... 718 ON-VEHICLE SERVICE.............................................................................. 719 Replacing Rear Oil Seal - 2WD Model......................................................... 719 Position Switch Check....................................................................... 719 REMOVAL AND INSTALLATION........................................................................ 720 MAJOR OVERHAUL.................................................................................. 722 Case Components............................................................................. 722 Gear Components - 2WD Model................................................................. 723 Gear Components - 4WD Model................................................................. 724 Shift Control Components.................................................................... 725 DISASSEMBLY..................................................................................... 726 Case Components............................................................................. 726 Shift Control Components.................................................................... 726 Gear Components............................................................................. 727 INSPECTION...................................................................................... 730 Shift Control Components.................................................................... 730 Gear Components............................................................................. 730 Gears and Shafts........................................................................ 730 Synchronizers........................................................................... 730 Bearings................................................................................ 731 ASSEMBLY........................................................................................ 732 Gear Components............................................................................. 732 Shift Control Components.................................................................... 738 Case Components............................................................................. 739 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................... 742 General Specifications...................................................................... 742 Inspection and Adjustment................................................................... 743 AT - Automatic Transmission.pdf..................................................................... 745 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS............................................................................... 745 PREPARATION AND PRECAUTIONS..................................................................... 747 Special Service Tools....................................................................... 747 Precautions For Supplemental Restraint System (SRS) "AIR BAG"............................... 749 Precautions................................................................................. 749 OVERALL SYSTEM.................................................................................. 750 Circuit Diagram............................................................................. 750 Wiring Diagram ............................................................................. 751 Cross-Sectional View........................................................................ 753 Hydraulic Control Circuits.................................................................. 754 Shift Mechanism............................................................................. 755 TROUBLE DIAGNOSIS - Basic Inspection............................................................ 757 Remarks..................................................................................... 757 A/T Fluid Check............................................................................. 757 Road Test................................................................................... 757 Shift Schedule.............................................................................. 759 TROUBLE DIAGNOSIS - General Description......................................................... 761 Symptom Chart............................................................................... 761 TROUBLE DIAGNOSIS FOR DTC P1550................................................................. 765 Torque Converter Clutch Solenoid Valve...................................................... 765 TROUBLE DIAGNOSES............................................................................... 767 Component Inspection........................................................................ 767 Final Check................................................................................. 770 TROUBLE DIAGNOSES - A/T Shift Lock System....................................................... 775 Description................................................................................. 775 Shift Lock System Electrical Parts Location................................................. 775 Wiring Diagram.............................................................................. 776 Diagnostic Procedure........................................................................ 777 Key Interlock Cable......................................................................... 779 Component Check............................................................................. 780 ON-VEHICLE SERVICE.............................................................................. 782 Control Valve Assembly and Accumulators Inspection.......................................... 782 Rear Oil Seal Replacement................................................................... 782 Parking Components Inspection............................................................... 783 Governor Valve.............................................................................. 783 Throttle Wire Adjustment.................................................................... 783 Inhibitor Switch Adjustment................................................................. 784 Manual Control Linkage Adjustment........................................................... 784 REMOVAL AND INSTALLATION........................................................................ 785 Removal..................................................................................... 785 Installation................................................................................ 786 MAJOR OVERHAUL.................................................................................. 787 Oil Channel................................................................................. 789 Locations of Needle Bearings, Thrust Washers and Snap Rings................................. 790 DISASSEMBLY..................................................................................... 791 Disassembly................................................................................. 791 REPAIR FOR COMPONENT PARTS...................................................................... 802 Oil Pump.................................................................................... 802 Control Valve Assembly...................................................................... 806 Control Valve Upper Body.................................................................... 811 Control Valve Lower Body.................................................................... 815 Governor Valve Assembly..................................................................... 817 Parking Gear................................................................................ 817 Reverse Clutch.............................................................................. 818 High Clutch................................................................................. 822 Forward and Overrun Clutches................................................................ 824 Low & Reverse Brake......................................................................... 828 Forward Clutch Drum Assembly................................................................ 831 Rear Internal Gear and Forward Clutch Hub................................................... 833 Band Servo Piston Assembly.................................................................. 835 Parking Pawl Components..................................................................... 839 ASSEMBLY........................................................................................ 841 Assembly (1)................................................................................ 841 Adjustment.................................................................................. 849 Assembly (2)................................................................................ 851 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................... 858 General Specifications...................................................................... 858 Specifications and Adjustment............................................................... 858 Vehicle Speed When Shifting Gears....................................................... 858 Vehicle Speed When Performing and Releasing Lock-Up..................................... 858 Stall Revolution........................................................................ 858 Line Pressure........................................................................... 858 Return Spring........................................................................... 859 Accumulator O-Ring...................................................................... 859 Clutches And Brakes..................................................................... 860 Oil Pump And Low One-Way Clutch......................................................... 861 Total End Play.......................................................................... 861 Parking Gear............................................................................ 861 Reverse Clutch Drum End Play............................................................ 861 Removal and Installation................................................................ 861 TF - Transfer.pdf................................................................................... 862 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS............................................................................... 862 PREPARATION..................................................................................... 863 Special Service Tools....................................................................... 863 Commercial Service Tools.................................................................... 864 Replacing Oil Seal.......................................................................... 865 Center Case Oil Seal.................................................................... 865 Shift Shaft Oil Seal.................................................................... 865 Rear Oil Seal........................................................................... 866 REMOVAL AND INSTALLATION........................................................................ 867 TRANSFER GEAR CONTROL........................................................................... 867 MAJOR OVERHAUL.................................................................................. 869 Case Components............................................................................. 869 Gear Components............................................................................. 870 Shift Control Components.................................................................... 871 DISASSEMBLY..................................................................................... 872 REPAIR AND COMPONENT PARTS...................................................................... 876 Mainshaft................................................................................... 876 Front Drive Shaft........................................................................... 878 Counter Gear................................................................................ 879 Main Gear................................................................................... 879 Front Case.................................................................................. 881 Shift Shaft Oil Seal.................................................................... 881 Front Case Cover............................................................................ 881 Cover Oil Seal.......................................................................... 881 Bearing Retainer............................................................................ 882 Oil Catcher............................................................................. 882 Rear Case................................................................................... 882 Rear Oil Seal........................................................................... 882 Air Breather............................................................................ 882 Shift Control Components.................................................................... 883 ASSEMBLY........................................................................................ 884 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................... 891 General Specifications...................................................................... 891 Inspection and Adjustment................................................................... 891 PD - Propeller Shaft & Differential Carrier.pdf..................................................... 892 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS............................................................................... 892 PREPARATION..................................................................................... 894 Special Service Tools....................................................................... 894 Propeller Shaft................................................................................. 899 PROPELLER SHAFT............................................................................. 899 On-vehicle Service...................................................................... 901 Removal and Installation................................................................ 901 Inspection.............................................................................. 901 Disassembly............................................................................. 902 Assembly................................................................................ 903 Final Drive..................................................................................... 905 ON-VEHICLE SERVICE.......................................................................... 905 Front Oil Seal Replacement (Front final drive).......................................... 905 Front Oil Seal Replacement (Rear final drive: Model H233B).............................. 905 Rear Cover Gasket Replacement (Rear final drive: Model C200)............................ 906 REMOVAL AND INSTALLATION (Front final drive)................................................ 907 REMOVAL AND INSTALLATION (Rear final drive)................................................. 908 R180A........................................................................................... 909 FRONT FINAL DRIVE........................................................................... 909 DISASSEMBLY................................................................................. 910 Pre-inspection.......................................................................... 910 Final Drive Housing..................................................................... 910 Differential Case....................................................................... 912 Extension Tube and Differential Side Shaft.............................................. 913 INSPECTION.................................................................................. 915 Ring Gear and Drive Pinion.............................................................. 915 Differential Case Assembly.............................................................. 915 Bearing................................................................................. 915 ADJUSTMENT.................................................................................. 916 Side Bearing Preload.................................................................... 916 Pinion Gear Height and Pinion Bearing Preload........................................... 917 Tooth Contact........................................................................... 921 ASSEMBLY.................................................................................... 922 Extension Tube and Differential Side Shaft.............................................. 922 Differential Case....................................................................... 922 Final Drive Housing..................................................................... 923 H190A........................................................................................... 927 REAR FINAL DRIVE............................................................................ 927 DISASSEMBLY................................................................................. 928 Pre-inspection.......................................................................... 928 Differential Carrier.................................................................... 928 Differential Case....................................................................... 930 INSPECTION.................................................................................. 932 Rear Gear and Drive Pinion.............................................................. 932 Differential Case Assembly.............................................................. 932 Bearing................................................................................. 932 LIMITED SLIP DIFFERENTIAL................................................................... 933 Preparation for Disassembly............................................................. 933 Disassembly............................................................................. 934 Inspection.............................................................................. 934 Assembly................................................................................ 935 ADJUSTMENT.................................................................................. 938 Side Bearing Preload.................................................................... 938 Pinion Gear Height...................................................................... 939 Tooth Contact........................................................................... 943 ASSEMBLY.................................................................................... 944 Differential Case....................................................................... 944 Differential Carrier.................................................................... 945 C200............................................................................................ 949 REAR FINAL DRIVE............................................................................ 949 DISASSEMBLY................................................................................. 950 Pre-Inspection.......................................................................... 950 Differenital Carrier.................................................................... 950 Differential Case....................................................................... 952 INSPECTION.................................................................................. 954 Ring Gear and Drive Pinion.............................................................. 954 Differential Case Assembly.............................................................. 954 Bearing................................................................................. 954 LIMITED SLIP DIFFERENTIAL................................................................... 955 Preparation and Disassembly............................................................. 955 Disassembly............................................................................. 955 Inspection.............................................................................. 956 Adjustment.............................................................................. 957 Assembly................................................................................ 959 ADJUSTMENT.................................................................................. 961 Side Bearing Preload.................................................................... 961 Pinion Gear Height...................................................................... 962 Tooth Contact........................................................................... 966 ASSEMBLY.................................................................................... 967 Differential Case....................................................................... 967 Differential Carrier.................................................................... 968 H233B........................................................................................... 972 REAR FINAL DRIVE............................................................................ 972 DISASSEMBLY................................................................................. 973 Pre-inspection.......................................................................... 973 Differential Carrier.................................................................... 973 Differential Case....................................................................... 975 INSPECTION.................................................................................. 977 Ring Gear and Drive Pinion.............................................................. 977 Differential Case Assembly.............................................................. 977 Bearing................................................................................. 977 LIMITED SLIP DIFFERENTIAL................................................................... 978 Preparation and Disassembly............................................................. 978 Disassembly............................................................................. 978 Inspection.............................................................................. 979 Adjustment.............................................................................. 980 Assembly................................................................................ 981 ADJUSTMENT.................................................................................. 984 Pinion Gear Height...................................................................... 984 Tooth Contact........................................................................... 987 ASSEMBLY.................................................................................... 988 Differential Case....................................................................... 988 Differential Carrier.................................................................... 989 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................... 992 Propeller Shaft............................................................................. 992 Final Drive................................................................................. 994 General Specifications.................................................................. 994 Inspection and Adjustment (R180A)....................................................... 995 Inspection and Adjustment (H190A)....................................................... 996 Inspection and Adjustment (C200)........................................................ 997 Inspection and Adjustment (H233B)....................................................... 998 FA - Front Axle & Front Suspension.pdf..............................................................1000 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS...............................................................................1000 PRECAUTIONS AND PREPARATION.....................................................................1001 Precautions.................................................................................1001 Special Service Tools.......................................................................1001 Commercial Service Tools....................................................................1001 FRONT AXLE AND FRONT SUSPENSION.................................................................1002 ON-VEHICLE SERVICE..............................................................................1004 Front Axle and Front Suspension Parts.......................................................1004 Front Wheel Bearing.........................................................................1005 Preload Adjustment (2WD)................................................................1005 Preload Adjustment (4WD)................................................................1006 Front Wheel Alignment.......................................................................1007 Preliminary Inspection..................................................................1007 Camber, Caster and Kingpin Inclication..................................................1008 Adjustment..............................................................................1008 Toe-In..................................................................................1011 Front Wheel Turning Angle...............................................................1012 Drive Shaft.................................................................................1013 FRONT AXLE......................................................................................1014 FRONT AXLE (4WD)................................................................................1016 Manual-lock Free-running Hub................................................................1016 Auto-lock Free-running Hub..................................................................1017 FRONT AXLE......................................................................................1023 Wheel Hub and Rotor Disc....................................................................1023 Knuckle Spindle.............................................................................1024 FRONT AXLE (4WD)................................................................................1027 Drive Shaft.................................................................................1027 FRONT SUSPENSION................................................................................1033 Shock Absorber..............................................................................1035 Torsion Bar Spring..........................................................................1035 Stabilizer Bar..............................................................................1038 Upper Link..................................................................................1039 Tension Rod or Compression Rod..............................................................1041 Lower Link..................................................................................1042 Upper Ball Joint and Lower Ball Joint.......................................................1043 SERVICE DATA AND SPECIFICATIONS.................................................................1044 General Specifications......................................................................1044 Inspection and Adjustment...................................................................1045 RA - Rear Axle & Rear Suspension.pdf................................................................1048 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS...............................................................................1048 PRECAUTIONS AND PREPARATION.....................................................................1049 Precautions.................................................................................1049 Special Service Tools.......................................................................1049 Commercial Service Tools....................................................................1049 REAR AXLE AND REAR SUSPENSION...................................................................1050 ON-VEHICLE SERVICE..............................................................................1051 Rear Axle and Rear Suspension Parts.........................................................1051 Rear Wheel Bearing..........................................................................1051 REAR AXLE.......................................................................................1052 Components..................................................................................1052 Removal.....................................................................................1052 Inspection..................................................................................1054 Installation................................................................................1054 REAR SUSPENSION.................................................................................1056 Shock Absorber..............................................................................1057 Leaf Spring.................................................................................1057 SERVICE DATA AND SPECIFICATIONS (SDS)...........................................................1059 General Specifications......................................................................1059 Inspection and Adjustment...................................................................1059 BR - Brake System.pdf...............................................................................1060 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS...............................................................................1060 PRECAUTIONS AND PREPARATION.....................................................................1061 Supplemental Restraint System (SRS) "AIR BAG"...............................................1061 Commercial Service Tools....................................................................1062 CHECK ADJUSTMENT................................................................................1063 Checking Brake Fluid Level..................................................................1063 Checking Brake Line.........................................................................1063 Changing Brake Fluid........................................................................1063 AIR BLEEDING....................................................................................1064 Bleeding Procedure..........................................................................1064 BRAKE HYDRAULIC LINE............................................................................1065 CONTROL VALVE...................................................................................1067 Proportioning Valve (4WD)...................................................................1067 Load Sensing Valve (2WD)....................................................................1068 BRAKE PEDAL AND BRACKET.........................................................................1070 Adjustment..................................................................................1071 MASTER CYLINDER.................................................................................1072 BRAKE BOOSTER...................................................................................1075 On-vehicle Service..........................................................................1075 VACUUM HOSE.....................................................................................1077 FRONT DISC BRAKE................................................................................1078 Pad Replacement.............................................................................1078 REAR DRUM BRAKE.................................................................................1083 PARKING BRAKE CONTROL...........................................................................1087 Adjustment..................................................................................1088 REAR WHEEL ANTI-LOCK BRAKE SYSTEM...............................................................1089 Purpose.....................................................................................1089 Operation...................................................................................1089 System Description..........................................................................1089 System Components...........................................................................1090 Hydraulic Circuit...........................................................................1090 Removal and Installation....................................................................1091 TROUBLE DIAGNOSIS...............................................................................1092 How to Perform Trouble Diagnoses for Quick and Accurate Repair..............................1092 Symptom Chart...............................................................................1093 Preliminary Check 1.........................................................................1094 Self-diagnosis..............................................................................1095 Component Parts and Harness Connector Location..............................................1096 Circuit Diagram.............................................................................1097 Wiring Diagram - ABS -......................................................................1098 Diagnostic Procedures.......................................................................1100 Electrical Components Inspection............................................................1108 SERVICE DATA AND SPECIFICATIONS (SDS)...........................................................1109 General Specifications......................................................................1109 Inspection and Adjustment...................................................................1110 ST - Steering System.pdf............................................................................1111 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS...............................................................................1111 PRECAUTIONS AND PREPARATION.....................................................................1112 Supplemental Restraint System (SRS) "AIR BAG"...............................................1112 Steering System.............................................................................1112 Special Service Tools.......................................................................1113 Commercial Service Tool.....................................................................1114 ON-VEHICLE SERVICE..............................................................................1115 Steering System.............................................................................1115 Checking and Adjusting Drive Belts (For power steering).....................................1115 Checking Fluid Level........................................................................1115 Checking Fluid Leakage......................................................................1116 Bleed Hydraulic System......................................................................1116 Checking Steering Wheel Turning Force (For power steering)..................................1117 Checking Steering Wheel Play................................................................1117 Checking Neutral Position on Steering Wheel.................................................1118 Checking Front Wheel Turning Angle..........................................................1118 Checking Hydraulic System...................................................................1118 STEERING WHEEL AND STEERING COLUMN..............................................................1120 Steering Wheel..............................................................................1120 Steering Column.............................................................................1121 Disassembly and Assembly....................................................................1122 Inspection..................................................................................1123 MANUAL STEERING GEAR (Model: VB66K).............................................................1124 Removal and Installation....................................................................1124 Disassembly.................................................................................1125 Assembly and Adjustment.....................................................................1125 Inspection..................................................................................1128 POWER STEERING SYSTEM (Model: PB59K)............................................................1130 Description.................................................................................1130 POWER STEERING GEAR (Model: PB59K)..............................................................1131 Removal and Installing......................................................................1131 Power Steering Gear Component...............................................................1131 Pre-disassembly Inspection and Adjustment...................................................1132 Disassembly.................................................................................1133 Assembly....................................................................................1134 POWER STEERING SYSTEM (Model: PB48S)............................................................1137 Description.................................................................................1137 POWER STEERING GEAR (Model: PB48S)..............................................................1138 Removal and Installing......................................................................1138 Power Steering Gear Component)..............................................................1138 Pre-disassembly Inspection and Adjustment...................................................1139 Disassembly.................................................................................1140 Assembly....................................................................................1142 POWER STEERING OIL PUMP.........................................................................1145 Disassembly and Assembly....................................................................1145 Pre-disassembly Inspection..................................................................1145 Inspection..................................................................................1146 Disassembly.................................................................................1146 Assembly....................................................................................1147 STEERING LINKAGE................................................................................1148 Removal and Installation....................................................................1148 Disassembly.................................................................................1149 Inspection..................................................................................1150 SERVICE DATA AND SPECIFICATIONS (SDS)...........................................................1151 General Specifications......................................................................1151 Inspection and Adjustment...................................................................1151 RS - Restraint System.pdf...........................................................................1154 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS...............................................................................1154 PRECAUTIONS.....................................................................................1155 Supplemental Restraint System (SRS) "AIR BAG"...............................................1155 SEAT BELTS......................................................................................1156 Front Seat Belt.............................................................................1157 Rear Seat Belt..............................................................................1158 SUPPLEMENTAL RESTRAINT SYSTEM (SRS).............................................................1159 Precautions for SRS "Air Bag" Service.......................................................1159 Special Service Tools.......................................................................1159 Description.................................................................................1160 SRS Component Parts Location................................................................1161 Maintenance Items...........................................................................1161 Diagnosis Sensor Unit and Crash Zone Sensor.................................................1162 Removal and Installation................................................................1162 Air Bag Module and Spiral Cable.............................................................1163 Removal.................................................................................1163 Installation............................................................................1164 Disposal of Air Bag Module..................................................................1166 Checking Deployment Tool................................................................1166 Deployment Procedures for Air Bag Module (Outside of Vehicle)...........................1167 Deployment of Air Bag Module While Mounted In Vehicle...................................1168 Disposing of Air Bag Module.............................................................1168 TROUBLE DIAGNOSES - Supplemental Restraing System (SRS).........................................1170 How to Perform Trouble Diagnoses for Quick and Accurate Repair..............................1170 Schematic...................................................................................1172 Wiring Diagram - SRS -......................................................................1173 Self-diagnosis..............................................................................1175 Diagnostic Procedures...................................................................1175 Trouble Diagnoses for Air Bag Warning Lamp..................................................1188 Diagnostic Procedures...................................................................1188 COLLISION DIAGNOSIS.............................................................................1190 SRS Inspection..............................................................................1190 BT - Body & Trim.pdf................................................................................1191 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS...............................................................................1191 PRECAUTIONS.....................................................................................1192 Supplemental Restraint System (SRS) "AIR BAG"...............................................1192 GENERAL SERVICING...............................................................................1193 Clip and Fastener...........................................................................1193 BODY END........................................................................................1196 Front End...................................................................................1196 Rear End....................................................................................1197 Step Bumper.................................................................................1198 DOOR............................................................................................1199 Front Door..................................................................................1199 INSTRUMENT PANEL................................................................................1200 INTERIOR TRIM...................................................................................1203 Side and Floor Trim - Passenger room........................................................1203 Roof Trim...................................................................................1205 EXTERIOR........................................................................................1207 SEAT............................................................................................1213 Front Seat..................................................................................1213 Jump Seat - King Cab Model..................................................................1214 SUNROOF.........................................................................................1215 Service Procedure...........................................................................1215 WINDSHIELD AND WINDOWS..........................................................................1216 Windshield..................................................................................1217 Back Window.................................................................................1218 Rear Side Window............................................................................1219 MIRROR..........................................................................................1220 Door Mirror.................................................................................1220 Rearview Mirror.............................................................................1221 CAB AND REAR BODY...............................................................................1222 Removal.....................................................................................1222 Cab Body................................................................................1222 Rear Body...............................................................................1222 Body Mounting...............................................................................1223 BODY ALIGNMENT..................................................................................1224 Engine Compartment..........................................................................1225 Underbody...................................................................................1226 HA - Heater & Air Conditioner.pdf...................................................................1233 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS...............................................................................1233 PRECAUTIONS AND PREPARATION.....................................................................1234 Precautions for Supplemental Restraint System (SRS) "AIR BAG"..............................1234 Introduction................................................................................1235 Precautions for Working with R-134a.........................................................1236 General Refrigerant Precautions.............................................................1236 Precautions for Refrigerant Connection......................................................1237 Precautions for Servicing Compressor........................................................1238 Special Service Tools.......................................................................1238 R-134a Service Tools and Equipment..........................................................1239 Precautions for Service Equipment...........................................................1241 DESCRIPTION.....................................................................................1243 Refrigeration Cycle.........................................................................1243 Component Layout............................................................................1244 Discharge Air Flow..........................................................................1245 Control Operation...........................................................................1246 TROUBLE DIAGNOSES...............................................................................1247 How to Perform Trouble Diagnoses for Quick and Accurate Repair..............................1247 Operational Check...........................................................................1248 Symptom Chart...............................................................................1250 Preliminary Check...........................................................................1251 Performance Test Diagnoses..................................................................1254 Performance Chart...........................................................................1256 Trouble Diagnoses for Abnormal Pressure.....................................................1257 Harness Layout..............................................................................1260 Circuit Diagram.............................................................................1261 Wiring Diagram - HEATER-....................................................................1262 Wiring Diagram - A/C -......................................................................1263 Mail Power Supply and Ground Circuit Check..................................................1265 Diagnostic Procedure 1......................................................................1266 Electrical Components Inspection............................................................1273 Control Linkage Adjustment..................................................................1274 SERVICE PROCEDURES..............................................................................1276 Checking Refrigerant Leaks..................................................................1276 Refrigerant Lines...........................................................................1279 R-134a Service Procedure....................................................................1280 Compressor Luibricant Quantity..............................................................1282 Compressor Mounting.........................................................................1284 Belt Tension................................................................................1284 Fast Idle Control Device (FICD).............................................................1284 Condenser...................................................................................1284 Compressor..................................................................................1285 Compressor Clutch...........................................................................1285 Thermal Protector...........................................................................1288 SERVICE DATA AND SPECIFICATIONS (SDS)...........................................................1289 General Specifications......................................................................1289 Inspection and Adjustment...................................................................1289 EL - Electric System.pdf............................................................................1290 QUICK REFERENCE INDEX........................................................................... 0 TABLE OF CONTENTS...............................................................................1290 PRECAUTIONS.....................................................................................1292 Supplemental Restraint System (SRS) "AIR BAG"...............................................1292 HARNESS CONNECTOR...............................................................................1293 STANDARDIZED RELAY..............................................................................1294 POWER SUPPLY ROUTING............................................................................1296 Schematic...................................................................................1296 Wiring Diagram - POWER -....................................................................1297 Fuse........................................................................................1301 Fusible Link................................................................................1301 Circuit Breaker Inspection..................................................................1301 GROUND DISTRIBUTION.............................................................................1302 BATTERY.........................................................................................1305 How to Handle Battery.......................................................................1305 Service Data Specifications (SDS)..........................................................1308 STARTING SYSTEM.................................................................................1309 System Description..........................................................................1309 Wiring Diagram - START -....................................................................1310 Starter.....................................................................................1312 Pinion/Clutch Check.........................................................................1314 Service Data and Specifications (SDS).......................................................1314 CHARGING SYSTEM.................................................................................1315 System Description..........................................................................1315 Wiring Diagram - CHARGE -...................................................................1316 Trouble Diagnoses...........................................................................1317 Generator...................................................................................1318 Diode Check.................................................................................1319 Disassembly and Assembly....................................................................1320 Service Data and Specifications (SDS).......................................................1321 COMBINATION SWITCH..............................................................................1322 Combination Switch/Check....................................................................1322 Combination Switch/Replacement..............................................................1323 Steering Switch/Check.......................................................................1324 HEADLAMP........................................................................................1325 System Description (For USA)................................................................1325 Wiring Diagram (For USA) - H/LAMP -.........................................................1326 Trouble Diagnoses (For USA).................................................................1327 System Description (For Canada).............................................................1328 Operation (Daytime light system for Canada).................................................1329 Schematic (For Canada)......................................................................1330 Wiring Diagram (For Canada) - DTRL -........................................................1332 Trouble Diagnoses (For Canada)..............................................................1335 Bulb Specifications.........................................................................1337 Aiming Adjustment...........................................................................1337 EXTERIOR LAMP...................................................................................1339 Back-up Lamp/Wiring Diagram - BACK/L -......................................................1339 Parking, License, Tail and Stop Lamps/Wiring Diagram - TAIL/L -.............................1340 Turn Signal and Hazard Warning Lamps/System Description.....................................1342 Turn Signal and Hazard Warning Lamps/Wiring Diagram - TURN -................................1344 Turn Signal and Hazard Warning Lamps/Trouble Diagnoses......................................1346 Combination Flasher Unit Check..............................................................1346 Bulb Specifications.........................................................................1347 INTERIOR LAMP...................................................................................1348 Illumination/System Description.............................................................1348 Illimunation/Schematic......................................................................1349 Illimunation/Wiring Diagram, - ILL -........................................................1350 Interior and Map Lamps/Wiring Diagram - INT/L -.............................................1353 Bulb Specifications.........................................................................1354 METERS AND GAUGES...............................................................................1355 Start Description...........................................................................1355 Combination Meter...........................................................................1356 Speedometer, Tachometer, Temp, and Fuel Guages/Wiring Diagram - METER -.....................1358 Inspection/Water Temperature Guage..........................................................1359 Inspection/Fuel Guage.......................................................................1360 Inspection/Tachometer.......................................................................1361 Inspection/Speedometer and Vehicle Speed Sensor.............................................1362 Inspection/Speedometer and Fuse ............................................................1363 Fuel Tank Guage Unit Check..................................................................1364 Fuel Warning Lamp Sensor Check..............................................................1364 Thermal Transmitter Check...................................................................1364 Oil Pressure Switch Check...................................................................1364 Vehicle Speed Sensor Signal Check...........................................................1365 WARNING LAMPS...................................................................................1366 System Description..........................................................................1366 Schematic...................................................................................1368 Wiring Diagram - WARN -.....................................................................1369 Diode Check.................................................................................1372 WARNING CHIME...................................................................................1373 System Description..........................................................................1373 Wiring Diagram - CHIME -....................................................................1374 Trouble Diagnoses...........................................................................1375 WIPER AND WASHER................................................................................1382 System Description..........................................................................1382 Wiring Diagram - WIPER -....................................................................1384 Trouble Diagnoses...........................................................................1386 Wiper Amplifier Check.......................................................................1389 Installation................................................................................1389 Washer Nozzle Adjustment....................................................................1390 HORN, LIGHTER, CLOCK............................................................................1391 Wiring Diagram - HORN -.....................................................................1391 AUDIO...........................................................................................1392 System Description..........................................................................1392 Schematic...................................................................................1393 Wiring Diagram - AUDIO -....................................................................1394 Trouble Diagnoses...........................................................................1397 ANTENNA.........................................................................................1399 Location of Antenna.........................................................................1399 Window Antenna Repair.......................................................................1400 MIRROR..........................................................................................1402 Wiring Diagram - MIRROR -...................................................................1402 AUTOMATIC SPEED CONTROL DEVICE (ASCD)...........................................................1404 Component Parts and Harness Connector Location..............................................1404 System Description..........................................................................1405 Schematic...................................................................................1407 Wiring Diagram - ASCD -.....................................................................1408 Trouble Diagnoses...........................................................................1413 POWER WINDOW....................................................................................1425 Component Layout............................................................................1425 System Description..........................................................................1426 Wiring diagram - WINDOW -...................................................................1428 Trouble Diagnoses...........................................................................1430 POWER DOOR LOCK.................................................................................1431 System Description..........................................................................1431 Schematic...................................................................................1432 Wiring Diagram - D/LOCK -...................................................................1434 Trouble Diagnoses...........................................................................1436 LOCATION OF ELECTRICAL UNITS....................................................................1440 Passenger Compartment.......................................................................1440 Engine Compartment..........................................................................1441 HARNESS LAYOUT..................................................................................1442 How To Read Harness Layout..................................................................1442 Outline.....................................................................................1443 Main Harness and Air Bag Harness............................................................1444 Instrument Harness..........................................................................1448 Engine Harness..............................................................................1449 Chassis and Tail Harness....................................................................1450 Front Door Harness..........................................................................1451 Room Lamp Harness...........................................................................1452 Foldout.pdf.........................................................................................1453 QUICK REFERENCE INDEX........................................................................... 0 ELECTRICAL SYSTEM............................................................................... 1 SUPER MULTIPLE JUNCTION (SMJ)...................................................................1453 INSTALLATION................................................................................1453 Terminal Arrangement........................................................................1454 JOINT CONNECTOR (J/C)...........................................................................1455 Location....................................................................................1455 FUSE BLOCK......................................................................................1456 Fuse Arrangement............................................................................1456 CONTROL UNITS/MODULE............................................................................1457 IDX - Index.pdf.....................................................................................1458 QUICK REFERENCE INDEX........................................................................... 0 ec......................................................................................................1466 QUICK REFERENCE INDEX............................................................................... 0 TABLE OF CONTENTS...................................................................................1466 DIAGNOSTIC TROUBLE CODE INDEX.......................................................................1468 Alphabetical & P No. Index for DTC..............................................................1468 PRECAUTIONS AND PREPARATION.........................................................................1470 ENGINE AND EMISSION CONTROL OVERALL SYSTEM..........................................................1475 Circuit Diagram.................................................................................1475 System Diagram..................................................................................1476 ECCS Component Parts Location...................................................................1477 Vacuum Hose Drawing.............................................................................1479 System Chart....................................................................................1480 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION................................................1481 Multiport Fuel Injection (MFI) System...........................................................1481 Distributor Ignition (DI) System................................................................1483 Air Conditioning Cut Control....................................................................1484 Fuel Cut control (at no load & high engine speed................................................1485 EVAPORATIVE EMISSION SYSTEM.........................................................................1486 Description.....................................................................................1486 Inspection......................................................................................1486 Evaporative Emission Line Drawing...............................................................1488 POSITIVE CRANKCASE VENTILATION......................................................................1490 Description.....................................................................................1490 Inspection......................................................................................1490 BASIC SERVICE PROCEDURE.............................................................................1491 Fuel Pressure Release...........................................................................1491 Fuel Pressure Check.............................................................................1491 Injector Removal and Installation...............................................................1492 Fast Idle Cam (FIC) Inspection and Adjustment...................................................1493 Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment........................................1494 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION..............................................................1500 Introduction....................................................................................1500 Two Trip Detection Logic........................................................................1500 Emission-related Diagnostic Information.........................................................1501 Malfunction Indicator Lamp (MIL)................................................................1511 OBD System Operation Chart......................................................................1514 CONSULT.........................................................................................1519 Generic Scan Tool (GST).........................................................................1532 TROUBLE DIAGNOSIS – Introduction....................................................................1534 Introduction....................................................................................1534 Diagnostic Worksheet............................................................................1534 TROUBLE DIAGNOSIS - Work Flow.......................................................................1536 Work Flow.......................................................................................1536 Description for Work Flow.......................................................................1537 TROUBLE DIAGNOSIS - Basic Inspection................................................................1538 Basic Inspection................................................................................1538 TROUBLE DIAGNOSIS - General Description.............................................................1541 Diagnostic Trouble Code (DTC) Inspection Priority Chart.........................................1541 Fail-Safe Chart.................................................................................1542 Symptom Matrix Chart............................................................................1543 CONSULT Reference Value in Data Monitor Mode....................................................1545 Major Sensor Reference Graph in Data Monitor Mode...............................................1547 ECM Terminals and Reference Value...............................................................1549 TROUBLE DIAGNOSIS FOR POWER SUPPLY..................................................................1555 Main Power Supply and Ground Circuit............................................................1555 DTC P0100, Mass Air Flow Sensor (MAFS)..............................................................1559 DTC P0105, Absolute Pressure Sensor.................................................................1566 DTC P0110, Intake Air Temperature Sensor............................................................1573 DTC P0115, Engine Coolant Temperature Sensor (ECTS).................................................1579 DTC P0120, Throttle Position Sensor.................................................................1584 DTC P0125, Engine Coolant Temperature (ECT) Sensor..................................................1590 DTC P0130, Front Heated Oxygen Sensor (Front HO2S)..................................................1595 DTC P0130, Closed Loop Control......................................................................1600 DTC P0135, Front Heated Oxygen Sensor Heater........................................................1601 DTC P0136, Rear Heated Oxygen Sensor (Rear (HO2S)...................................................1605 DTC P0141, Rear Heated Oxygen Sensor Heater.........................................................1609 DTC P0171, Fuel Injection System Function (Lean side)...............................................1614 DTC P0172, Fuel Injection system Function (Rich side)...............................................1619 DTC P0180, Tank Fuel Temperature Sensor.............................................................1624 DTC P0300 - P0304, No. 4 - 1 Cylinder Misfire, Multiple Cylinder Misfire............................1628 DTC P0335, Crankshaft Position Sensor (CKPS) (OBD)..................................................1632 DTC P0340, Camshaft Position Sensor (CMPS)..........................................................1637 DTC P0400, EGR Function.............................................................................1642 DTC P0402, EGRC-BPT Valve Function..................................................................1650 DTC P0420, Three Way Catalyst Function..............................................................1652 DTC P0440, Evaporative Emission (EVAP) Control System (Small Leak)..................................1655 DTC P0443, Evaporative Emission (EVAP) Canister Purge Control Valve/Solenoid Valve..................1665 DTC P0446, Evaporative Emission (EVAP) Canister Vent Control Valve..................................1673 DTC P0450, Evaporative Emission (EVAP) Control System Pressure Sensor...............................1678 DTC P0500, Vehicle Speed Sensor (VSS)...............................................................1683 DTC P0505, Idle Air Control Valve (IACV) - Auxiliary Air Control (AAC) Valve........................1687 DTC P0510, Closed Throttle Position Switch..........................................................1692 DTC P0605, Engine Control Module (ECM)-ECCS Control Module..........................................1696 DTC P0705, Park/Neutral Position Switch.............................................................1698 DTC P1105, Manifold Absolute Pressure (MAP)/Barometric Pressure (BARO) Switch Solenoid Valve........1703 DTC P1130, Swirl Control Valve Control Solenoid Valve...............................................1709 DTC P1165, Swirl Control Valve Vacuum Check Switch..................................................1717 DTC P1320, Ignition Signal..........................................................................1722 DTC P1336, Crankshaft Position Sensor (CKPS) (OBD) (COG)............................................1728 DTC P1400, EGRC-Solenoid Valve......................................................................1733 DTC P1401, EGR Temperature Sensor...................................................................1737 DTC P1441, Vacuum Cut Valve Bypass Valve............................................................1742 DTC P1445, Evaporative Emission (EVAP) Canister Purge Volume Control Valve..........................1747 DTC P1447, Evaporative Emission (EVAP) Control System Purge Flow Monitoring.........................1754 DTC P1550, Torque Converter Clutch Solenoid Valve...................................................1761 DTC P1900, Overheat.................................................................................1766 TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS..........................................................1769 Injector........................................................................................1769 Start Signal....................................................................................1772 Fuel Pump.......................................................................................1775 Power Steering Oil Pressure Switch..............................................................1779 IACV-FICD Solenoid Valve........................................................................1783 MIL & Data Link Connectors......................................................................1787 SERVICE DATA AND SPECIFICATIONS.....................................................................1789 General Specfications...........................................................................1789 Inspection and Adjustment.......................................................................1789 el......................................................................................................1791 QUICK REFERENCE INDEX............................................................................... 0 TABLE OF CONTENTS...................................................................................1791 PRECAUTIONS.........................................................................................1793 Supplemental Restraint System (SRS) "AIR BAG"...................................................1793 HARNESS CONNECTOR...................................................................................1794 STANDARDIZED RELAY..................................................................................1795 POWER SUPPLY ROUTING................................................................................1797 Schematic.......................................................................................1797 Wiring Diagram - POWER -........................................................................1798 Fuse............................................................................................1802 Fusible Link....................................................................................1802 Circuit Breaker Inspection......................................................................1802 GROUND DISTRIBUTION.................................................................................1803 BATTERY.............................................................................................1806 How to Handle Battery...........................................................................1806 Service Data Specifications (SDS)..............................................................1809 STARTING SYSTEM.....................................................................................1810 System Description..............................................................................1810 Wiring Diagram - START -........................................................................1811 Starter.........................................................................................1813 Pinion/Clutch Check.............................................................................1815 Service Data and Specifications (SDS)...........................................................1815 CHARGING SYSTEM.....................................................................................1816 System Description..............................................................................1816 Wiring Diagram - CHARGE -.......................................................................1817 Trouble Diagnoses...............................................................................1818 Generator.......................................................................................1819 Diode Check.....................................................................................1820 Disassembly and Assembly........................................................................1821 Service Data and Specifications (SDS)...........................................................1822 COMBINATION SWITCH..................................................................................1823 Combination Switch/Check........................................................................1823 Combination Switch/Replacement..................................................................1824 Steering Switch/Check...........................................................................1825 HEADLAMP............................................................................................1826 System Description (For USA)....................................................................1826 Wiring Diagram (For USA) - H/LAMP -.............................................................1827 Trouble Diagnoses (For USA).....................................................................1828 System Description (For Canada).................................................................1829 Operation (Daytime light system for Canada).....................................................1830 Schematic (For Canada)..........................................................................1831 Wiring Diagram (For Canada) - DTRL -............................................................1833 Trouble Diagnoses (For Canada)..................................................................1836 Bulb Specifications.............................................................................1838 Aiming Adjustment...............................................................................1838 EXTERIOR LAMP.......................................................................................1840 Back-up Lamp/Wiring Diagram - BACK/L -..........................................................1840 Parking, License, Tail and Stop Lamps/Wiring Diagram - TAIL/L -.................................1841 Turn Signal and Hazard Warning Lamps/System Description.........................................1843 Turn Signal and Hazard Warning Lamps/Wiring Diagram - TURN -....................................1845 Turn Signal and Hazard Warning Lamps/Trouble Diagnoses..........................................1847 Combination Flasher Unit Check..................................................................1847 Bulb Specifications.............................................................................1848 INTERIOR LAMP.......................................................................................1849 Illumination/System Description.................................................................1849 Illimunation/Schematic..........................................................................1850 Illimunation/Wiring Diagram, - ILL -............................................................1851 Interior and Map Lamps/Wiring Diagram - INT/L -.................................................1854 Bulb Specifications.............................................................................1855 METERS AND GAUGES...................................................................................1856 Start Description...............................................................................1856 Combination Meter...............................................................................1857 Speedometer, Tachometer, Temp, and Fuel Guages/Wiring Diagram - METER -.........................1859 Inspection/Water Temperature Guage..............................................................1860 Inspection/Fuel Guage...........................................................................1861 Inspection/Tachometer...........................................................................1862 Inspection/Speedometer and Vehicle Speed Sensor.................................................1863 Inspection/Speedometer and Fuse ................................................................1864 Fuel Tank Guage Unit Check......................................................................1865 Fuel Warning Lamp Sensor Check..................................................................1865 Thermal Transmitter Check.......................................................................1865 Oil Pressure Switch Check.......................................................................1865 Vehicle Speed Sensor Signal Check...............................................................1866 WARNING LAMPS.......................................................................................1867 System Description..............................................................................1867 Schematic.......................................................................................1869 Wiring Diagram - WARN -.........................................................................1870 Diode Check.....................................................................................1873 WARNING CHIME.......................................................................................1874 System Description..............................................................................1874 Wiring Diagram - CHIME -........................................................................1875 Trouble Diagnoses...............................................................................1876 WIPER AND WASHER....................................................................................1883 System Description..............................................................................1883 Wiring Diagram - WIPER -........................................................................1885 Trouble Diagnoses...............................................................................1887 Wiper Amplifier Check...........................................................................1890 Installation....................................................................................1890 Washer Nozzle Adjustment........................................................................1891 HORN, LIGHTER, CLOCK................................................................................1892 Wiring Diagram - HORN -.........................................................................1892 AUDIO...............................................................................................1893 System Description..............................................................................1893 Schematic.......................................................................................1894 Wiring Diagram - AUDIO -........................................................................1895 Trouble Diagnoses...............................................................................1898 ANTENNA.............................................................................................1900 Location of Antenna.............................................................................1900 Window Antenna Repair...........................................................................1901 MIRROR..............................................................................................1903 Wiring Diagram - MIRROR -.......................................................................1903 AUTOMATIC SPEED CONTROL DEVICE (ASCD)...............................................................1905 Component Parts and Harness Connector Location..................................................1905 System Description..............................................................................1906 Schematic.......................................................................................1908 Wiring Diagram - ASCD -.........................................................................1909 Trouble Diagnoses...............................................................................1914 POWER WINDOW........................................................................................1926 Component Layout................................................................................1926 System Description..............................................................................1927 Wiring diagram - WINDOW -.......................................................................1929 Trouble Diagnoses...............................................................................1931 POWER DOOR LOCK.....................................................................................1932 System Description..............................................................................1932 Schematic.......................................................................................1933 Wiring Diagram - D/LOCK -.......................................................................1935 Trouble Diagnoses...............................................................................1937 LOCATION OF ELECTRICAL UNITS........................................................................1941 Passenger Compartment...........................................................................1941 Engine Compartment..............................................................................1942 HARNESS LAYOUT......................................................................................1943 How To Read Harness Layout......................................................................1943 Outline.........................................................................................1944 Main Harness and Air Bag Harness................................................................1945 Instrument Harness..............................................................................1949 Engine Harness..................................................................................1950 Chassis and Tail Harness........................................................................1951 Front Door Harness..............................................................................1952 Room Lamp Harness...............................................................................1953 em......................................................................................................1954 QUICK REFERENCE INDEX............................................................................... 0 TABLE OF CONTENTS...................................................................................1954 PRECAUTIONS.........................................................................................1955 Supplemental Restraint System (SRS) "AIR BAG"...................................................1955 Parts Requiring Angular Tightening..............................................................1955 Liquid Gasket Application Procedure.............................................................1955 PREPARATION.........................................................................................1956 Special Service Tools...........................................................................1956 Commercial Service Tools........................................................................1958 OUTER COMPONENT PARTS...............................................................................1959 COMPRESSION PRESSURE................................................................................1960 Measurement of Compression Pressure.............................................................1960 OIL PAN.............................................................................................1961 Removal.........................................................................................1961 Installation....................................................................................1961 TIMING CHAIN........................................................................................1963 Removal.........................................................................................1963 Inspection......................................................................................1964 Installation....................................................................................1965 OIL SEAL REPLACEMENT................................................................................1967 Valve Oil Seal..................................................................................1967 Front Oil Seal..................................................................................1967 Rear Oil Seal...................................................................................1968 CYLINDER HEAD.......................................................................................1969 Removal.........................................................................................1970 Disassembly.....................................................................................1972 Inspection......................................................................................1972 Assembly........................................................................................1978 Installation....................................................................................1979 ENGINE REMOVAL......................................................................................1982 Removal.........................................................................................1983 Installation....................................................................................1984 CYLINDER BLOCK......................................................................................1985 Disassembly.....................................................................................1986 Inspection......................................................................................1986 Assembly........................................................................................1992 SERVICE DATA AND SPECIFICATIONS (SDS)...............................................................1995 General Specifications..........................................................................1995 Inspection and Adjusement.......................................................................1995 fa......................................................................................................2002 QUICK REFERENCE INDEX............................................................................... 0 TABLE OF CONTENTS...................................................................................2002 PRECAUTIONS AND PREPARATION.........................................................................2003 Precautions.....................................................................................2003 Special Service Tools...........................................................................2003 Commercial Service Tools........................................................................2003 FRONT AXLE AND FRONT SUSPENSION.....................................................................2004 ON-VEHICLE SERVICE..................................................................................2006 Front Axle and Front Suspension Parts...........................................................2006 Front Wheel Bearing.............................................................................2007 Preload Adjustment (2WD)....................................................................2007 Preload Adjustment (4WD)....................................................................2008 Front Wheel Alignment...........................................................................2009 Preliminary Inspection......................................................................2009 Camber, Caster and Kingpin Inclication......................................................2010 Adjustment..................................................................................2010 Toe-In......................................................................................2013 Front Wheel Turning Angle...................................................................2014 Drive Shaft.....................................................................................2015 FRONT AXLE..........................................................................................2016 FRONT AXLE (4WD)....................................................................................2018 Manual-lock Free-running Hub....................................................................2018 Auto-lock Free-running Hub......................................................................2019 FRONT AXLE..........................................................................................2025 Wheel Hub and Rotor Disc........................................................................2025 Knuckle Spindle.................................................................................2026 FRONT AXLE (4WD)....................................................................................2029 Drive Shaft.....................................................................................2029 FRONT SUSPENSION....................................................................................2035 Shock Absorber..................................................................................2037 Torsion Bar Spring..............................................................................2037 Stabilizer Bar..................................................................................2040 Upper Link......................................................................................2041 Tension Rod or Compression Rod..................................................................2043 Lower Link......................................................................................2044 Upper Ball Joint and Lower Ball Joint...........................................................2045 SERVICE DATA AND SPECIFICATIONS.....................................................................2046 General Specifications..........................................................................2046 Inspection and Adjustment.......................................................................2047 fe......................................................................................................2050 QUICK REFERENCE INDEX............................................................................... 0 TABLE OF CONTENTS...................................................................................2050 ACCELERATOR CONTROL SYSTEM..........................................................................2051 Adjusting Accelerator Wire......................................................................2051 FUEL SYSTEM.........................................................................................2052 Fuel Tank.......................................................................................2052 Fuel Pump and Gauge.............................................................................2055 EXHAUST SYSTEM......................................................................................2056 foldout.................................................................................................2058 QUICK REFERENCE INDEX............................................................................... 0 ELECTRICAL SYSTEM................................................................................... 1 SUPER MULTIPLE JUNCTION (SMJ).......................................................................2058 INSTALLATION....................................................................................2058 Terminal Arrangement............................................................................2059 JOINT CONNECTOR (J/C)...............................................................................2060 Location........................................................................................2060 FUSE BLOCK..........................................................................................2061 Fuse Arrangement................................................................................2061 CONTROL UNITS/MODULE................................................................................2062 gi......................................................................................................2063 QUICK REFERENCE INDEX............................................................................... 0 TABLE OF CONTENTS...................................................................................2063 PRECAUTIONS.........................................................................................2064 Precautions for Supplemental Restraint System (SRS) "AIR BAG"...................................2064 General Precautions.............................................................................2065 Precautions for Engine Oils.....................................................................2067 Precautions for Multiport Fuel Injection System or ECCS Engine..................................2068 Precautions for Three Way Catalyst..............................................................2068 Precautions for Fuel............................................................................2068 Precautions for Air Conditioning................................................................2068 HOW TO USE THIS MANUAL..............................................................................2069 HOW TO READ WIRING DIAGRAMS.........................................................................2071 Sample/Wiring Diagram - EXAMPL -................................................................2071 Description.....................................................................................2073 Connector Symbols...........................................................................2075 Switch Positions............................................................................2076 Detectable Lines And Non-Detectable Lines...................................................2077 Multiple Switch.............................................................................2077 Foldout Page................................................................................2078 Wiring Diagram Codes (Cell Codes)...............................................................2079 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT.......................................2080 Work Flow.......................................................................................2080 Incident Simulation Tests.......................................................................2081 Circuit Inspection..............................................................................2085 Introduction................................................................................2085 Testing for "Opens" In The Circuit..........................................................2086 Testing for "Shorts" In The Circuit.........................................................2087 Ground Inspection...........................................................................2088 Voltage Drop Tests..........................................................................2089 HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES.......................................................2092 CONSULT CHECKING SYSTEM.............................................................................2095 IDENTIFICATION INFORMATION..........................................................................2096 Model Variation.................................................................................2096 Identification Number...........................................................................2098 Dimensions......................................................................................2100 Wheels & Tires..................................................................................2100 LIFTING POINTS AND TWO TRUCK TOWING.................................................................2101 Pantograph Jack.................................................................................2101 Screw Jack......................................................................................2101 Garage Jack and Safety Stand....................................................................2102 2-pole Lift.....................................................................................2103 Tow Truck Towing................................................................................2104 Towing Point....................................................................................2105 TIGHTENING TORQUE OF STANDARD BOLTS.................................................................2106 SAE J1930 TERMINOLOGY LIST..........................................................................2107 ha......................................................................................................2111 QUICK REFERENCE INDEX............................................................................... 0 TABLE OF CONTENTS...................................................................................2111 PRECAUTIONS AND PREPARATION.........................................................................2112 Precautions for Supplemental Restraint System (SRS) "AIR BAG"..................................2112 Introduction....................................................................................2113 Precautions for Working with R-134a.............................................................2114 General Refrigerant Precautions.................................................................2114 Precautions for Refrigerant Connection..........................................................2115 Precautions for Servicing Compressor............................................................2116 Special Service Tools...........................................................................2116 R-134a Service Tools and Equipment..............................................................2117 Precautions for Service Equipment...............................................................2119 DESCRIPTION.........................................................................................2121 Refrigeration Cycle.............................................................................2121 Component Layout................................................................................2122 Discharge Air Flow..............................................................................2123 Control Operation...............................................................................2124 TROUBLE DIAGNOSES...................................................................................2125 How to Perform Trouble Diagnoses for Quick and Accurate Repair..................................2125 Operational Check...............................................................................2126 Symptom Chart...................................................................................2128 Preliminary Check...............................................................................2129 Performance Test Diagnoses......................................................................2132 Performance Chart...............................................................................2134 Trouble Diagnoses for Abnormal Pressure.........................................................2135 Harness Layout..................................................................................2138 Circuit Diagram.................................................................................2139 Wiring Diagram - HEATER-........................................................................2140 Wiring Diagram - A/C -..........................................................................2141 Mail Power Supply and Ground Circuit Check......................................................2143 Diagnostic Procedure 1..........................................................................2144 Electrical Components Inspection................................................................2151 Control Linkage Adjustment......................................................................2152 SERVICE PROCEDURES..................................................................................2154 Checking Refrigerant Leaks......................................................................2154 Refrigerant Lines...............................................................................2157 R-134a Service Procedure........................................................................2158 Compressor Luibricant Quantity..................................................................2160 Compressor Mounting.............................................................................2162 Belt Tension....................................................................................2162 Fast Idle Control Device (FICD).................................................................2162 Condenser.......................................................................................2162 Compressor......................................................................................2163 Compressor Clutch...............................................................................2163 Thermal Protector...............................................................................2166 SERVICE DATA AND SPECIFICATIONS (SDS)...............................................................2167 General Specifications..........................................................................2167 Inspection and Adjustment.......................................................................2167 idx.....................................................................................................2168 QUICK REFERENCE INDEX............................................................................... 0 lc......................................................................................................2176 QUICK REFERENCE INDEX............................................................................... 0 TABLE OF CONTENTS...................................................................................2176 PRECAUTIONS AND PREPARATION.........................................................................2177 Supplemental Restraint System (SRS) "AIR BAG"..................................................2177 Liquid Gasket Application Procedure.............................................................2177 Special Service Tools...........................................................................2178 ENGINE LUBRICATION SYSTEM...........................................................................2179 Lubrication Circuit.............................................................................2179 Oil Pressure Check..............................................................................2180 Oil Pump........................................................................................2180 ENGINE COOLING SYSTEM...............................................................................2182 Cooling Circuit.................................................................................2182 System Check....................................................................................2182 Water Pump......................................................................................2183 Thermostat......................................................................................2184 Radiator........................................................................................2186 Cooling Fan.....................................................................................2187 Overheating Cause Analysis......................................................................2188 SERVICE DATA AND SPECIFICATIONS (SDS)...............................................................2189 Engine Lubrication System.......................................................................2189 Engine Cooling System...........................................................................2189 ma......................................................................................................2190 QUICK REFERENCE INDEX............................................................................... 0 TABLE OF CONTENTS...................................................................................2190 PRECAUTIONS AND PREPARATION.........................................................................2191 Supplemental Restraint System (SRS) "AIR BAG"...................................................2191 Special Service Tool............................................................................2191 GENERAL MAINTENANCE.................................................................................2192 PERIODIC MAINTENANCE................................................................................2194 Schecule 1......................................................................................2195 Schedule 2......................................................................................2196 RECOMMENDED FLUIDS AND LUBRICANTS...................................................................2197 Fluids and Lubricants...........................................................................2197 SAE Viscosity Number............................................................................2198 Antifreeze Coolant Mixture Ratio................................................................2198 ENGINE MAINTENANCE..................................................................................2199 Checking Drive Belts............................................................................2199 Changing Engine Coolant.........................................................................2200 Checking Fuel Lines.............................................................................2201 Changing Fuel Filter............................................................................2201 Changing Air Cleaner Filter.....................................................................2201 Changing Engine Oil.............................................................................2202 Changing Oil Filter.............................................................................2202 Changing Spark Plugs............................................................................2203 Checking EVAP Vapor Purge Lines.................................................................2204 Changing Positive Crankcase Ventillation (PCV) Filter...........................................2204 CHASSIS AND BODY MAINTENANCE........................................................................2205 Checking Exhaust System.........................................................................2205 Checking Clutch Fluid Level and Leaks...........................................................2205 Checking M/T Oil................................................................................2205 Changing M/T Oil................................................................................2205 Checking Water Entry - For 4WD models...........................................................2205 Checking A/T Fluid..............................................................................2205 Changint A/T Fluid..............................................................................2206 Checking Transfer Fluid.........................................................................2206 Changing Transfer Fluid.........................................................................2207 Checking Propeller Shaft........................................................................2207 Checking Differential Gear Oil..................................................................2207 Changing Differential Gear Oil..................................................................2208 Balancing Wheels................................................................................2208 Tire Roataion...................................................................................2208 Checking Brake Fluid Level and Leaks............................................................2209 Checking Brake System...........................................................................2209 Checking Disc Brake.............................................................................2209 Checking Drum Brake.............................................................................2209 Checking Steering Gear and Linkage..............................................................2210 Checking Power Steering Fluid and Lines.........................................................2210 Checking Steering Gear Oil Level and Leaks......................................................2210 Lubricating Hood Latches, Locks and Hinges......................................................2211 Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters.................................2212 SERVICE DATA AND SPECIFICATIONS (SDS................................................................2213 Engine Maintenance..............................................................................2213 Chassis and Body Maintenance....................................................................2213 mt......................................................................................................2214 QUICK REFERENCE INDEX............................................................................... 0 TABLE OF CONTENTS...................................................................................2214 PREPARATION.........................................................................................2215 Special Service Tools...........................................................................2215 Commercial Service Tools........................................................................2216 ON-VEHICLE SERVICE..................................................................................2217 Replacing Rear Oil Seal - 2WD Model.............................................................2217 Position Switch Check...........................................................................2217 REMOVAL AND INSTALLATION............................................................................2218 MAJOR OVERHAUL......................................................................................2220 Case Components.................................................................................2220 Gear Components - 2WD Model.....................................................................2221 Gear Components - 4WD Model.....................................................................2222 Shift Control Components........................................................................2223 DISASSEMBLY.........................................................................................2224 Case Components.................................................................................2224 Shift Control Components........................................................................2224 Gear Components.................................................................................2225 INSPECTION..........................................................................................2228 Shift Control Components........................................................................2228 Gear Components.................................................................................2228 Gears and Shafts............................................................................2228 Synchronizers...............................................................................2228 Bearings....................................................................................2229 ASSEMBLY............................................................................................2230 Gear Components.................................................................................2230 Shift Control Components........................................................................2236 Case Components.................................................................................2237 SERVICE DATA AND SPECIFICATIONS (SDS)...............................................................2240 General Specifications..........................................................................2240 Inspection and Adjustment.......................................................................2241 pd......................................................................................................2243 QUICK REFERENCE INDEX............................................................................... 0 TABLE OF CONTENTS...................................................................................2243 PREPARATION.........................................................................................2245 Special Service Tools...........................................................................2245 Propeller Shaft.....................................................................................2250 PROPELLER SHAFT.................................................................................2250 On-vehicle Service..........................................................................2252 Removal and Installation....................................................................2252 Inspection..................................................................................2252 Disassembly.................................................................................2253 Assembly....................................................................................2254 Final Drive.........................................................................................2256 ON-VEHICLE SERVICE..............................................................................2256 Front Oil Seal Replacement (Front final drive)..............................................2256 Front Oil Seal Replacement (Rear final drive: Model H233B)..................................2256 Rear Cover Gasket Replacement (Rear final drive: Model C200)................................2257 REMOVAL AND INSTALLATION (Front final drive)....................................................2258 REMOVAL AND INSTALLATION (Rear final drive).....................................................2259 R180A...............................................................................................2260 FRONT FINAL DRIVE...............................................................................2260 DISASSEMBLY.....................................................................................2261 Pre-inspection..............................................................................2261 Final Drive Housing.........................................................................2261 Differential Case...........................................................................2263 Extension Tube and Differential Side Shaft..................................................2264 INSPECTION......................................................................................2266 Ring Gear and Drive Pinion..................................................................2266 Differential Case Assembly..................................................................2266 Bearing.....................................................................................2266 ADJUSTMENT......................................................................................2267 Side Bearing Preload........................................................................2267 Pinion Gear Height and Pinion Bearing Preload...............................................2268 Tooth Contact...............................................................................2272 ASSEMBLY........................................................................................2273 Extension Tube and Differential Side Shaft..................................................2273 Differential Case...........................................................................2273 Final Drive Housing.........................................................................2274 H190A...............................................................................................2278 REAR FINAL DRIVE................................................................................2278 DISASSEMBLY.....................................................................................2279 Pre-inspection..............................................................................2279 Differential Carrier........................................................................2279 Differential Case...........................................................................2281 INSPECTION......................................................................................2283 Rear Gear and Drive Pinion..................................................................2283 Differential Case Assembly..................................................................2283 Bearing.....................................................................................2283 LIMITED SLIP DIFFERENTIAL.......................................................................2284 Preparation for Disassembly.................................................................2284 Disassembly.................................................................................2285 Inspection..................................................................................2285 Assembly....................................................................................2286 ADJUSTMENT......................................................................................2289 Side Bearing Preload........................................................................2289 Pinion Gear Height..........................................................................2290 Tooth Contact...............................................................................2294 ASSEMBLY........................................................................................2295 Differential Case...........................................................................2295 Differential Carrier........................................................................2296 C200................................................................................................2300 REAR FINAL DRIVE................................................................................2300 DISASSEMBLY.....................................................................................2301 Pre-Inspection..............................................................................2301 Differenital Carrier........................................................................2301 Differential Case...........................................................................2303 INSPECTION......................................................................................2305 Ring Gear and Drive Pinion..................................................................2305 Differential Case Assembly..................................................................2305 Bearing.....................................................................................2305 LIMITED SLIP DIFFERENTIAL.......................................................................2306 Preparation and Disassembly.................................................................2306 Disassembly.................................................................................2306 Inspection..................................................................................2307 Adjustment..................................................................................2308 Assembly....................................................................................2310 ADJUSTMENT......................................................................................2312 Side Bearing Preload........................................................................2312 Pinion Gear Height..........................................................................2313 Tooth Contact...............................................................................2317 ASSEMBLY........................................................................................2318 Differential Case...........................................................................2318 Differential Carrier........................................................................2319 H233B...............................................................................................2323 REAR FINAL DRIVE................................................................................2323 DISASSEMBLY.....................................................................................2324 Pre-inspection..............................................................................2324 Differential Carrier........................................................................2324 Differential Case...........................................................................2326 INSPECTION......................................................................................2328 Ring Gear and Drive Pinion..................................................................2328 Differential Case Assembly..................................................................2328 Bearing.....................................................................................2328 LIMITED SLIP DIFFERENTIAL.......................................................................2329 Preparation and Disassembly.................................................................2329 Disassembly.................................................................................2329 Inspection..................................................................................2330 Adjustment..................................................................................2331 Assembly....................................................................................2332 ADJUSTMENT......................................................................................2335 Pinion Gear Height..........................................................................2335 Tooth Contact...............................................................................2338 ASSEMBLY........................................................................................2339 Differential Case...........................................................................2339 Differential Carrier........................................................................2340 SERVICE DATA AND SPECIFICATIONS (SDS)...............................................................2343 Propeller Shaft.................................................................................2343 Final Drive.....................................................................................2345 General Specifications......................................................................2345 Inspection and Adjustment (R180A)...........................................................2346 Inspection and Adjustment (H190A)...........................................................2347 Inspection and Adjustment (C200)............................................................2348 Inspection and Adjustment (H233B)...........................................................2349 ra......................................................................................................2351 QUICK REFERENCE INDEX............................................................................... 0 TABLE OF CONTENTS...................................................................................2351 PRECAUTIONS AND PREPARATION.........................................................................2352 Precautions.....................................................................................2352 Special Service Tools...........................................................................2352 Commercial Service Tools........................................................................2352 REAR AXLE AND REAR SUSPENSION.......................................................................2353 ON-VEHICLE SERVICE..................................................................................2354 Rear Axle and Rear Suspension Parts.............................................................2354 Rear Wheel Bearing..............................................................................2354 REAR AXLE...........................................................................................2355 Components......................................................................................2355 Removal.........................................................................................2355 Inspection......................................................................................2357 Installation....................................................................................2357 REAR SUSPENSION.....................................................................................2359 Shock Absorber..................................................................................2360 Leaf Spring.....................................................................................2360 SERVICE DATA AND SPECIFICATIONS (SDS)...............................................................2362 General Specifications..........................................................................2362 Inspection and Adjustment.......................................................................2362 rs......................................................................................................2363 QUICK REFERENCE INDEX............................................................................... 0 TABLE OF CONTENTS...................................................................................2363 PRECAUTIONS.........................................................................................2364 Supplemental Restraint System (SRS) "AIR BAG"...................................................2364 SEAT BELTS..........................................................................................2365 Front Seat Belt.................................................................................2366 Rear Seat Belt..................................................................................2367 SUPPLEMENTAL RESTRAINT SYSTEM (SRS).................................................................2368 Precautions for SRS "Air Bag" Service...........................................................2368 Special Service Tools...........................................................................2368 Description.....................................................................................2369 SRS Component Parts Location....................................................................2370 Maintenance Items...............................................................................2370 Diagnosis Sensor Unit and Crash Zone Sensor.....................................................2371 Removal and Installation....................................................................2371 Air Bag Module and Spiral Cable.................................................................2372 Removal.....................................................................................2372 Installation................................................................................2373 Disposal of Air Bag Module......................................................................2375 Checking Deployment Tool....................................................................2375 Deployment Procedures for Air Bag Module (Outside of Vehicle)...............................2376 Deployment of Air Bag Module While Mounted In Vehicle.......................................2377 Disposing of Air Bag Module.................................................................2377 TROUBLE DIAGNOSES - Supplemental Restraing System (SRS).............................................2379 How to Perform Trouble Diagnoses for Quick and Accurate Repair..................................2379 Schematic.......................................................................................2381 Wiring Diagram - SRS -..........................................................................2382 Self-diagnosis..................................................................................2384 Diagnostic Procedures.......................................................................2384 Trouble Diagnoses for Air Bag Warning Lamp......................................................2397 Diagnostic Procedures.......................................................................2397 COLLISION DIAGNOSIS.................................................................................2399 SRS Inspection..................................................................................2399 st......................................................................................................2400 QUICK REFERENCE INDEX............................................................................... 0 TABLE OF CONTENTS...................................................................................2400 PRECAUTIONS AND PREPARATION.........................................................................2401 Supplemental Restraint System (SRS) "AIR BAG"...................................................2401 Steering System.................................................................................2401 Special Service Tools...........................................................................2402 Commercial Service Tool.........................................................................2403 ON-VEHICLE SERVICE..................................................................................2404 Steering System.................................................................................2404 Checking and Adjusting Drive Belts (For power steering).........................................2404 Checking Fluid Level............................................................................2404 Checking Fluid Leakage..........................................................................2405 Bleed Hydraulic System..........................................................................2405 Checking Steering Wheel Turning Force (For power steering)......................................2406 Checking Steering Wheel Play....................................................................2406 Checking Neutral Position on Steering Wheel.....................................................2407 Checking Front Wheel Turning Angle..............................................................2407 Checking Hydraulic System.......................................................................2407 STEERING WHEEL AND STEERING COLUMN..................................................................2409 Steering Wheel..................................................................................2409 Steering Column.................................................................................2410 Disassembly and Assembly........................................................................2411 Inspection......................................................................................2412 MANUAL STEERING GEAR (Model: VB66K).................................................................2413 Removal and Installation........................................................................2413 Disassembly.....................................................................................2414 Assembly and Adjustment.........................................................................2414 Inspection......................................................................................2417 POWER STEERING SYSTEM (Model: PB59K)................................................................2419 Description.....................................................................................2419 POWER STEERING GEAR (Model: PB59K)..................................................................2420 Removal and Installing..........................................................................2420 Power Steering Gear Component...................................................................2420 Pre-disassembly Inspection and Adjustment.......................................................2421 Disassembly.....................................................................................2422 Assembly........................................................................................2423 POWER STEERING SYSTEM (Model: PB48S)................................................................2426 Description.....................................................................................2426 POWER STEERING GEAR (Model: PB48S)..................................................................2427 Removal and Installing..........................................................................2427 Power Steering Gear Component)..................................................................2427 Pre-disassembly Inspection and Adjustment.......................................................2428 Disassembly.....................................................................................2429 Assembly........................................................................................2431 POWER STEERING OIL PUMP.............................................................................2434 Disassembly and Assembly........................................................................2434 Pre-disassembly Inspection......................................................................2434 Inspection......................................................................................2435 Disassembly.....................................................................................2435 Assembly........................................................................................2436 STEERING LINKAGE....................................................................................2437 Removal and Installation........................................................................2437 Disassembly.....................................................................................2438 Inspection......................................................................................2439 SERVICE DATA AND SPECIFICATIONS (SDS)...............................................................2440 General Specifications..........................................................................2440 Inspection and Adjustment.......................................................................2440 tf......................................................................................................2443 QUICK REFERENCE INDEX............................................................................... 0 TABLE OF CONTENTS...................................................................................2443 PREPARATION.........................................................................................2444 Special Service Tools...........................................................................2444 Commercial Service Tools........................................................................2445 Replacing Oil Seal..............................................................................2446 Center Case Oil Seal........................................................................2446 Shift Shaft Oil Seal........................................................................2446 Rear Oil Seal...............................................................................2447 REMOVAL AND INSTALLATION............................................................................2448 TRANSFER GEAR CONTROL...............................................................................2448 MAJOR OVERHAUL......................................................................................2450 Case Components.................................................................................2450 Gear Components.................................................................................2451 Shift Control Components........................................................................2452 DISASSEMBLY.........................................................................................2453 REPAIR AND COMPONENT PARTS..........................................................................2457 Mainshaft.......................................................................................2457 Front Drive Shaft...............................................................................2459 Counter Gear....................................................................................2460 Main Gear.......................................................................................2460 Front Case......................................................................................2462 Shift Shaft Oil Seal........................................................................2462 Front Case Cover................................................................................2462 Cover Oil Seal..............................................................................2462 Bearing Retainer................................................................................2463 Oil Catcher.................................................................................2463 Rear Case.......................................................................................2463 Rear Oil Seal...............................................................................2463 Air Breather................................................................................2463 Shift Control Components........................................................................2464 ASSEMBLY............................................................................................2465 SERVICE DATA AND SPECIFICATIONS (SDS)...............................................................2472 General Specifications..........................................................................2472 Inspection and Adjustment.......................................................................2472
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DESCRIPTION:
1997 NISSAN TRUCK D21 Series Service Manual PDF DOWNLOAD
FOREWORD
- This manual contains maintenance and repair procedures for the 1997 Nissan TRUCK.
- In order to assure your safety and the efficient functioning of the vehicle, this manual should be read thoroughly.
- It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task.
- All information in this manual is based on the latest product information at the time of publication. The right is reserved to make changes in specifications and methods at any time without notice.
Important Safety Notice:
- The proper performance of service is essential for both the safety of the technician and the efficient functioning of the vehicle.
- The service methods in this Service Manual are described in such a manner that the service may be performed safely and accurately.
- Service varies with the procedures used, the skills of the technician and the tools and parts available.
- Accordingly, anyone using service procedures, tools or parts which are not specifically recommended by NISSAN must first be completely satisfied that neither personal safety nor the vehicle’s safety will be jeopardized by the service method selected
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
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