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1998 INFINITI QX4 R50 Series Service Manual – PDF DOWNLOAD
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Description
1998 INFINITI QX4 R50 Series Service Manual – PDF DOWNLOAD
FILE DETAILS:
1998 INFINITI QX4 R50 Series Service Manual – PDF DOWNLOAD
Language : English
Pages : 1794
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
1998 INFINITI QX4 R50 Series Service Manual – PDF DOWNLOAD
FOREWORD:
This manual contains maintenance and repair procedures for the 1998 INFINITI QX4.
- 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 infor mation at the time of
publication. The right is reserved to make changes in specifications and methods at any time
without notice.
IMPORTANT SAFETY NOTICE:
- The proper performance of service is essential for both the safety of the technician and the
efficient functioning of the vehicle. - The service methods in this Service Manual are described in such a manner that the service may be
performed safely and accurately. - Service varies with the procedures used, the skills of the technician and the tools and parts
available. Accordingly, anyone using service procedures, tools or parts which are not specifically
recommended by INFINITI must first be completely satisfied that neither personal safety nor
the vehicle’s safety will be jeopardized by the service method selected.
TABLE OF CONTENTS:
1998 INFINITI QX4 R50 Series Service Manual – PDF DOWNLOAD
fwd.............................................................................................................................. 1 QUICK REFERENCE INDEX........................................................................................................ 1 FOREWORD..................................................................................................................... 2 GI - General Information..................................................................................................... 0 MA - Maintenance............................................................................................................. 0 EM - Engine Mechanical....................................................................................................... 0 LC - Engine Lubrication & Cooling Systems.................................................................................... 0 EC - Engine Control System................................................................................................... 0 FE - Accelerator Control, Fuel & Exhaust Systems............................................................................. 0 AT - Automatic Transmission.................................................................................................. 0 TF - Transfer................................................................................................................ 0 PD - Propeller Shaft & Differential Carrier.................................................................................. 0 AX - Front & Rear Axle....................................................................................................... 0 SU - Front & Rear Suspension................................................................................................. 0 BR - Brake System............................................................................................................ 0 ST - Steering System......................................................................................................... 0 RS - Restraint System........................................................................................................ 0 BT - Body & Trim............................................................................................................. 0 HA - Heater & Air Conditioner................................................................................................ 0 SC - Starting & Charging System.............................................................................................. 0 EL - Electrical System....................................................................................................... 0 IDX - Alphabetical Index..................................................................................................... 1 Foldout...................................................................................................................... 0 Comment Sheet................................................................................................................ 3 Inch to Metric Conversion Table.............................................................................................. 4 Quick Reference Chart........................................................................................................ 5 GST Mode 6 - Test Value & Test Limit Chart................................................................................... 6 at............................................................................................................................... 7 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................ 7 TROUBLE DIAGNOSIS - INDEX.................................................................................................... 10 Alphabetical & P No. Index for DTC....................................................................................... 10 PRECAUTIONS.................................................................................................................. 12 Precautions for Supplemental Restraint System (SRS) "AIR BAG"............................................................ 12 Precautions for On Board Diagnostic (OBD) System of A/T and Engine....................................................... 12 System of A/T and Engine................................................................................................. 12 Precautions.............................................................................................................. 12 Service Notice or Precautions............................................................................................ 14 Wiring Diagrams and Trouble Diagnosis.................................................................................... 15 PREPARATION.................................................................................................................. 16 Special Service Tools.................................................................................................... 16 OVERALL SYSTEM............................................................................................................... 18 A/T Electrical Parts Location............................................................................................ 18 Circuit Diagram.......................................................................................................... 19 Cross-sectional View..................................................................................................... 20 Hydraulic Control Circuit................................................................................................ 21 Shift Mechanism.......................................................................................................... 22 Control System........................................................................................................... 31 Control Mechanism........................................................................................................ 32 Control Valve............................................................................................................ 37 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION....................................................................................... 39 Introduction............................................................................................................. 39 OBD-II Function for A/T System........................................................................................... 39 One or Two Trip Detection Logic of OBD-II................................................................................ 39 OBD-II Diagnostic Trouble Code (DTC)..................................................................................... 39 Malfunction Indicator Lamp (MIL)......................................................................................... 43 CONSULT.................................................................................................................. 43 TROUBLE DIAGNOSIS - INTRODUCTION............................................................................................. 56 Introduction............................................................................................................. 56 Work Flow................................................................................................................ 60 TROUBLE DIAGNOSIS - BASIC INSPECTION......................................................................................... 62 A/T Fluid Check.......................................................................................................... 62 Stall Test............................................................................................................... 62 Line Pressure Test....................................................................................................... 65 Road Test................................................................................................................ 66 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION...................................................................................... 77 Symptom Chart............................................................................................................ 77 TCM Terminals and Reference Valve........................................................................................ 88 TROUBLE DIAGNOSIS FOR POWER SUPPLY........................................................................................... 93 Wiring Diagram - AT - MAIN............................................................................................... 93 DTC P0705 INHIBITOR SWITCH................................................................................................... 95 Description.............................................................................................................. 95 Wiring Diagram - AT - INH/SW............................................................................................. 97 Diagnostic Procedure..................................................................................................... 98 Component Inspection..................................................................................................... 99 DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT............................................................................... 100 Description.............................................................................................................. 100 Wiring Diagram - AT - FTS................................................................................................ 102 Diagnostic Procedure..................................................................................................... 103 Component Inspection..................................................................................................... 104 DTC P0720 VEHICLE SPEED SENSOR - A/T (REVOLUTION SENSOR)..................................................................... 105 Description.............................................................................................................. 105 Wiring Diagram - AT - VSSA/T............................................................................................. 107 Diagnostic Procedure..................................................................................................... 108 Component Inspection..................................................................................................... 109 DTC P0725 ENGINE SPEED SIGNAL................................................................................................ 110 Description.............................................................................................................. 110 Wiring Diagram - AT - ENGSS.............................................................................................. 112 Diagnostic Procedure..................................................................................................... 113 DTC P0731 IMPROPER SHIFTING TO 1ST GEAR POSITION............................................................................. 114 Description.............................................................................................................. 114 Wiring Diagram - AT - 1ST................................................................................................ 117 Diagnostic Procedure..................................................................................................... 118 Component Inspection..................................................................................................... 119 DTC P0732 IMPROPER SHIFTING TO 2ND GEAR POSITION............................................................................. 120 Description.............................................................................................................. 120 Wiring Diagram - AT - 2ND................................................................................................ 123 Diagnostic Procedure..................................................................................................... 124 Component Inspection..................................................................................................... 124 DTC P0733 IMPROPER SHIFTING TO 3RD GEAR POSITION............................................................................. 126 Description.............................................................................................................. 126 Wiring Diagram - AT - 3RD................................................................................................ 129 Diagnostic Procedure..................................................................................................... 130 Component Inspection..................................................................................................... 130 DTC P0734 IMPROPER SHIFTING TO 4TH GEAR POSITION............................................................................. 132 Description.............................................................................................................. 132 Wiring Diagram - AT - 4TH................................................................................................ 136 Diagnostic Procedure..................................................................................................... 137 Component Inspection..................................................................................................... 140 DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE............................................................................. 141 Description.............................................................................................................. 141 Wiring Diagram - AT - TCV................................................................................................ 143 Diagnostic Procedure..................................................................................................... 144 Component Inspection..................................................................................................... 145 DTC P0744 IMPROPER LOCK-UP OPERATION......................................................................................... 146 Description.............................................................................................................. 146 Wiring Diagram - AT - TCCSIG............................................................................................. 149 Diagnostic Procedure..................................................................................................... 150 Component Inspection..................................................................................................... 153 DTC P0745 LINE PRESSURE SOLENOID VALVE....................................................................................... 154 Description.............................................................................................................. 154 Wiring Diagram - AT - LPSV............................................................................................... 156 Diagnostic Procedure..................................................................................................... 157 Component Inspection..................................................................................................... 158 DTC P0750 SHIFT SOLENOID VALVE A............................................................................................. 160 Description.............................................................................................................. 160 Wiring Diagram - AT - SSV/A.............................................................................................. 162 Diagnostic Procedure..................................................................................................... 163 Component Inspection..................................................................................................... 164 DTC P0755 SHIFT SOLENOID VALVE B............................................................................................. 165 Description.............................................................................................................. 165 Wiring Diagram - AT - SSV/B.............................................................................................. 167 Diagnostic Procedure..................................................................................................... 168 Component Inspection..................................................................................................... 169 DTC P1705 THROTTLE POSITION SENSOR........................................................................................... 170 Description.............................................................................................................. 170 Wiring Diagram - AT - TPS................................................................................................ 173 Diagnostic Procedure..................................................................................................... 174 Component Inspection..................................................................................................... 176 DTC P1760 OVERRUN CLUTCH SOLENOID VALVE...................................................................................... 177 Description.............................................................................................................. 177 Wiring Diagram - AT - OVRCSV............................................................................................. 179 Diagnostic Procedure..................................................................................................... 180 Component Inspection..................................................................................................... 181 DTC BATT/FLUID TEMP SEN A/T FLUID TEMPERATURE SENSOR CIRCUIT AND TCM POWER SOURCE............................................ 182 Description.............................................................................................................. 182 Wiring Diagram - AT - BA/FTS............................................................................................. 184 Diaganostic Procedure.................................................................................................... 185 Component Inspection..................................................................................................... 186 VEHICLE SPEED SENSOR-MTR..................................................................................................... 187 Description.............................................................................................................. 187 Wiring Diagram - AT - VSSMTR............................................................................................. 189 Diagnostic Procedure..................................................................................................... 190 TROUBLE DIAGNOSES FOR SYMPTOMS............................................................................................... 191 Wiring Diagram - AT - NONDTC............................................................................................. 191 1. O/D OFF Indictor Lamp Does Not Come On................................................................................ 199 2. Engine Cannot Be Started in "O" or "N" Position....................................................................... 201 3. In "P" Position, Vehicle Moves Forward Or Backward When Pushed........................................................ 202 4. In "N" Position, Vehicle Moves........................................................................................ 203 5. Large Shock. "N" - "R" Position....................................................................................... 205 6. Vehicle Does Not Creep Backward in "R" Position....................................................................... 206 7. Vehicle Does Not Creep Forward In "D", "2" Or "1" Position............................................................ 208 8. Vehicle Cannot Be Started From D1..................................................................................... 210 9. A/T Does Not Shift: D1 - D2 Or Does Not Kickdown: D4 - D2............................................................. 212 10. A/T Does Not Shift: D2 - D3.......................................................................................... 214 11. A/T Does Not Shift: D3 - D4.......................................................................................... 216 12. A/T Does Not Perform Lock-up......................................................................................... 218 13. A/T Does Not Hold Lock-up Condition.................................................................................. 219 14. Lock-up Is Not Released.............................................................................................. 220 15. Engine Speed Does Not Return To Idle (Light Braking D4 - D3)......................................................... 221 16. Vehicle Does Not Start From D1....................................................................................... 222 17. A/T Does Not Shift: D4 - D3, When Overdrive Control Switch "ON" - "OFF".............................................. 223 18. A/T Does Not Shift: D3 - 2-2, When Selector Lever "D" - "2" Position................................................. 224 19. A/T Does Not Shift: 2-2 - 1-1, When Selector Lever "2" - "1" Position................................................ 225 20. Vehicle Does Not Decelearte By Engine Brake.......................................................................... 225 21. TCM Self-diagnosis Does Not Activate (Inhibitor, Overdrive Control and Throttle Position Switches Circuit Checks).... 226 A/T SHIFT LOCK SYSTEM........................................................................................................ 232 Description.............................................................................................................. 232 Wiring Diagram - SHIFT -................................................................................................. 233 Diagnostic Procedure..................................................................................................... 234 Component Check.......................................................................................................... 236 KEY INTERLOCK CABLE.......................................................................................................... 237 Components............................................................................................................... 237 Removal.................................................................................................................. 237 Installation............................................................................................................. 238 ON-VEHICLE SERVICE........................................................................................................... 239 Control Valve Assembly and Accumulators.................................................................................. 239 Revolution Sensor Replacement............................................................................................ 240 Rear Oil Seal Replacement................................................................................................ 240 Parking Components Inspection............................................................................................ 240 Inhibitor Switch Adjustment.............................................................................................. 240 Manual Control Linkage Adjustment........................................................................................ 241 REMOVAL AND INSTALLATION..................................................................................................... 242 Removal.................................................................................................................. 242 Installation............................................................................................................. 243 OVERHAUL..................................................................................................................... 245 Components............................................................................................................... 245 Oil Channel.............................................................................................................. 247 Locations of Needle Bearings, Thrust Washers and Snap Rings.............................................................. 248 DISASSEMBLY.................................................................................................................. 249 REPAIR FOR COMPONENT PARTS................................................................................................... 260 Oil Pump................................................................................................................. 260 Control Valve Assembly................................................................................................... 264 Control Valve Upper Body................................................................................................. 270 Control Valve Lower Body................................................................................................. 275 Reverse Clutch........................................................................................................... 277 High Clutch.............................................................................................................. 281 Forward and Overrun Clutches............................................................................................. 283 Low & Reverse Brake...................................................................................................... 287 Forward Clutch Drum Assembly............................................................................................. 291 Rear Internal Gear and Forward Clutch Hub................................................................................ 293 Band Servo Piston Assembly............................................................................................... 296 Parking Pawl Components.................................................................................................. 300 ASSEMBLY..................................................................................................................... 302 Assembly (1)............................................................................................................. 302 Adjustment............................................................................................................... 306 Assembly (2)............................................................................................................. 310 A/T FLUID COOLER SYSTEM...................................................................................................... 320 A/T Fluid Cooler......................................................................................................... 320 Removal and Installation................................................................................................. 320 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................................................ 321 General Specifications................................................................................................... 321 Shift Schedule........................................................................................................... 321 Stall Revolution......................................................................................................... 321 Line Pressure............................................................................................................ 321 Return Springs........................................................................................................... 322 Accumulator O-ring....................................................................................................... 323 Clutches and Brakes...................................................................................................... 323 Oil Pump and Low One-way Clutch.......................................................................................... 325 Total End Play........................................................................................................... 325 Reverse Clutch Drum End Play............................................................................................. 326 Removal and Installation................................................................................................. 326 ax............................................................................................................................... 327 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................ 327 FRONT AXLE................................................................................................................... 328 Precautions.............................................................................................................. 328 PRECAUTIONS.......................................................................................................... 328 Preparation.............................................................................................................. 328 SPECIAL SERVICE TOOLS................................................................................................ 328 COMMERCIAL SERVICE TOOLS............................................................................................. 328 Noise, Vibration and Harshness (NVH) Troubleshooting..................................................................... 329 NVH TROUBLESHOOTING CHART............................................................................................ 329 On-vehicle Service....................................................................................................... 329 FRONT AXLE PARTS..................................................................................................... 329 FRONT WHEEL BEARING.................................................................................................. 330 DRIVE SHAFT.......................................................................................................... 331 Wheel Hub and Rotor Disc................................................................................................. 332 COMPONENTS........................................................................................................... 332 REMOVAL.............................................................................................................. 332 INSTALLATION......................................................................................................... 333 DISASSEMBLY.......................................................................................................... 334 INSPECTION........................................................................................................... 334 ASSEMBLY............................................................................................................. 334 Knuckle Spindle.......................................................................................................... 335 REMOVAL.............................................................................................................. 335 INSPECTION........................................................................................................... 336 INSTALLATION......................................................................................................... 336 Drive Shaft.............................................................................................................. 336 COMPONENTS........................................................................................................... 336 REMOVAL.............................................................................................................. 337 DISASSEMBLY.......................................................................................................... 337 INSPECTION........................................................................................................... 338 ASSEMBLY............................................................................................................. 339 INSTALLATION......................................................................................................... 340 REAR AXLE.................................................................................................................... 342 Precautions.............................................................................................................. 342 PRECAUTIONS.......................................................................................................... 342 Preparation.............................................................................................................. 342 SPECIAL SERVICE TOOLS................................................................................................ 342 COMMERCIAL SERVICE TOOLS............................................................................................. 343 Noise, Vibration and Harshness (NVH) Troubleshooting..................................................................... 343 On-vehicle Service....................................................................................................... 343 REAR AXLE PARTS...................................................................................................... 343 REAR WHEEL BEARING................................................................................................... 343 Components............................................................................................................... 344 Removal.................................................................................................................. 344 Inspection............................................................................................................... 346 AXLE SHAFT........................................................................................................... 346 BEARING CAGE......................................................................................................... 346 REAR AXLE HOUSING.................................................................................................... 346 Installation............................................................................................................. 346 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................................................ 348 Wheel Bearing (Front).................................................................................................... 348 Drive Shaft.............................................................................................................. 348 DRIVE SHAFT END SNAP RING............................................................................................ 348 Wheel Bearing (Rear)..................................................................................................... 348 br............................................................................................................................... 349 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................ 349 PRECAUTION................................................................................................................... 351 Supplemental Restraint System (SRS) 'AIR BAG"............................................................................ 351 Precautions for Brake System............................................................................................. 351 Wiring Diagrams and Trouble Diagnosis.................................................................................... 351 PREPARATION.................................................................................................................. 352 Special Service Tools.................................................................................................... 352 Commercial Service Tools................................................................................................. 352 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING......................................................................... 352 NVH Troubleshooting Chart................................................................................................ 352 ON-VEHICLE SERVICE........................................................................................................... 354 Checking Brake Fluid Level............................................................................................... 354 Checking Brake Line...................................................................................................... 354 Changing Brake Fluid..................................................................................................... 354 Bleeding Brake System.................................................................................................... 355 BRAKE HYDRAULIC LINE......................................................................................................... 356 Hydraulic Circuit........................................................................................................ 356 Removal.................................................................................................................. 356 Inspection............................................................................................................... 357 Installation............................................................................................................. 357 LOAD SENSING VALVE........................................................................................................... 358 Inspection............................................................................................................... 358 Removal and Installation................................................................................................. 359 BRAKE PEDAL AND BRACKET...................................................................................................... 361 Removal and Installation................................................................................................. 361 Inspection............................................................................................................... 361 Adjustment............................................................................................................... 361 MASTER CYLINDER.............................................................................................................. 363 Removal.................................................................................................................. 363 Disassembly.............................................................................................................. 363 Inspection............................................................................................................... 364 Assembly................................................................................................................. 364 Installation............................................................................................................. 365 BRAKE BOOSTER................................................................................................................ 366 On-vehicle Service....................................................................................................... 366 OPERATING CHECK...................................................................................................... 366 AIRTIGHT CHECK....................................................................................................... 366 Removal.................................................................................................................. 366 Inspection............................................................................................................... 366 OUTPUT ROD LENGTH CHECK.............................................................................................. 366 Installation............................................................................................................. 367 VACUUM PIPING................................................................................................................ 368 Vacuum Hose.............................................................................................................. 368 Removal and Installation................................................................................................. 368 Inspection............................................................................................................... 368 HOSES AND CONNECTORS................................................................................................. 368 CHECK VALVE.......................................................................................................... 368 FRONT DISC BRAKE............................................................................................................. 369 Components............................................................................................................... 369 Pad Replacement.......................................................................................................... 369 Removal.................................................................................................................. 370 Disassembly.............................................................................................................. 371 Inspection............................................................................................................... 371 CALIPER.............................................................................................................. 371 ROTOR................................................................................................................ 371 Assembly................................................................................................................. 372 Installation............................................................................................................. 372 Brake Burnishing Procedure............................................................................................... 372 REAR DRUM BRAKE.............................................................................................................. 373 Components............................................................................................................... 373 Removal.................................................................................................................. 373 Inspection............................................................................................................... 374 WHEEL CYLINDER....................................................................................................... 374 Wheel Cylinder Overhaul.................................................................................................. 375 Inspection............................................................................................................... 375 DRUM................................................................................................................. 375 LINING............................................................................................................... 375 Installation............................................................................................................. 375 PARKING BRAKE CONTROL........................................................................................................ 377 Components............................................................................................................... 377 Removal and Installation................................................................................................. 377 Inspection............................................................................................................... 377 Adjustment............................................................................................................... 378 ABS.......................................................................................................................... 379 DESCRIPTION.............................................................................................................. 379 Purpose.............................................................................................................. 379 Operation............................................................................................................ 379 ABS Hydraulic Circuit................................................................................................ 379 System Components.................................................................................................... 380 System Description................................................................................................... 380 SENSOR........................................................................................................... 380 CONTROL UNIT..................................................................................................... 380 G SENSOR......................................................................................................... 381 ACTUATOR......................................................................................................... 382 Component Parts and Harness Connector Location....................................................................... 383 Circuit Diagram for Quick Pinpoint Check............................................................................. 384 Wiring Diagram - ABS -............................................................................................... 385 ON BOARD DIAGNOSTIC SYSTEM............................................................................................... 389 Self-diagnosis....................................................................................................... 389 FUNCTION......................................................................................................... 389 SELF-DIAGNOSIS PROCEDURE......................................................................................... 389 HOW TO READ SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES).......................................................... 390 HOW TO ERASE SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES.......................................................... 390 CONSULT.............................................................................................................. 391 CONSULT APPLICATION TO ABS....................................................................................... 391 ECU (ABS CONTROL UNIT) PART NUMBER MODE.......................................................................... 391 CONSULT Inspection Procedure......................................................................................... 392 SELF-DIAGNOSIS PROCEDURE......................................................................................... 392 SELF-DIAGNOSTIC RESULTS MODE..................................................................................... 393 DATA MONITOR PROCEDURE........................................................................................... 394 ACTIVE TEST PROCEDURE............................................................................................ 395 DATA MONITOR MODE................................................................................................ 396 ACTIVE TEST MODE................................................................................................. 396 TROUBLE DIAGNOSIS - INTRODUCTION......................................................................................... 397 How to Perform Trouble Diagnoses for Quick and Accurate Repari....................................................... 397 INTRODUCTION..................................................................................................... 397 TROUBLE DIAGNOSIS - BASIC INSPECTION..................................................................................... 398 Preliminary Check.................................................................................................... 398 Ground Circuit Check................................................................................................. 400 ACTUATOR MOTOR GROUND............................................................................................ 400 CONTROL UNIT GROUND.............................................................................................. 400 ACTUATOR GROUND.................................................................................................. 400 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION.................................................................................. 401 Malfunction Code/Symptom Chart....................................................................................... 401 WHEEL SENSOR OR ROTOR.................................................................................................... 402 Diagnostic Procedure................................................................................................. 402 ABS ACTUATOR SOLENOID VALVE.............................................................................................. 403 Diagnostic Procedure................................................................................................. 403 SOLENOID VALVE RELAY..................................................................................................... 406 Diagnostic Procedure................................................................................................. 406 MOTOR RELAY OR MOTOR..................................................................................................... 409 Diagnostic Procedure................................................................................................. 409 LOW VOLTAGE.............................................................................................................. 413 Diagnostic Procedure................................................................................................. 413 G SENSOR................................................................................................................. 414 Diagnostic Procedure................................................................................................. 414 Electrical Components Inspection..................................................................................... 416 G SENSOR......................................................................................................... 416 CONTROL UNIT............................................................................................................. 417 Diagnostic Procedure................................................................................................. 417 TROUBLE DIAGNOSES FOR SYMPTOMS........................................................................................... 418 1. ABS Works Frequently.............................................................................................. 418 2. Unexpected Pedal Action........................................................................................... 418 3. Long Stopping Distance............................................................................................ 419 4. ABS Does Not Work................................................................................................. 420 5. Pedal Vibration and Noise......................................................................................... 420 6. Warning Lamp Does Not Come On When Ignition Switch Is Turned On................................................... 421 7.Warning Lamp Stays On When Ignition Switch Is Turned On............................................................ 424 8. Vehicle Vibrates Excessively When ABS Is Operating................................................................ 427 REMOVAL AND INSTALLATION................................................................................................. 429 Front Wheel Sensor................................................................................................... 429 Rear Wheel Sensor.................................................................................................... 429 Front Sensor Rotor................................................................................................... 430 REMOVAL.......................................................................................................... 430 INSTALLATION..................................................................................................... 430 Rear Sensor Rotor.................................................................................................... 430 REMOVAL.......................................................................................................... 430 INSTALLATION..................................................................................................... 430 Control Unit......................................................................................................... 431 REMOVAL.......................................................................................................... 431 G Sensor............................................................................................................. 431 Actuator............................................................................................................. 432 REMOVAL.......................................................................................................... 432 INSTALLATION..................................................................................................... 432 Actuator Relays...................................................................................................... 433 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................... 434 General Specifications............................................................................................... 434 Disc Brake........................................................................................................... 434 Drum Brake........................................................................................................... 434 Brake Pedal.......................................................................................................... 434 Parking Brake Control................................................................................................ 435 bt............................................................................................................................... 436 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................ 436 PRECAUTIONS.................................................................................................................. 437 Service Notice........................................................................................................... 437 Supplemental Restraint System (SRS) "AIR BAG"............................................................................ 437 CLIP AND FASTENER............................................................................................................ 438 Description.............................................................................................................. 438 BODY FRONT END............................................................................................................... 440 Removal and Installation................................................................................................. 440 FRONT BUMPER ASSEMBLY................................................................................................ 440 BODY REAR END AND OPENER..................................................................................................... 443 Removal and Installation................................................................................................. 443 REAR BUMPER ASSEMBLY................................................................................................. 443 FRONT DOOR................................................................................................................... 446 Overhaul................................................................................................................. 446 REAR DOOR.................................................................................................................... 447 Overhaul................................................................................................................. 447 INSTRUMENT PANEL ASSEMBLY.................................................................................................... 448 Removal and Installation................................................................................................. 448 SIDE AND FLOOR TRIM.......................................................................................................... 452 Removal and Installation................................................................................................. 452 DOOR TRIM.................................................................................................................... 454 Removal and Installation................................................................................................. 454 ROOF TRIM.................................................................................................................... 455 Removal and Installation................................................................................................. 455 BACK DOOR TRIM............................................................................................................... 456 Removal and Installation................................................................................................. 456 EXTERIOR..................................................................................................................... 457 Removal and Installation................................................................................................. 457 FRONT SEAT................................................................................................................... 464 Removal and Installation................................................................................................. 464 POWER SEAT........................................................................................................... 464 MANUAL SEAT.......................................................................................................... 465 HEATED SEAT.......................................................................................................... 466 REAR SEAT.................................................................................................................... 467 Removal and Installation................................................................................................. 467 SUNROOF...................................................................................................................... 468 Adjustment............................................................................................................... 468 Removal and Installation................................................................................................. 469 Trouble Diagnosis........................................................................................................ 472 DIAGNOSTIC TABLE..................................................................................................... 472 WIND DEFLECTOR....................................................................................................... 472 ADJUSTMENT........................................................................................................... 473 DRAIN HOSES.......................................................................................................... 474 WEATHERSTRIP......................................................................................................... 474 LINK AND WIRE ASSEMBLY............................................................................................... 475 WINDSHIELD AND WINDOWS....................................................................................................... 476 Removal and Installation................................................................................................. 476 REMOVAL.............................................................................................................. 476 INSTALLATION......................................................................................................... 476 WINDSHIELD........................................................................................................... 477 REAR SIDE WINDOW..................................................................................................... 478 DOOR MIRROR.................................................................................................................. 479 Removal and Installation................................................................................................. 479 BODY (ALIGNMENT)............................................................................................................. 480 Alignment................................................................................................................ 480 ENGINE COMPARTMENT................................................................................................... 481 UNDERBODY............................................................................................................ 483 ec............................................................................................................................... 485 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................ 485 TROUBLE DIAGNOSIS - INDEX.................................................................................................... 492 Alphabetical & P No. Index for DTC....................................................................................... 492 PRECAUTIONS.................................................................................................................. 498 Supplemental Restraint System (SRS) "AIR BAG"............................................................................ 498 Precautions for On Board Diagnostic (OBD) System of Engine and A/T....................................................... 498 Engine Fuel & Emission Control System.................................................................................... 499 Precautions.............................................................................................................. 500 Wiring Diagram and Trouble Diagnosis..................................................................................... 501 PREPARATION.................................................................................................................. 502 Special Service Tools.................................................................................................... 502 Commercial Service Tools................................................................................................. 502 ENGINE AND EMISSION CONTROL OVERALL SYSTEM................................................................................... 504 ECCS Component Parts Location............................................................................................ 504 Circuit Diagram.......................................................................................................... 506 System Diagram........................................................................................................... 507 Vacuum Hose Drawing...................................................................................................... 508 System Chart............................................................................................................. 509 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION......................................................................... 510 Multiport Fuel Injection (MFI) System.................................................................................... 510 Distributor Ignition (DI) System......................................................................................... 512 Air Conditioning Cut Control............................................................................................. 513 Fuel Cut Control (at no load & high engine speed)........................................................................ 514 Evaporative Emission System.............................................................................................. 514 Positive Crankcase Ventilation........................................................................................... 520 BASIC SERVICE PROCEDURE...................................................................................................... 521 Fuel Pressure Release.................................................................................................... 521 Fuel Pressure Check...................................................................................................... 521 Fuel Pressure Regulator Check............................................................................................ 522 Injector................................................................................................................. 523 Fast Idle Cam (FIC)...................................................................................................... 524 Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment................................................................. 525 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION....................................................................................... 534 Introduction............................................................................................................. 534 Two Trip Detection Logic................................................................................................. 534 Emission-related Diagnostic Information.................................................................................. 535 Malfunction Indicator Lamp (MIL)......................................................................................... 547 OBD System Operation Chart............................................................................................... 551 CONSULT.................................................................................................................. 556 Generic Scan Tool (GST).................................................................................................. 569 TROUBLE DIAGNOSIS - INTRODUCTION............................................................................................. 571 Introduction............................................................................................................. 571 Work Flow................................................................................................................ 573 TROUBLE DIAGNOSIS - BASIC INSPECTION......................................................................................... 575 Basic Inspection......................................................................................................... 575 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION...................................................................................... 577 DTC Inspection Priority Chart............................................................................................ 577 Fail-safe Chart.......................................................................................................... 578 Symptom Matrix Chart..................................................................................................... 579 CONSULT Reference Value in Data Monitor Mode............................................................................. 583 Major Sensor Reference Graph in Data Monitor Mode........................................................................ 585 ECM Terminals and Reference Value........................................................................................ 588 TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT.................................................................................. 597 Description.............................................................................................................. 597 Diagnostic Procedure..................................................................................................... 597 TROUBLE DIAGNOSIS FOR POWER SUPPLY........................................................................................... 598 Main Power Supply and Ground Circuit..................................................................................... 598 DTC P0100 MASS AIR FLOW SENSOR (MAFS)........................................................................................ 605 Component Description.................................................................................................... 605 CONSULT Reference Value In Data Monitor Mode............................................................................. 605 ECM Terminals and Reference Value........................................................................................ 605 On Board Diagnosis Logic................................................................................................. 605 DTC Confirmation Procedure............................................................................................... 606 Wiring Diagram........................................................................................................... 609 Diagnostic Procedure..................................................................................................... 610 Component Inspection..................................................................................................... 612 DTC P0105 ABSOLUTE PRESSURE SENSOR........................................................................................... 613 Component Description.................................................................................................... 613 On Board Diagnosis Logic................................................................................................. 613 DTC Confirmation Procedure............................................................................................... 613 Wiring Diagram........................................................................................................... 616 Diagnostic Procedure..................................................................................................... 617 Component Inspection..................................................................................................... 621 DTC P0110 INTAKE AIR TEMPERATURE SENSOR...................................................................................... 622 Component Description.................................................................................................... 622 On Board Diagnosis Logic................................................................................................. 622 DTC Confirmation Procedure............................................................................................... 622 Wiring Diagram........................................................................................................... 625 Diagnostic Procedure..................................................................................................... 626 Component Inspection..................................................................................................... 627 DTC P0115 ENGINE COOLANT TEMPERATURE SENSOR (ECTS) (CIRCUIT)................................................................. 628 Component Description.................................................................................................... 628 On Board Diagnosis Logic................................................................................................. 628 DTC Confirmation Procedure............................................................................................... 629 Wiring Diagram........................................................................................................... 630 Diagnostic Procedure..................................................................................................... 631 Component Inspection..................................................................................................... 632 DTC P0120 THROTTLE POSITION SENSOR........................................................................................... 633 Component Description.................................................................................................... 633 CONSULT Reference Value in Data Monitor Mode............................................................................. 633 ECM Terminals and Reference Value........................................................................................ 633 On Board Diagnosis Logic................................................................................................. 634 DTC Confirmation Procedure............................................................................................... 634 Wiring Diagram........................................................................................................... 639 Diagnostic Procedure..................................................................................................... 640 Component Inspection..................................................................................................... 642 DTC P0125 ENGINE COOLANT TEMPERATURE (ECT) SENSOR............................................................................ 643 Component Description.................................................................................................... 643 On Board Diagnosis Logic................................................................................................. 643 DTC Confirmation Procedure............................................................................................... 643 Wiring Diagram........................................................................................................... 645 Diagnostic Procedure..................................................................................................... 646 Component Inspection..................................................................................................... 647 DTC P0130 (RIGHT BANK, -B1), P0150 (LEFT BANK, -B2) FRONT HEATED OXYGEN SENSOR (FRONT HO2S) (CIRCUIT)........................ 648 Component Description.................................................................................................... 648 CONSULT Reference Value in Data Monitor Mode............................................................................. 648 ECM Terminals and Reference Value........................................................................................ 648 On Board Diagnosis Logic................................................................................................. 649 DTC Confirmation Procedure............................................................................................... 649 Overall Function Check................................................................................................... 650 Wiring Diagram........................................................................................................... 651 Diagnostic Procedure..................................................................................................... 653 Component Inspection..................................................................................................... 654 DTC P0131 (RIGHT BANK, -B1), P0151 (LEFT BANK, -B2) FRONT HEATED OXYGEN SENSOR (FRONT HO2S) (LEAN SHIFT MONITORING).......... 656 Component Description.................................................................................................... 656 CONSULT Reference Value in Data Monitor Mode............................................................................. 656 ECM Terminals and Reference Value........................................................................................ 656 On Board Diagnosis Logic................................................................................................. 657 DTC Confirmation Procedure............................................................................................... 657 Overall Function Check................................................................................................... 658 Diagnostic Procedure..................................................................................................... 659 Component Inspection..................................................................................................... 660 DTC P0132 (RIGHT BANK, -B1), P0152 (LEFT BANK, -B2) FRONT HEATED OXYGEN SENSOR (FRONT HO2S) (RICH SHIFT MONITORING).......... 662 Component Description.................................................................................................... 662 CONSULT Reference Value in Data Monitor Mode............................................................................. 662 ECM Terminals and Reference Value........................................................................................ 662 On Board Diagnosis Logic................................................................................................. 663 DTC Confirmation Procedure............................................................................................... 663 Overall Function Check................................................................................................... 664 Diagnostic Procedure..................................................................................................... 665 Component Inspection..................................................................................................... 666 DTC P0133 (RIGHT BANK, -B1), P0153 (LEFT BANK, -B2) FRONT HEATED OXYGEN SENSOR (FRONT HO2S) (RESPONSE MONITORING)............ 668 Component Description.................................................................................................... 668 CONSULT Reference Value in Data Monitor Mode............................................................................. 668 ECM Terminals and Reference Value........................................................................................ 668 On Board Diagnosis Logic................................................................................................. 669 DTC Confirmation Procedure............................................................................................... 669 Overall Function Check................................................................................................... 670 Wiring Diagram........................................................................................................... 671 Diagnostic Procedure..................................................................................................... 673 Component Inspection..................................................................................................... 675 DTC P0134 (RIGHT BANK, -B1) P0154 (LEFT BANK, -B2) FRONT HEATED OXYGEN SENSOR (FRONT HO2S) (HIGH VOLTAGE).................... 677 Component Description.................................................................................................... 677 CONSULT Reference Value in Data Monitor Mode............................................................................. 677 ECM Terminals and Reference Value........................................................................................ 677 On Board Diagnosis Logic................................................................................................. 678 DTC Confirmation Procedure............................................................................................... 678 Wiring Diagram........................................................................................................... 679 Diagnostic Procedure..................................................................................................... 681 Component Inspection..................................................................................................... 682 DTC P0135 (RIGHT BANK, -B1), P0155 (LEFT BANK, -B2) FRONT HEATED OXYGEN SENSOR HEATER........................................ 684 Description.............................................................................................................. 684 CONSULT Reference Value in Data Monitor Mode............................................................................. 684 ECM Terminals and Reference Value........................................................................................ 684 On Board Diagnosis Logic................................................................................................. 684 DTC Confirmation Procedure............................................................................................... 685 Wiring Diagram........................................................................................................... 686 Diagnostic Procedure..................................................................................................... 688 Component Inspection..................................................................................................... 689 DTC P0137 (RIGHT BANK, -B1) P0157 (LEFT BANK, -B2) REAR HEATED OXYGEN SENSOR (REAR HO2S) (MIN. VOLTAGE MONITORING)........... 690 Component Description.................................................................................................... 690 CONSULT Reference Value in Data Monitor Mode............................................................................. 690 ECM Terminals and Reference Value........................................................................................ 690 On Board Diagnosis Logic................................................................................................. 690 DTC Confirmation Procedure............................................................................................... 691 Overall Function Check................................................................................................... 692 Wiring Diagram........................................................................................................... 693 Diagnostic Procedure..................................................................................................... 695 Component Inspection..................................................................................................... 697 DTC P0138 (RIGHT BANK, -B1) P0158 (LEFT BANK, -B2) REAR HATED OXYGEN SENSOR (REAR HO2S) (MAX. VOLTAGE MONITORING)............ 698 Component Description.................................................................................................... 698 CONSULT Reference Value in Data Monitor Mode............................................................................. 698 ECM Terminals and Reference Value........................................................................................ 698 On Board Diagnosis Logic................................................................................................. 698 DTC Confirmation Procedure............................................................................................... 699 Overall Function Check................................................................................................... 700 Wiring Diagram........................................................................................................... 701 Diagnostic Procedure..................................................................................................... 703 Component Inspection..................................................................................................... 705 DTC P0139 (RIGHT BANK, -B1), P0159 (LEFT BANK, -B2) REAR HEATED OXYGEN SENSOR (REAR H02S) (RESPONSE MONITORING............... 706 Component Description.................................................................................................... 706 CONSULT Reference Value in Data Monitor Mode............................................................................. 706 ECM Terminals and Reference Value........................................................................................ 706 On Board Diagnosis Logic................................................................................................. 706 DTC Confirmation Procedure............................................................................................... 707 Overall Function Check................................................................................................... 708 Wiring Diagram........................................................................................................... 709 Diagnostic Procedure..................................................................................................... 711 Component Inspection..................................................................................................... 712 DTC P0140 (RIGHT BANK, -B1), P0160 (LEFT BANK, -B2) REAR HEATED OXYGEN SENSOR (REAR HO2S) (HIGH VOLTAGE)..................... 714 Component Description.................................................................................................... 714 CONSULT Reference Value in Data Monitor Mode............................................................................. 714 ECM Terminals and Reference Value........................................................................................ 714 On Board Diagnosis Logic................................................................................................. 714 DTC Confirmation Procedure............................................................................................... 715 Overall Function Check................................................................................................... 715 Wiring Diagram........................................................................................................... 716 Diagnostic Procedure..................................................................................................... 718 Component Inspection..................................................................................................... 719 DTC P0141 (RIGHT BANK, -B1), P0161 (LEFT BANK, -B2) REAR HEATED OXYGEN SENSOR HEATER......................................... 721 Description.............................................................................................................. 721 CONSULT Reference Value in Data Monitor Mode............................................................................. 721 ECM Terminals and Reference Value........................................................................................ 721 On Board Diagnosis Logic................................................................................................. 721 DTC Confirmation Procedure............................................................................................... 722 Wiring Diagram........................................................................................................... 723 Diagnostic Procedure..................................................................................................... 725 Component Inspection..................................................................................................... 726 DTC P0171 (RIGHT BANK, -B1), P0174 (LEFT BANK, -B2) FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE)............................... 727 On Board Diagnosis Logic................................................................................................. 727 DTC Confirmation Procedure............................................................................................... 727 Wiring Diagram........................................................................................................... 729 Diagnostic Procedure..................................................................................................... 731 DTC P0172 (RIGHT BANK, -B1) P0175 (LEFT BANK, -B2) FUEL INJECTION SYSTEM FUNCTION (RICH SIDE)................................ 734 On Board Diagnosis Logic................................................................................................. 734 DTC Confirmation Procedure............................................................................................... 734 Wiring Diagram........................................................................................................... 734 Diagnostic Procedure..................................................................................................... 736 DTC P0180 TANK FUEL TEMPERATURE SENSOR....................................................................................... 741 Component Description.................................................................................................... 741 On Board Diagnosis Logic................................................................................................. 741 DTC Confirmation Procedure............................................................................................... 741 Wiring Diagram........................................................................................................... 743 Diagnostic Procedure..................................................................................................... 744 Component Inspection..................................................................................................... 744 DTC P0300 - P0306 NO. 6 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE...................................................... 745 On Board Diagnosis Logic................................................................................................. 745 DTC Confirmation Procedure............................................................................................... 745 Diagnostic Procedure..................................................................................................... 746 Component Inspection..................................................................................................... 749 DTC P0325 KNOCK SENSOR (KS).................................................................................................. 750 Component Description.................................................................................................... 750 ECM Terminals and Reference Value........................................................................................ 750 On Board Diagnosis Logic................................................................................................. 750 DTC Confirmation Procedure............................................................................................... 750 Wiring Diagram........................................................................................................... 751 Diagnostic Procedure..................................................................................................... 752 Component Inspection..................................................................................................... 753 DTC P0335 CRANKSHAFT POSITION SENSOR (CKPS) (OBD)............................................................................ 754 Component Description.................................................................................................... 754 ECM Terminals and Reference Value........................................................................................ 754 On Board Diagnosis Logic................................................................................................. 754 DTC Confirmation Procedure............................................................................................... 755 Wiring Diagram........................................................................................................... 756 Diagnostic Procedure..................................................................................................... 757 Component Inspection..................................................................................................... 758 DTC P0340 CAMSHAFT POSITION SENSOR (CMPS).................................................................................... 759 Component Description.................................................................................................... 759 ECM Terminals and Reference Value........................................................................................ 759 On Board Diagnosis Logic................................................................................................. 760 DTC Confirmation Procedure............................................................................................... 760 Wiring Diagram........................................................................................................... 762 Diagnostic Procedure..................................................................................................... 763 Component Inspection..................................................................................................... 764 DTC P0400 EGR FUNCTION (CLOSE)............................................................................................... 766 Description.............................................................................................................. 766 On Board Diagnosis Logic................................................................................................. 767 DTC Confirmation Procedure............................................................................................... 768 Overall Function Check................................................................................................... 769 Wiring Diagram........................................................................................................... 770 Diagnostic Procedure..................................................................................................... 771 Component Inspection..................................................................................................... 773 DTC P0402 EGRC-BPT VALVE FUNCTION............................................................................................ 774 Description.............................................................................................................. 774 On Board Diagnosis Logic................................................................................................. 774 DTC Confirmation Procedure............................................................................................... 775 Overall Function Check................................................................................................... 775 Diagnostic Procedure..................................................................................................... 776 Component Inspection..................................................................................................... 777 DTC P0420 (RIGHT BANK, -B1), P0430 (LEFT BANK, -B2) THREE WAY CATALYST FUNCTION.............................................. 778 On Board Diagnosis Logic................................................................................................. 778 DTC Confirmation Procedure............................................................................................... 778 Overall Function Check................................................................................................... 779 Diagnostic Procedure..................................................................................................... 780 DTC P0440 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM (SMALL LEAK) (NEGATIVE PRESSURE)........................................ 782 On Board Diagnosis Logic................................................................................................. 782 DTC Confirmation Procedure............................................................................................... 783 Diagnostic Procedure..................................................................................................... 784 DTC P0443 EVAPORATIVE EMISSION (EVAP) CANISTER PURGE VOLUME CONTROL SOLENOID VALVE........................................... 789 Description.............................................................................................................. 789 CONSULT Reference Value in Data Monitor Mode............................................................................. 789 ECM Terminals and Reference Value........................................................................................ 790 On Board Diagnosis Logic................................................................................................. 790 DTC Confirmation Procedure............................................................................................... 790 Wiring Diagram........................................................................................................... 792 Diagnostic Procedure..................................................................................................... 793 Component Inspection..................................................................................................... 794 DTC P0446 EVAPORATIVE EMISSION (EVAP) CANISTER VENT CONTROL VALVE............................................................ 795 Component Description.................................................................................................... 795 CONSULT Reference Value in Data Monitor Mode............................................................................. 795 ECM Terminals and Reference Value........................................................................................ 795 On Board Diagnosis Logic................................................................................................. 795 DTC Confirmation Procedure............................................................................................... 795 Wiring Diagram........................................................................................................... 797 Diagnostic Procedure..................................................................................................... 798 Component Inspection..................................................................................................... 799 DTC P0450 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM PRESSURE SENSOR......................................................... 801 Component Description.................................................................................................... 801 CONSULT Reference Value in Data Monitor Mode............................................................................. 801 ECM Terminals and Reference Value........................................................................................ 801 On Board Diagnosis Logic................................................................................................. 802 DTC Confirmation Procedure............................................................................................... 802 Wiring Diagram........................................................................................................... 804 Diagnostic Procedure..................................................................................................... 805 Component Inspction...................................................................................................... 807 DTC P0500 VEHICLE SPEED SENSOR (VSS)......................................................................................... 809 Component Description.................................................................................................... 809 ECM Terminals and Reference Value........................................................................................ 809 On Board Diagnosis Logic................................................................................................. 809 DTC Confirmation Procedure............................................................................................... 809 Overall Function Check................................................................................................... 810 Wiring Diagram........................................................................................................... 810 Diagnostic Procedure..................................................................................................... 812 DTC P0505 IDLE AIR CONTROL VALVE (IACV) - AUSILIARY AIR CONTROL (AAC) VALVE.................................................. 813 Description.............................................................................................................. 813 CONSULT Reference Value in Data Monitor Mode............................................................................. 814 ECM Terminals and Reference Value........................................................................................ 814 On Board Diagnosis Logic................................................................................................. 814 DTC Confirmation Procedure............................................................................................... 814 Wiring Diagram........................................................................................................... 816 Diagnostic Procedure..................................................................................................... 817 Component Inspection..................................................................................................... 818 DTC P0510 CLOSED THROTTLE POSITION SWITCH.................................................................................... 819 Component Description.................................................................................................... 819 ECM Terminals and Reference Valve........................................................................................ 819 On Board Diagnosis Logic................................................................................................. 819 DTC Confirmation Procedure............................................................................................... 819 Overall Function Check................................................................................................... 820 Wiring Diagram........................................................................................................... 821 Diagnostic Procedure..................................................................................................... 822 Component Inspection..................................................................................................... 823 DTC P0600 A/T CONTROL........................................................................................................ 824 System Description....................................................................................................... 824 ECM Terminals and Referene Value......................................................................................... 824 On Board Diagnosis Logic................................................................................................. 824 DTC Confirmation Procedure............................................................................................... 824 Overall Function Check................................................................................................... 824 Wiring Diagram........................................................................................................... 825 Diagnostic Procedure..................................................................................................... 826 DTC P0605 ENGINE CONTROL MODULE (ECM)-ECCS CONTROL MODULE.................................................................... 827 Component Description.................................................................................................... 827 On Board Diagnosis Logic................................................................................................. 827 DTC Confirmation Procedure............................................................................................... 827 Diagnostic Procedure..................................................................................................... 828 DTC P1105 MANIFOLD ABSOLUTE PRESSURE (MAP)/BAROMETRIC PRESSURE (BARO) SWITCH SOLENOID VALVE.................................. 829 Description.............................................................................................................. 829 CONSULT Reference Value in Data Monitor Mode............................................................................. 829 ECM Terminals and Reference Value........................................................................................ 830 On Board Diagnosis Logic................................................................................................. 830 DTC Confirmation Procedure............................................................................................... 830 Wiring Diagram........................................................................................................... 832 Diagnostic Procedure..................................................................................................... 833 Component Inspection..................................................................................................... 837 DTC P1148 (RIGHT BANK, -B1), P1168 (LEFT BANK, -B2) CLOSED LOOP CONTROL...................................................... 838 On Board Diagnosis Logic................................................................................................. 838 DTC Confirmation Procedure............................................................................................... 838 Overall Function Check................................................................................................... 839 Diagnostic Procedure..................................................................................................... 839 DTC P1320 IGNITION SIGNAL.................................................................................................... 840 Component Description.................................................................................................... 840 CONSULT Reference Value in Data Monitor Mode............................................................................. 840 ECM Terminals and Reference Value........................................................................................ 840 On Board Diagnosis Logic................................................................................................. 841 DTC Confirmation Procedure............................................................................................... 841 Wiring Diagram........................................................................................................... 843 Diagnostic Procedure..................................................................................................... 844 Component Inspection..................................................................................................... 846 DTC P1336 CRANKSHAFT POSITION SENSOR (CKPS) (OBD) (COG)...................................................................... 847 Component Description.................................................................................................... 847 ECM Terminals and Reference Value........................................................................................ 847 On Board Diagnosis Logic................................................................................................. 847 DTC Confirmation Procedure............................................................................................... 848 Wiring Diagram........................................................................................................... 849 Diagnostic Procedure..................................................................................................... 850 Component Inspection..................................................................................................... 851 DTC P1400 EGRC-SOLENOID VALVE................................................................................................ 852 Component Description.................................................................................................... 852 CONSULT Reference Value in Data Monitor Mode............................................................................. 852 ECM Terminals and Reference Value........................................................................................ 852 On Board Diagnosis Logic................................................................................................. 852 DTC Confirmation Procedure............................................................................................... 852 Wiring Diagram........................................................................................................... 854 Diagnostic Procedure..................................................................................................... 855 Component Inspection..................................................................................................... 855 DTC P1401 EGR TEMPERATURE SENSOR............................................................................................. 857 Component Description.................................................................................................... 857 On Board Diagnosis Logic................................................................................................. 857 DTC Confirmation Procedure............................................................................................... 858 Overall Function Check................................................................................................... 859 Wiring Diagram........................................................................................................... 860 Diagnostic Procedure..................................................................................................... 861 Component Inspection..................................................................................................... 862 DTC P1402 EGR FUNCTION (OPEN)................................................................................................ 863 Description.............................................................................................................. 863 On Board Diagnosis Logic................................................................................................. 864 DTC Confirmation Procedure............................................................................................... 864 Wiring Diagram........................................................................................................... 866 Diagnostic Procedure..................................................................................................... 867 Component Inspection..................................................................................................... 868 DTC P1440 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM (SMALL LEAK) (POSITIVE PRESSURE)........................................ 870 On Board Diagnosis Logic................................................................................................. 870 DTC Confirmation Procedure............................................................................................... 871 Diagnostic Procedure..................................................................................................... 872 DTC P1444 EVAPORATIVE EMISSION (EVAP) CANISTER PURGE VOLUME CONTROL SOLENOID VALVE........................................... 877 Description.............................................................................................................. 877 CONSULT Reference Value in Data Monitor Mode............................................................................. 877 ECM Terminals and Reference Value........................................................................................ 878 On Board Diagnosis Logic................................................................................................. 878 DTC Confirmation Procedure............................................................................................... 879 Wiring Diagram........................................................................................................... 880 Diagnostic Procedure..................................................................................................... 881 Component Inspection..................................................................................................... 883 DTC P1446 EVAPORATIVE EMISSION (EVAP) CANISTER VENT CONTROL VALVE (CLOSE).................................................... 884 Component Description.................................................................................................... 884 CONSULT Reference Value in Data Monitor Mode............................................................................. 884 ECM Terminals and Reference Value........................................................................................ 884 On Board Diagnosis Logic................................................................................................. 884 DTC Confirmation Procedure............................................................................................... 885 Wiring Diagram........................................................................................................... 886 Diagnostic Procedure..................................................................................................... 887 Component Inspection..................................................................................................... 888 DTC P1447 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM PURGE FLOW MONITORING................................................... 889 System Description....................................................................................................... 889 On Board Diagnosis Logic................................................................................................. 889 DTC Confirmation Procedure............................................................................................... 890 Overall Function Check................................................................................................... 890 Diagnostic Procedure..................................................................................................... 891 DTC P1448 EVAPORATIVE EMISSION (EVAP) CANISTER VENT CONTROL VALVE (OPEN)..................................................... 894 Component Description.................................................................................................... 894 CONSULT Reference Value in Data Monitor Mode............................................................................. 894 ECM Terminals and Reference Value........................................................................................ 894 On Board Diagnosis Logic................................................................................................. 894 DTC Confirmation Procedure............................................................................................... 895 Overall Function Check................................................................................................... 896 Wiring Diagram........................................................................................................... 897 Diagnostic Procedure..................................................................................................... 898 Component Inspection..................................................................................................... 899 DTC P1490 VACUUM CUT VALVE BYPASS VALVE (CIRCUIT)............................................................................ 900 Description.............................................................................................................. 900 CONSULT Reference Value in Data Monitor Mode............................................................................. 900 ECM Terminals and Reference Value........................................................................................ 900 On Board Diagnosis Logic................................................................................................. 901 DTC Confirmation Procedure............................................................................................... 901 Wiring Diagram........................................................................................................... 902 Diagnostic Procedure..................................................................................................... 903 Component Inspection..................................................................................................... 904 DTC P1491 VACUUM CUT VALVE BYPASS VALVE...................................................................................... 905 Description.............................................................................................................. 905 CONSULT Reference Value in Data Monitor Mode............................................................................. 905 ECM Terminals and Reference Value........................................................................................ 905 On Board Diagnosis Logic................................................................................................. 906 DTC Confirmation Procedure............................................................................................... 906 Overall Function Check................................................................................................... 907 Wiring Diagram........................................................................................................... 908 Diagnostic Procedure..................................................................................................... 909 Component Inspection..................................................................................................... 911 DTC P1605 A/T DIAGNOSIS COMMUNICATION LINE................................................................................... 912 Component Description.................................................................................................... 912 ECM Terminals and Reference Value........................................................................................ 912 On Board Diagnosis Logic................................................................................................. 912 DTC Confirmation Procedure............................................................................................... 912 Wiring Diagram........................................................................................................... 913 Diagnostic Procedure..................................................................................................... 914 DTC P1706 PARK/NEUTRAL POSITION SWITCH....................................................................................... 915 Component Description.................................................................................................... 915 CONSULT Reference Value in Data Monitor Mode............................................................................. 915 ECM Terminals and Reference Value........................................................................................ 915 On Board Diagnosis Logic................................................................................................. 915 DTC Confirmation Procedure............................................................................................... 915 Overall Function Check................................................................................................... 916 Wiring Diagram........................................................................................................... 917 Diagnostic Procedure..................................................................................................... 918 INJECTOR..................................................................................................................... 919 Wiring Diagram........................................................................................................... 919 Component Description.................................................................................................... 920 ECM Terminals and Reference Value........................................................................................ 920 Diagnostic Procedure..................................................................................................... 921 Component Inspection..................................................................................................... 924 START SIGNAL................................................................................................................. 925 Wiring Diagram........................................................................................................... 925 CONSULT Reference Value in Data Monitor Mode............................................................................. 926 ECM Terminals and Reference Value........................................................................................ 926 Diagnostic Procedure..................................................................................................... 926 FUEL PUMP.................................................................................................................... 929 Description.............................................................................................................. 929 CONSULT Reference Value in Data Monitor Mode............................................................................. 929 ECM Terminals and Reference Value........................................................................................ 930 Wiring Diagram........................................................................................................... 931 Diagnostic Procedure..................................................................................................... 932 Component Inspection..................................................................................................... 934 POWER STEERING OIL PRESSURE SWITCH........................................................................................... 935 Wiring Diagram........................................................................................................... 935 Component Description.................................................................................................... 936 CONSULT Reference Value in Data Monitor Mode............................................................................. 936 ECM Terminals and Reference Value........................................................................................ 936 Diagnostic Procedure..................................................................................................... 937 Component Inspection..................................................................................................... 938 IACV-FICD SOLENOID VALVE..................................................................................................... 939 Wiring Diagram........................................................................................................... 939 Component Description.................................................................................................... 940 ECM Terminals and Reference Value........................................................................................ 940 Diagnostic Procedure..................................................................................................... 941 Component Inspection..................................................................................................... 942 MIL & DATA LINK CONNECTORS................................................................................................... 944 Wiring Diagram........................................................................................................... 944 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................................................ 945 Fuel Pressure Regulator.................................................................................................. 945 Idle Speed and Ignition Timing........................................................................................... 945 Ignition Coil............................................................................................................ 945 Mass Air Flow Sensor..................................................................................................... 945 Engine Coolant Temperature Sensor........................................................................................ 945 EGR Temperature Sensor................................................................................................... 945 Front Heated Oxygen Sensor Heater........................................................................................ 945 Fuel Pump................................................................................................................ 946 IACV-AAC Valve........................................................................................................... 946 Injector................................................................................................................. 946 Resistor................................................................................................................. 946 Throttle Position Sensor................................................................................................. 946 Calculated Load Value.................................................................................................... 946 Intake Air Temperature Sensor............................................................................................ 946 Rear Heated Oxygen Sensor Heater......................................................................................... 946 Crankshaft Position Sensor (OBD)......................................................................................... 946 Tank Fuel Temperature Sensor............................................................................................. 946 el............................................................................................................................... 947 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................ 947 PRECAUTIONS.................................................................................................................. 950 Supplemental Restraint System (SRS) "AIR BAG"............................................................................ 950 Wiring Diagrams and Trouble Diagnosis.................................................................................... 950 HARNESS CONNECTOR............................................................................................................ 951 Description.............................................................................................................. 951 STANDARDIZED RELAY........................................................................................................... 952 Description.............................................................................................................. 952 POWER SUPPLY ROUTING......................................................................................................... 954 Schematic................................................................................................................ 954 Wiring Diagram - POWER -................................................................................................. 955 Inspection............................................................................................................... 959 GROUND....................................................................................................................... 962 Ground Distribution...................................................................................................... 962 COMBINATION SWITCH........................................................................................................... 966 Check.................................................................................................................... 966 Replacement.............................................................................................................. 967 STEERING SWITCH.............................................................................................................. 968 Check.................................................................................................................... 968 HEADLAMP (FOR USA)........................................................................................................... 969 System Description....................................................................................................... 969 Wiring Diagram - H/LAMP -................................................................................................ 971 Trouble Diagnoses........................................................................................................ 971 Bulb Replacement......................................................................................................... 971 Aiming Adjustment........................................................................................................ 972 HEADLAMP (FOR CANADA) - DAYTIME LIGHT SYSTEM -............................................................................... 974 System Description....................................................................................................... 974 Schematic................................................................................................................ 976 Wiring Diagram - DTRL -.................................................................................................. 977 Trouble Diagnoses........................................................................................................ 980 Bulb Replacement......................................................................................................... 981 Aiming Adjustment........................................................................................................ 981 PARKING, LICENSE AND TAIL LAMPS.............................................................................................. 982 Wiring Diagram - TAIL/L -................................................................................................ 982 STOP LAMP.................................................................................................................... 984 Wiring Diagram - STOP/L -................................................................................................ 984 BACK-UP LAMP................................................................................................................. 986 Wiring Diagram - BACK/L -................................................................................................ 986 FRONT FOG LAMP............................................................................................................... 987 System Description....................................................................................................... 987 Wiring Diagram - F/FOG -................................................................................................. 988 Aiming Adjustment........................................................................................................ 989 TURN SIGNAL AND HAZARD WARNING LAMPS......................................................................................... 990 System Description....................................................................................................... 990 Wiring Diagram - TURN -.................................................................................................. 992 Trouble Diagnoses........................................................................................................ 994 Electrical Components Inspection......................................................................................... 994 ILLUMINATION................................................................................................................. 995 System Description....................................................................................................... 995 Schematic................................................................................................................ 996 Wiring Diagram - ILL -................................................................................................... 997 INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS.........................................................................1000 System Description.......................................................................................................1000 Schematic................................................................................................................1001 Wiring Diagram - INT/L -.................................................................................................1002 METER AND GAUGES.............................................................................................................1006 Component Parts and Harness Connector Location...........................................................................1006 System Description.......................................................................................................1006 Combination Meter........................................................................................................1008 Wiring Diagram - METER -.................................................................................................1009 Meter/Gauge Operation and Odo/Trip Meter Segment Check in Diagnosis Mode.................................................1010 Flexible Print Circuit (FPC).............................................................................................1011 Trouble Diagnoses........................................................................................................1012 Electrical Components Inspection.........................................................................................1017 COMPASS AND THERMOMETER......................................................................................................1019 System Description.......................................................................................................1019 Wiring Diagram - COMPAS -................................................................................................1020 Trouble Diagnoses........................................................................................................1021 Calibration Procedure for Compass........................................................................................1022 WARNING LAMPS................................................................................................................1023 Schematic................................................................................................................1023 Wiring Diagram - WARN -..................................................................................................1024 Electrical Components Inspection.........................................................................................1030 WARNING CHIME................................................................................................................1031 Component Parts and Harness Connector Location...........................................................................1031 System Description.......................................................................................................1031 Wiring Diagram - CHIME -.................................................................................................1033 Trouble Diagnoses........................................................................................................1035 FRONT WIPER AND WASHER.......................................................................................................1039 System Description.......................................................................................................1039 Wiring Diagram - WIPER -.................................................................................................1041 Trouble Diagnoses........................................................................................................1043 Removal and Installation.................................................................................................1045 Washer Nozzle Adjustment.................................................................................................1046 Washer Tube Layout.......................................................................................................1047 REAR WIPER AND WASHER........................................................................................................1048 System Description.......................................................................................................1048 Schematic................................................................................................................1050 Wiring Diagram - WIP/R -.................................................................................................1051 Trouble Diagnoses........................................................................................................1054 Removal and Installation.................................................................................................1054 Washer Nozzle Adjustment.................................................................................................1055 Washer Tube Layout.......................................................................................................1055 Check Valve..............................................................................................................1055 HORN.........................................................................................................................1056 Wiring Diagram - HORN -..................................................................................................1056 CIGARETTE LIGHTER............................................................................................................1057 Wiring Diagram - CIGAR -.................................................................................................1057 REAR WINDOW DEFOGGER.........................................................................................................1058 Component Parts and Harness Connector Location...........................................................................1058 System Description.......................................................................................................1058 Wiring Diagram - DEF -...................................................................................................1060 Trouble Diagnoses........................................................................................................1062 Electrical Components Inspection.........................................................................................1064 Filament Check...........................................................................................................1064 Filament Repair..........................................................................................................1065 AUDIO........................................................................................................................1066 System Description.......................................................................................................1066 Schematic................................................................................................................1067 Wiring Diagram - AUDIO -.................................................................................................1068 Trouble Diagnoses........................................................................................................1072 Inspection...............................................................................................................1073 AUDIO ANTENNA................................................................................................................1074 System Description.......................................................................................................1066 Wiring Diagram - P/ANT -.................................................................................................1075 Trouble Diagnoses........................................................................................................1076 Location of Antenna......................................................................................................1076 Antenna Rod Replacement..................................................................................................1076 POWER SUNROOF................................................................................................................1078 Wiring Diagram - SROOF -.................................................................................................1078 DOOR MIRROR..................................................................................................................1079 Wiring Diagram - MIRROR -................................................................................................1079 GLASS HATCH OPENER...........................................................................................................1080 Wiring Diagram - TLID -..................................................................................................1080 POWER SEAT...................................................................................................................1081 Wiring Diagram - SEAT -..................................................................................................1081 HEATED SEAT..................................................................................................................1083 Wiring Diagram - HSEAT -.................................................................................................1083 AUTOMATIC SPEED CONTROL DEVICE (ASCD)........................................................................................1084 Component Parts and Harness Connector Location...........................................................................1084 System Description.......................................................................................................1085 Schematic................................................................................................................1087 Wiring Diagram - ASCD -..................................................................................................1088 Fail-safe System.........................................................................................................1093 Trouble Diagnoses........................................................................................................1094 Electrical Component Inspection..........................................................................................1103 ASCD Wire Adjustment.....................................................................................................1103 POWER WINDOW.................................................................................................................1105 System Description.......................................................................................................1105 Schematic................................................................................................................1107 Wiring Diagram - WINDOW -................................................................................................1108 Trouble Diagnoses........................................................................................................1112 POWER DOOR LOCK..............................................................................................................1113 Component Parts and Harness Connector Location...........................................................................1113 System Description.......................................................................................................1113 Schematic................................................................................................................1115 Wiring Diagram - D/LOCK -................................................................................................1116 Trouble Diagnoses........................................................................................................1120 MULTI-REMOTE CONTROL SYSTEM..................................................................................................1128 Component Parts and Harness Connector Location...........................................................................1128 System Description.......................................................................................................1128 Schematic................................................................................................................1130 Wiring Diagram - MULTI -.................................................................................................1131 Trouble Diagnoses........................................................................................................1135 ID Code Entry Procedure..................................................................................................1143 Remote Controller Battery Replacement....................................................................................1144 THEFT WARNING SYSTEM.........................................................................................................1145 Component Parts and Harness Connector Location...........................................................................1145 System Description.......................................................................................................1146 Schematic................................................................................................................1149 Wiring Diagram - THEFT -.................................................................................................1151 Trouble Diagnoses........................................................................................................1157 SMART ENTRANCE CONTROL UNIT..................................................................................................1170 Description..............................................................................................................1170 Schematic................................................................................................................1171 Smart Entrance Control Unit Inspection Table.............................................................................1173 INTEGRATED HOMELINK TRANSMITTER..............................................................................................1174 Wiring Diagram - TRNSMT -................................................................................................1174 Trouble Diagnoses........................................................................................................1175 ELECTRICAL UNITS LOCATION....................................................................................................1176 Engine Compartment.......................................................................................................1176 Passenger Compartment....................................................................................................1177 HARNESS LAYOUT...............................................................................................................1179 How to Read Harness Layout...............................................................................................1179 Outline..................................................................................................................1180 Main Harness.............................................................................................................1181 Engine Room Harness......................................................................................................1183 Engine Control Harness...................................................................................................1185 Body Harness LH..........................................................................................................1187 Body Harness RH..........................................................................................................1188 Back Door Harness........................................................................................................1189 Engine and Transmission Harness..........................................................................................1190 Room Lamp................................................................................................................1191 Air Bag Harness..........................................................................................................1192 Front Door Harness.......................................................................................................1193 Rear Door Harness........................................................................................................1194 BULB SPECIFICATIONS..........................................................................................................1195 Headlamp.................................................................................................................1195 Exterior Lamp............................................................................................................1195 Interior Lamp............................................................................................................1195 WIRING DIAGRAM CODES (CELL CODES)............................................................................................1196 SUPER MULTIPLE JUNCTION (SMJ)................................................................................................ 0 Installation............................................................................................................. 0 Terminal Arrangement..................................................................................................... 1 FUSE BLOCK - JUNCTION BOX (J/B).............................................................................................. 2 Terminal Arrangement..................................................................................................... 2 FUSE AND FUSIBLE LINK BOX.................................................................................................... 2 Terminal Arrangement..................................................................................................... 3 ELECTRICAL UNITS............................................................................................................. 4 Terminal Arrangement..................................................................................................... 4 em...............................................................................................................................1198 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................1198 PRECAUTIONS..................................................................................................................1200 Parts Requiring Angular Tightening.......................................................................................1200 Liquid Gasket Application Procedure......................................................................................1200 PREPARATION..................................................................................................................1201 Special Service Tools....................................................................................................1201 Commercial Service Tools.................................................................................................1203 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING.........................................................................1205 NVH Troubleshooting Chart - Engine Noise.................................................................................1206 OUTER COMPONENT PARTS........................................................................................................1207 Removal and Installation.................................................................................................1207 WARM-UP THREE WAY CATALYST LH........................................................................................1209 MEASUREMENT OF COMPRESSION PRESSURE..........................................................................................1210 OIL PAN......................................................................................................................1211 Removal..................................................................................................................1211 Installation.............................................................................................................1212 TIMING BELT..................................................................................................................1214 Components...............................................................................................................1214 Removal..................................................................................................................1215 Inspection...............................................................................................................1216 BELT TENSIONER AND TENSIONER SPRING..................................................................................1217 Installation.............................................................................................................1217 BELT TENSION CHECK...................................................................................................1219 OIL SEAL.....................................................................................................................1220 Replacement..............................................................................................................1220 VALVE OIL SEAL.......................................................................................................1220 OIL SEAL INSTALLING DIRECTION........................................................................................1220 CAMSHAFT OIL SEAL....................................................................................................1221 FRONT OIL SEAL.......................................................................................................1221 REAR OIL SEAL........................................................................................................1221 CYLINDER HEAD................................................................................................................1222 Components...............................................................................................................1222 Removal..................................................................................................................1223 Disassembly..............................................................................................................1225 Inspection...............................................................................................................1226 CYLINDER HEAD DISTORTION.............................................................................................1226 CAMSHAFT VISUAL CHECK................................................................................................1226 CAMSHAFT RUNOUT......................................................................................................1226 CAMSHAFT CAM HEIGHT..................................................................................................1226 CAMSHAFT JOURNAL CLEARANCE...........................................................................................1227 CAMSHAFT END PLAY....................................................................................................1227 CAMSHAFT SPROCKET RUNOUT.............................................................................................1228 VALVE GUIDE CLEARANCE................................................................................................1228 VALVE GUIDE REPLACEMENT..............................................................................................1228 VALVE SEATS..........................................................................................................1229 REPLACING VALVE SEAT FOR SERVICE PARTS...............................................................................1229 VALVE DIMENSIONS.....................................................................................................1230 VALVE SPRING.........................................................................................................1230 ROCKER SHAFT AND ROCKER ARM..........................................................................................1231 HYDRAULIC VALVE LIFTER...............................................................................................1231 Assembly.................................................................................................................1232 Installation.............................................................................................................1232 ENGINE ASSEMBLY..............................................................................................................1237 Removal and Installation.................................................................................................1237 REMOVAL..............................................................................................................1238 CYLINDER BLOCK...............................................................................................................1240 Components...............................................................................................................1240 CYLINDER BLOCK HEATER................................................................................................1241 Removal and Installation.................................................................................................1241 Disassembly..............................................................................................................1242 PISTON AND CRANKSHAFT................................................................................................1242 Inspection...............................................................................................................1242 PISTON AND PISTON PIN CLEARANCE......................................................................................1242 PISTON RING SIDE CLEARANCE...........................................................................................1243 PISTON RING END GAP..................................................................................................1243 CONNECTING ROD BEND AND TORSION......................................................................................1243 CYLINDER BLOCK DISTORTION AND WEAR...................................................................................1244 PISTON-TO-BORE CLEARANCE.............................................................................................1244 CRANKSHAFT...........................................................................................................1246 BEARING CLEARANCE....................................................................................................1246 CONNECTING ROD BUSHING CLEARANCE (SMALL END).........................................................................1248 REPLACEMENT OF CONNECTING ROD BUSHING (SMALL END)....................................................................1249 DRIVE PLATE RUNOUT...................................................................................................1249 Assembly.................................................................................................................1249 PISTON...............................................................................................................1249 CRANKSHAFT...........................................................................................................1249 REPLACING PILOT CONVERTER............................................................................................1251 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................................................1252 General Specifications...................................................................................................1252 Cylinder Head............................................................................................................1253 Valve....................................................................................................................1253 VALVE................................................................................................................1253 VALVE SPRING.........................................................................................................1254 HYDRAULIC VALVE LFITER...............................................................................................1254 VALVE GUIDE..........................................................................................................1254 ROCKER SHAFT AND ROCKER ARM..........................................................................................1254 Valve Seat...............................................................................................................1255 INTAKE VALVE SEAT....................................................................................................1255 EXHAUST VALVE SEAT...................................................................................................1256 Camshaft and Camshaft Bearing............................................................................................1257 Cylinder Block...........................................................................................................1258 Piston, Piston Ring and Piston Pin.......................................................................................1259 AVAILABLE PISTON.....................................................................................................1259 PISTON RING..........................................................................................................1259 PISTON PIN...........................................................................................................1260 Connecting Rod...........................................................................................................1260 Crankshaft...............................................................................................................1260 Available Main Bearing...................................................................................................1261 NO. 1 MAIN BEARING...................................................................................................1261 NO. 2 AND 3 MAIN BEARING.............................................................................................1261 NO. 4 MAIN BEARING...................................................................................................1261 UNDER SIZE...........................................................................................................1261 Available Connecting Rod Bearing.........................................................................................1262 CONNECTING ROD BEARING UNDERSIZE.....................................................................................1262 Miscellaneous Components.................................................................................................1262 BEARING CLEARANCE....................................................................................................1262 fe...............................................................................................................................1263 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................1263 PREPARATION..................................................................................................................1264 Special Service Tools....................................................................................................1264 ACCELERATOR CONTROL SYSTEM...................................................................................................1265 Removal and Installation.................................................................................................1265 Adjusting Accelerator Wire...............................................................................................1265 FUEL SYSTEM..................................................................................................................1266 Removal and Installation.................................................................................................1266 FUEL TANK............................................................................................................1267 FUEL PUMP AND GAUGE..................................................................................................1268 EXHAUST SYSTEM...............................................................................................................1270 Removal and Installation.................................................................................................1270 foldout..........................................................................................................................1273 QUICK REFERENCE INDEX........................................................................................................ 0 ELECTRICAL SYSTEM............................................................................................................ 2 SUPER MULTIPLE JUNCTION (SMJ)................................................................................................1273 Installation.............................................................................................................1273 Terminal Arrangement.....................................................................................................1274 FUSE BLOCK - JUNCTION BOX (J/B)..............................................................................................1275 Terminal Arrangement.....................................................................................................1275 FUSE AND FUSIBLE LINK BOX....................................................................................................1276 Terminal Arrangement.....................................................................................................1276 ELECTRICAL UNITS.............................................................................................................1277 Terminal Arrangement\....................................................................................................1277 gi...............................................................................................................................1278 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................1278 PRECAUTIONS..................................................................................................................1280 Precautions..............................................................................................................1280 PRECAUTIONS FOR SUPPLEMENTAL RESTRAINT SYSTEM (SRS) "AIR BAG"........................................................1280 GENERAL PRECAUTIONS..................................................................................................1280 PRECAUTIONS FOR MULTIPORT FUEL INJECTION SYSTEM OR ECCS ENGINE.......................................................1282 PRECAUTIONS FOR THREE WAY CATALYST...................................................................................1282 PRECAUTIONS FOR ENGINE OILS..........................................................................................1282 PRECAUTIONS FOR FUEL.................................................................................................1282 PRECAUTIONS FOR AIR CONDITIONING.....................................................................................1282 HOW TO USE THIS MANUAL.......................................................................................................1284 HOW TO READ WIRING DIAGRAMS..................................................................................................1286 Sample/Wiring Diagram - EXAMPL -.........................................................................................1286 OPTIONAL SPLICE......................................................................................................1287 Description..............................................................................................................1288 CONNECTOR SYMBOLS....................................................................................................1290 HARNESS INDICATION...................................................................................................1291 COMPONENT INDICATION.................................................................................................1291 SWITCH POSITIONS.....................................................................................................1291 DETECTABLE LINES AND NON-DETECTABLE LINES............................................................................1292 MULTIPLE SWITCH......................................................................................................1293 FOLDOUT PAGE.........................................................................................................1294 HOW TO CHECK TERMINAL........................................................................................................1295 Connector and Termianl Pin Kit...........................................................................................1295 How to Probe Connectors..................................................................................................1295 PROBING FROM HARNESS SIDE............................................................................................1295 PROBING FROM TERMINAL SIDE...........................................................................................1295 How To Check Enlarged Contact Spring of Terminal.........................................................................1296 Waterproof Connector Inspection..........................................................................................1297 RUBBER SEAL INSPECTION...............................................................................................1297 WIRE SEAL INSPECTION.................................................................................................1297 Terminal Lock Inspection.................................................................................................1297 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT................................................................1298 Work Flow................................................................................................................1298 Incident Simulation Tests................................................................................................1299 INTRODUCTION.........................................................................................................1299 VEHICLE VIBRATION....................................................................................................1299 HEAT SENSITIVE.......................................................................................................1300 FREEZING.............................................................................................................1300 WATER INTRUSION......................................................................................................1301 ELECTRICAL LOAD......................................................................................................1301 COLD OR HOT START UP.................................................................................................1301 Circuit Inspection.......................................................................................................1301 INTRODUCTION.........................................................................................................1301 TESTING FOR "OPENS" IN THE CIRCUIT...................................................................................1302 TESTING FOR "SHORTS" IN THE CIRCUIT..................................................................................1303 GROUND INSPECTION....................................................................................................1304 VOLTAGE DROP TESTS...................................................................................................1304 CONTROL UNIT CIRCUIT TEST............................................................................................1306 HOW TO FOLLOW TROUBLE DIAGNOSES..............................................................................................1308 How to Follow Test Groups in Trouble Diagnoses...........................................................................1309 Key to Symbols Signifying Measurements or Procedures.....................................................................1310 CONSULT CHECKING SYSTEM......................................................................................................1312 Function and System Application..........................................................................................1312 Lithium Battery Replacement..............................................................................................1312 Checking Equipment.......................................................................................................1312 Loading Procedure........................................................................................................1313 CONSULT Data Link Connector (DLC) Circuit................................................................................1313 INSPECTION PROCEDURE.................................................................................................1313 IDENTIFICATION INFORMATION...................................................................................................1314 Model Variation..........................................................................................................1314 Identification Number....................................................................................................1314 VEHICLE IDENTIFICATION NUMBER ARRANGEMENT............................................................................1315 IDENTIFICATION PLATE.................................................................................................1315 ENGINE SERIAL NUMBER.................................................................................................1316 AUTOMATIC TRANSMISSION NUMBER........................................................................................1316 TRANSFER SERIAL NUMBER...............................................................................................1316 Dimensions...............................................................................................................1316 Wheels & Tires...........................................................................................................1317 FOR U.S.A............................................................................................................1317 FOR CANADA...........................................................................................................1317 LIFTING POINTS AND TOW TRUCK TOWING..........................................................................................1318 Screw Jack...............................................................................................................1318 Garage Jack and Safety Stand.............................................................................................1319 2-pole Lift..............................................................................................................1320 Tow Truck Towing.........................................................................................................1320 VEHICLE RECOVERY.....................................................................................................1321 TIGHTENING TORQUE OF STANDARD BOLTS..........................................................................................1322 SAE J1930 TERMINOLOGY LIST...................................................................................................1323 SAE J1930 Terminology List...............................................................................................1323 ha...............................................................................................................................1327 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................1327 PRECAUTIONS..................................................................................................................1328 Supplemental Restraint System (SRS) "AIR BAG"............................................................................1328 Precautions for Working with HFC-134a (R-134a)...........................................................................1328 General Refrigerant Precautions..........................................................................................1328 Precautions for Refrigerant Connection...................................................................................1329 Precautions for Servicing Compressor.....................................................................................1331 Precautions for Service Equipment........................................................................................1331 Wiring Diagrams and Trouble Diagnosis....................................................................................1333 PREPARATION..................................................................................................................1334 Special Service Tools....................................................................................................1334 HFC-134a (R-134a) Service Tools and Equipment............................................................................1335 DESCRIPTION..................................................................................................................1337 Refrigeration System.....................................................................................................1337 V-6 Variable Displacement Compressor.....................................................................................1338 Component Layout.........................................................................................................1344 Introduction.............................................................................................................1345 Features.................................................................................................................1345 Overview of Control System...............................................................................................1348 Control Operation........................................................................................................1348 Discharge Air Flow.......................................................................................................1350 TROUBLE DIAGNOSES............................................................................................................1352 Harness Layout...........................................................................................................1352 Circuit Diagram..........................................................................................................1354 Wiring Diagram - A/C, A-.................................................................................................1355 Auto Amp. Terminals and Reference Valve..................................................................................1359 Self-diagnosis...........................................................................................................1361 How to Perform Trouble Diagnoses for Quick and Accurate Repair...........................................................1367 Operational Check........................................................................................................1368 A/C System...............................................................................................................1371 Mode Door Motor..........................................................................................................1373 Air Mix Door Motor.......................................................................................................1378 Intake Door Motor........................................................................................................1382 Blower Motor.............................................................................................................1387 Magnet Clutch............................................................................................................1393 Insufficient Cooling.....................................................................................................1398 Insufficient Heating.....................................................................................................1406 Noise....................................................................................................................1407 Self-diagnosis...........................................................................................................1408 Memory Function..........................................................................................................1409 ECON (ECONOMY) Mode......................................................................................................1410 Ambient Sensor Circuit...................................................................................................1410 In-vehicle Sensor Circuit................................................................................................1413 Sunload Sensor Circuit...................................................................................................1415 Intake Sensor Circuit....................................................................................................1418 Air Mix Door Motor PBR Circuit...........................................................................................1420 SERVICE PROCEDURES...........................................................................................................1421 HFC-134a (R-134a) Service Procedure......................................................................................1421 Maintenance of Lubricant Quantity in Compressor..........................................................................1423 Compressor...............................................................................................................1425 Compressor Clutch........................................................................................................1426 Refrigerant Lines........................................................................................................1430 Belt.....................................................................................................................1433 Fast Idle Control Device (FICD)..........................................................................................1433 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................................................1434 Compressor...............................................................................................................1434 Lubricant................................................................................................................1434 Refrigerant..............................................................................................................1434 Engine Idling Speed (When A/C is ON).....................................................................................1434 Belt Tension.............................................................................................................1434 idx..............................................................................................................................1435 QUICK REFERENCE INDEX........................................................................................................ 0 lc...............................................................................................................................1443 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................1443 ENGINE LUBRICATION SYSTEM....................................................................................................1444 Precautions..............................................................................................................1444 LIQUID GASKET APPLICATION PROCEDURE..................................................................................1444 Preparation..............................................................................................................1444 SPECIAL SERVICE TOOLS................................................................................................1444 Lubrication Circuit......................................................................................................1445 Oil Pressure Check.......................................................................................................1445 Oil Pump.................................................................................................................1446 REMOVAL AND INSTALLATION.............................................................................................1446 DISASSEMBLY AND ASSEMBLY.............................................................................................1446 INSPECTION...........................................................................................................1447 REGULATOR VALVE INSPECTION...........................................................................................1447 OIL FILTER...........................................................................................................1447 OIL FILTER BRACKET...................................................................................................1448 ENGINE COOLING SYSTEM........................................................................................................1449 Precautions..............................................................................................................1449 LIQUID GASKET APPLICATION PROCEDURE..................................................................................1449 Preparation..............................................................................................................1449 SPECIAL SERVICE TOOLS................................................................................................1449 Cooling Circuit..........................................................................................................1450 System Check.............................................................................................................1450 CHECKING COOLING SYSTEM HOSES........................................................................................1450 CHECKING RADIATOR CAP................................................................................................1450 CHECKING COOLING SYSTEM FOR LEAKS....................................................................................1451 Water Pump...............................................................................................................1451 REMOVAL AND INSTALLATION.............................................................................................1451 INSPECTION...........................................................................................................1452 Thermostat...............................................................................................................1452 REMOVAL..............................................................................................................1452 INSPECTION...........................................................................................................1453 INSTALLATION.........................................................................................................1453 Radiator.................................................................................................................1454 REMOVAL AND INSTALLATION.............................................................................................1454 COMPONENTS...........................................................................................................1454 PREPARATION..........................................................................................................1455 DISASSEMBLY..........................................................................................................1455 ASSEMBLY.............................................................................................................1456 INSPECTION...........................................................................................................1457 Cooling Fan (Crankshaft driven)..........................................................................................1458 REMOVAL AND INSTALLATION.............................................................................................1458 INSPECTION...........................................................................................................1458 Refilling Engine Coolant.................................................................................................1459 Overheating Cause Analysis...............................................................................................1459 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................................................1461 Oil Pressure.............................................................................................................1461 Regulator Valve..........................................................................................................1461 Oil Pump.................................................................................................................1461 Thermostat...............................................................................................................1461 Radiator.................................................................................................................1461 ma...............................................................................................................................1462 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................1462 PRECAUTIONS..................................................................................................................1463 Precautions for Supplemental Restraint System (SRS) "AIR BAG"............................................................1463 PREPARATION..................................................................................................................1464 Special Service Tools....................................................................................................1464 GENERAL MAINTENANCE..........................................................................................................1465 PERIODIC MAINTENANCE.........................................................................................................1467 Schedule 1...............................................................................................................1468 EMISSION CONTROL SYSTEM MAINTENANCE..................................................................................1468 CHASSIS AND BODY MAINTENANCE.........................................................................................1470 Schedule 2...............................................................................................................1470 EMISSION CONTROL SYSTEM MAINTENANCE..................................................................................1470 CHASSIS AND BODY MAINTENANCE.........................................................................................1471 RECOMMENDED FLUIDS AND LUBRICANTS............................................................................................1472 Fluids and Lubricants....................................................................................................1472 SAE Viscosity Number.....................................................................................................1473 GASOLINE ENGINE OIL..................................................................................................1473 GEAR OIL.............................................................................................................1473 Anti-freeze Coolant Mixture Ratio........................................................................................1473 ENGINE MAINTENANCE...........................................................................................................1474 Checking Drive Belts.....................................................................................................1474 Checking Engine Coolant..................................................................................................1475 Checking Fuel Lines......................................................................................................1477 Changing Fuel Filter.....................................................................................................1477 WITH CONSULT.........................................................................................................1477 WITHOUT CONSULT......................................................................................................1477 Changing Air Cleaner Filter..............................................................................................1478 VISCOUS PAPER TYPE...................................................................................................1478 Changing Engine Oil......................................................................................................1478 Changing Oil Filter......................................................................................................1479 Changing Spark Plugs.....................................................................................................1479 Checking EVAP Vapor Lines................................................................................................1482 CHASSIS AND BODY MAINTENANCE.................................................................................................1482 Checking Exhaust System..................................................................................................1482 Checking A/T Fluid.......................................................................................................1482 Changing A/T Fluid.......................................................................................................1482 Checking All Mode 4WD Transfer Fluid.....................................................................................1483 Changing All Mode 4WD Transfer Fluid.....................................................................................1483 Checking Propeller Shaft.................................................................................................1484 Greasing Propeller Shaft.................................................................................................1484 Checking Differential Gear Oil...........................................................................................1484 Changing Differential Gear Oil...........................................................................................1485 LIMITED-SLIP DIFFERENTIAL GEAR.......................................................................................1485 Balancing Wheels.........................................................................................................1485 Tire Rotation............................................................................................................1485 Checking Brake Fluid Level and Leaks.....................................................................................1486 Checking Brake Lines and Cables..........................................................................................1486 Checking Disc Brake......................................................................................................1486 ROTOR................................................................................................................1486 CALIPER..............................................................................................................1486 PAD..................................................................................................................1486 Checking Drum Brake......................................................................................................1487 WHEEL CYLINDER.......................................................................................................1487 DRUM.................................................................................................................1487 LINING...............................................................................................................1487 TEMPORARY METHOD FOR CHECKING LINING WEAR............................................................................1487 Checking Steering Gear, Linkage and Transfer Gear........................................................................1487 STEERING GEAR........................................................................................................1487 STEERING LINKAGE.....................................................................................................1487 STEERING TRANSFER GEAR...............................................................................................1487 Checking Power Steering Fluid and Lines..................................................................................1488 CHECKING FLUID LEVEL.................................................................................................1488 CHECKING LINES.......................................................................................................1488 Lubricating Locks, Hinges and Hood Latches...............................................................................1488 Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters..........................................................1489 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................................................1490 Engine Maintenance.......................................................................................................1490 DRIVE BELT DEFLECTION................................................................................................1490 SPARK PLUG TYPE......................................................................................................1490 Chassis and Body Maintenance.............................................................................................1490 WHEEL BALANCE........................................................................................................1490 pd...............................................................................................................................1491 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................1491 PROPELLER SHAFT..............................................................................................................1493 Preparation..............................................................................................................1493 SPECIAL SERVICE TOOLS................................................................................................1493 Noise, Vibration and Harshness (NVH) Troubleshooting.....................................................................1494 NVH TROUBLESHOOTING CHART............................................................................................1494 Components...............................................................................................................1495 FRONT PROPELLER SHAFT................................................................................................1495 REAR PROPELLER SHAFT.................................................................................................1496 On-vehicle Service.......................................................................................................1496 PROPELLER SHAFT VIBRATION............................................................................................1496 APPEARANCE CHECKING..................................................................................................1496 Removal and Installation.................................................................................................1497 Inspection...............................................................................................................1497 Disassembly..............................................................................................................1497 JOURNAL (71H AND 80B)................................................................................................1497 ASSEMBLY.................................................................................................................1498 JOURNAL (71H AND 80B)................................................................................................1498 R200A........................................................................................................................1500 FRONT FINAL DRIVE........................................................................................................1500 Preparation..........................................................................................................1500 SPECIAL SERVICE TOOLS............................................................................................1500 Noise, Vibration and Harshness (NVH) Troubleshooting.................................................................1502 On-vehicle Service...................................................................................................1502 FRONT OIL SEAL REPLACEMENT.......................................................................................1502 REAR COVER GASKET REPLACEMENT....................................................................................1503 Components...........................................................................................................1504 Removal and Installation.............................................................................................1505 REMOVAL..........................................................................................................1505 INSTALLATION.....................................................................................................1505 Disassembly..........................................................................................................1505 PRE-INSPECTION...................................................................................................1505 FINAL DRIVE HOUSING..............................................................................................1506 DIFFERENTIAL CASE................................................................................................1508 DIFFERENTIAL SIDE SHAFT..........................................................................................1509 Inspection...........................................................................................................1510 RING GEAR AND DRIVE PINION.......................................................................................1510 DIFFERENTIAL CASE ASSEMBLY.......................................................................................1510 BEARING..........................................................................................................1510 Adjustment...........................................................................................................1511 SIDE BEARING PRELOAD.............................................................................................1511 PINION GEAR HEIGHT AND PINION BEARING PRELOAD....................................................................1512 TOOTH CONTACT....................................................................................................1516 Assembly.............................................................................................................1517 DIFFERENTIAL SIDE SHAFT..........................................................................................1517 DIFFERENTIAL CASE................................................................................................1518 FINAL DRIVE HOUSING..............................................................................................1519 H233B........................................................................................................................1524 REAR FINAL DRIVE.........................................................................................................1524 Preparation..........................................................................................................1524 SPECIAL SERVICE TOOLS............................................................................................1524 Noise, Vibration and Harshness (NVH) Troubleshooting.................................................................1526 On-vehicle Service...................................................................................................1526 FRONT OIL SEAL REPLACEMENT.......................................................................................1526 Components...........................................................................................................1528 Removal and Installation.............................................................................................1529 REMOVAL..........................................................................................................1529 INSTALLATION.....................................................................................................1529 Disassembly..........................................................................................................1529 PRE-INSPECTION...................................................................................................1529 DIFFERENTIAL CARRIER.............................................................................................1530 DIFFERENTIAL CASE................................................................................................1532 Inspection...........................................................................................................1533 RING GEAR AND DRIVE PINION.......................................................................................1533 DIFFERENTIAL CASE ASSEMBLY.......................................................................................1533 BEARING..........................................................................................................1533 Limited Slip Differential............................................................................................1533 PREPARATION FOR DISASSEMBLY......................................................................................1533 DISASSEMBLY......................................................................................................1534 INSPECTION.......................................................................................................1535 ADJUSTMENT.......................................................................................................1536 ASSEMBLY.........................................................................................................1537 Adjustment...........................................................................................................1539 PINION GEAR HEIGHT...............................................................................................1539 TOOTH CONTACT....................................................................................................1542 Assembly.............................................................................................................1543 DIFFERENTIAL CASE................................................................................................1543 DIFFERENTIAL CARRIER.............................................................................................1544 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................................................1548 General Specifications...................................................................................................1548 Service Data.............................................................................................................1548 Snap Ring (80B)..........................................................................................................1548 Snap Ring (71H)..........................................................................................................1548 R200A....................................................................................................................1549 GENERAL SPECIFICATIONS...............................................................................................1549 RING GEAR RUNOUT.....................................................................................................1549 SIDE GEAR ADJUSTMENT.................................................................................................1549 SIDE BEARING ADJUSTMENT..............................................................................................1549 TOTAL PRELOAD ADJUSTMENT.............................................................................................1549 DRIVE PINION HEIGHT ADJUSTMENT.......................................................................................1550 DRIVE PINION PRELOAD ADJUSTMENT......................................................................................1550 H233B....................................................................................................................1550 GENERAL SPECIFICATIONS...............................................................................................1550 RING GEAR RUNOUT.....................................................................................................1551 SIDE GEAR ADJUSTMENT.................................................................................................1551 DIFFERENTIAL TORQUE ADJUSTMENT (LSD MODELS)..........................................................................1551 TOTAL PRELOAD ADJUSTMENT.............................................................................................1551 DRIVE PINION HEIGHT ADJUSTMENT.......................................................................................1552 DRIVE PINION PRELOAD ADJUSTMENT......................................................................................1552 rs...............................................................................................................................1553 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................1553 SEAT BELTS...................................................................................................................1554 Precautions..............................................................................................................1554 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) "AIR BAG"........................................................................1554 PRECAUTION FOR SEAT BELT SERVICE.....................................................................................1554 Front Seat Belt..........................................................................................................1555 REMOVAL AND INSTALLATION.............................................................................................1555 Rear Seat Belt...........................................................................................................1556 REMOVAL AND INSTALLATION.............................................................................................1556 Seat Belt Inspection.....................................................................................................1557 AFTER A COLLISION....................................................................................................1557 PRELIMINARY CHECKS...................................................................................................1557 SEAT BELT RETRACTOR ON-VEHICLE CHECK.................................................................................1557 SEAT BELT RETRACTOR OFF-VEHICLE CHECK................................................................................1558 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)..........................................................................................1560 Precautions..............................................................................................................1560 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) "AIR BAG"........................................................................1560 PRECAUTIONS FOR SRS "AIR BAG" SERVICE................................................................................1560 WIRING DIAGRAMS AND TROUBLE DIAGNOSIS................................................................................1560 Preparation..............................................................................................................1561 SPECIAL SERVICE TOOLS................................................................................................1561 Description..............................................................................................................1562 SRS Component Parts Location.............................................................................................1562 Maintenance Items........................................................................................................1563 Diagnosis Sensor Unit....................................................................................................1563 REMOVAL AND INSTALLATION.............................................................................................1563 Driver Air Bag Module and Spiral Cable...................................................................................1564 REMOVAL AND INSTALLATION.............................................................................................1563 REMOVAL..............................................................................................................1564 INSTALLATION.........................................................................................................1566 Front Passenger Air Bag Module...........................................................................................1566 REMOVAL..............................................................................................................1566 INSTALLATION.........................................................................................................1567 Disposal of Air Bag Module...............................................................................................1568 CHECKING DEPLOYMENT TOOL.............................................................................................1568 DEPLOYMENT PROCEDURES FOR AIR BAG MODULE (OUTSIDE OF VEHICLE)........................................................1569 DEPLOYMENT OF AIR BAG MODULE WHILE MOUNTED IN VEHICLE................................................................1571 DISPOSING OF AIR BAG MODULE..........................................................................................1572 Trouble Diagnoses Introduction...........................................................................................1572 DIAGNOSIS FUNCTION...................................................................................................1572 DIAGNOSIS MODE FOR CONSULT...........................................................................................1572 HOW TO CHANGE SELF-DIAGNOSIS MODE WITH CONSULT.......................................................................1574 HOW TO CHANGE SELF-DIAGNOSIS MODE WITHOUT CONSULT....................................................................1574 HOW TO ERASE SELF-DIAGNOSIS RESULTS..................................................................................1574 How to Perform Trouble Diagnoses for Quick and Accurate Repair...........................................................1575 INFORMATION FROM CUSTOMER............................................................................................1575 PRELIMINARY CHECK....................................................................................................1575 WORK FLOW............................................................................................................1575 Schematic................................................................................................................1576 Wiring Diagram - SRS -...................................................................................................1577 SRS Operation Check......................................................................................................1579 DIAGNOSTIC PROCEDURE 1...............................................................................................1579 Trouble Diagnoses with CONSULT...........................................................................................1580 DIAGNOSTIC PROCEDURE 2...............................................................................................1580 DIAGNOSTIC PROCEDURE 3...............................................................................................1582 DIAGNOSTIC PROCEDURE 4 (CONTINUED FROM DIAGNOSTIC PROCEDURE 2).......................................................1584 DIAGNOSTIC PROCEDURE 5...............................................................................................1584 Trouble Diagnoses without CONSULT........................................................................................1588 DIAGNOSTIC PROCEDURE 6...............................................................................................1588 DIAGNOSTIC PROCEDURE 7...............................................................................................1589 DIAGNOSTIC PROCEDURE 8 (CONTINUED FROM DIAGNOSTIC PROCEDURE 6).......................................................1591 Trouble Diagnoses: "AIR BAG" Warning Lamp Does Not Turn Off..............................................................1592 DIAGNOSTIC PROCEDURE 9...............................................................................................1592 Trouble Diagnoses: "AIR BAG" Warning Lamp Does Not Turn On...............................................................1593 DIAGNOSTIC PROCEDURE 10..............................................................................................1593 Trouble Diagnoses: SRS Does Not Enter Diagnosis Mode Using Door Switch...................................................1594 DIAGNOSTIC PROCEDURE 11..............................................................................................1594 Collision Diagnosis......................................................................................................1595 SRS INSPECTION.......................................................................................................1595 sc...............................................................................................................................1597 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................1597 PRECAUTIONS..................................................................................................................1598 Supplemental Restraint System (SRS) "AIR BAG"............................................................................1598 Wiring Diagrams and Trouble Diagnosis....................................................................................1598 BATTERY......................................................................................................................1599 How to Handle Battery....................................................................................................1599 METHODS OF PREVENTING OVER-DISCHARGE.................................................................................1599 CHECKING ELECTROLYTE LEVEL...........................................................................................1599 SPECIFIC GRAVITY CHECK...............................................................................................1600 CHARGING THE BATTERY.................................................................................................1601 STARTING SYSTEM..............................................................................................................1602 System Description.......................................................................................................1602 Wiring Diagram - START -.................................................................................................1603 Construction.............................................................................................................1604 Removal and Installation.................................................................................................1604 Pinion/Clutch Check......................................................................................................1604 CHARGING SYSTEM..............................................................................................................1605 System Description.......................................................................................................1605 Wiring Diagram - CHARGE -................................................................................................1606 Trouble Diagnoses........................................................................................................1607 WITH IC REGULATOR....................................................................................................1607 MALFUNCTION INDICATOR................................................................................................1607 Construction.............................................................................................................1608 Removal and Installation.................................................................................................1608 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................................................1609 Battery..................................................................................................................1609 Starter..................................................................................................................1609 Alternator...............................................................................................................1609 st...............................................................................................................................1610 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................1610 PRECAUTIONS..................................................................................................................1611 Supplemental Restraint System (SRS) "AIR BAG"............................................................................1611 Precautions for Steering System..........................................................................................1611 PREPARATION..................................................................................................................1612 Special Service Tools....................................................................................................1612 Commercial Service Tools.................................................................................................1614 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING.........................................................................1615 NVH Troubleshooting Chart................................................................................................1615 ON-VEHICLE SERVICE...........................................................................................................1616 Checking Steering Wheel Play.............................................................................................1616 Checking Neutral Position on Steering Wheel..............................................................................1616 PRE-CHECKING.........................................................................................................1616 CHECKING.............................................................................................................1616 Front Wheel Turning Angle................................................................................................1616 Checking Gear Housing Movement...........................................................................................1617 Adjusting Rack Retainer..................................................................................................1617 Checking and Adjusting Drive Belts.......................................................................................1617 Checking Fluid Level.....................................................................................................1617 Checking Fluid Leakage...................................................................................................1617 Bleeding Hydraulic System................................................................................................1618 Checking Steering Wheel Turning Force....................................................................................1618 Checking Hydraulic System................................................................................................1619 STEERING WHEEL AND STEERING COLUMN...........................................................................................1620 Components...............................................................................................................1620 Removal and Installation.................................................................................................1620 STEERING WHEEL.......................................................................................................1620 STEERING COLUMN......................................................................................................1621 Disassembly and Assembly.................................................................................................1622 Inspection...............................................................................................................1623 TILT MECHANISM.......................................................................................................1623 STEERING TRANSFER GEAR.......................................................................................................1624 Components...............................................................................................................1624 Removal..................................................................................................................1625 Installation.............................................................................................................1626 Disassembly..............................................................................................................1626 OUTPUT SHAFT SIDE....................................................................................................1626 INPUT SHAFT SIDE.....................................................................................................1627 Inspection...............................................................................................................1628 Assembly.................................................................................................................1628 POWER STEERING GEAR AND LINKAGE..............................................................................................1633 Components...............................................................................................................1633 Removal and Installation.................................................................................................1634 Disassembly..............................................................................................................1635 Inspection...............................................................................................................1636 BOOT.................................................................................................................1636 RACK.................................................................................................................1636 PINION ASSEMBLY......................................................................................................1636 GEAR HOUSING CYLINDER................................................................................................1636 TIE-ROD OUTER AND INNER SOCKETS......................................................................................1637 Assembly.................................................................................................................1637 Adjustment...............................................................................................................1640 POWER STEERING OIL PUMP......................................................................................................1643 Components...............................................................................................................1643 Pre-disassembly Inspection...............................................................................................1643 Disassembly..............................................................................................................1644 Inspection...............................................................................................................1645 Assembly.................................................................................................................1645 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................................................1647 General Specifications...................................................................................................1647 Steering Wheel...........................................................................................................1647 Steering Column..........................................................................................................1647 Steering Transfer Gear...................................................................................................1647 Steering Gear and Linkage................................................................................................1648 Power Steering...........................................................................................................1648 su...............................................................................................................................1649 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................1649 FRONT SUSPENSION.............................................................................................................1650 Precautions..............................................................................................................1650 PRECAUTIONS..........................................................................................................1650 Preparation..............................................................................................................1650 SPECIAL SERVICE TOOLS................................................................................................1650 COMMERCIAL SERVICE TOOLS.............................................................................................1650 Noise, Vibration and Harshness (NVH) Troubleshooting.....................................................................1651 NVH TROUBLESHOOTING CHART............................................................................................1651 Components...............................................................................................................1652 On-vehicle Service.......................................................................................................1653 FRONT SUSPENSION PARTS...............................................................................................1653 FRONT WHEEL ALIGNMENT................................................................................................1654 Coil Spring and Strut Assembly...........................................................................................1656 COMPONENTS...........................................................................................................1656 REMOVAL..............................................................................................................1657 DISASSEMBLY..........................................................................................................1657 INSPECTION...........................................................................................................1657 ASSEMBLY.............................................................................................................1658 Stabilizer Bar...........................................................................................................1658 REMOVAL AND INSTALLATION.............................................................................................1658 INSPECTION...........................................................................................................1659 Transverse Link and Lower Ball Joint.....................................................................................1659 REMOVAL AND INSTALLATION.............................................................................................1659 INSPECTION...........................................................................................................1660 REAR SUSPENSION..............................................................................................................1661 Precautions..............................................................................................................1661 PRECAUTIONS..........................................................................................................1661 Preparation..............................................................................................................1661 COMMERCIAL SERVICE TOOLS.............................................................................................1661 Noise, Vibration and Harshness (NVH) Troubleshooting.....................................................................1661 Components...............................................................................................................1662 On-vehicle Service.......................................................................................................1662 REAR SUSPENSION PARTS................................................................................................1662 Removal and Installation.................................................................................................1663 Coil Spring and Shock Absorber...........................................................................................1665 COMPONENTS...........................................................................................................1665 REMOVAL AND INSTALLATION.............................................................................................1666 INSPECTION...........................................................................................................1666 Upper Link, LoweR Link and Panhard Rod...................................................................................1666 INSPECTION...........................................................................................................1666 BUSHING REPLACEMENT..................................................................................................1666 INSTALLATION.........................................................................................................1667 Stabilizer Bar...........................................................................................................1667 REMOVAL AND INSTALLATION.............................................................................................1667 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................................................1668 General Specifications (Front)...........................................................................................1668 Wheel Alignment (Unladen*1)..............................................................................................1668 Lower Ball Joint.........................................................................................................1668 Wheelarch Height (Unladen*)..............................................................................................1669 Wheel Runout Average*....................................................................................................1669 General Specifications (Rear)............................................................................................1669 tf...............................................................................................................................1670 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................1670 PRECAUTIONS..................................................................................................................1672 Supplemental Restraint System (SRS) "AIR BAG"............................................................................1672 Service Notice...........................................................................................................1672 Wiring Diagrams and Trouble Diagnosis....................................................................................1673 PREPARATION..................................................................................................................1674 Special Service Tools....................................................................................................1674 Commercial Service Tools.................................................................................................1678 ALL-MODE 4WD SYSTEM..........................................................................................................1679 Cross-sectional View.....................................................................................................1679 Control System...........................................................................................................1680 ALL-MODE 4WD TRANSFER BASIC CONTROL.................................................................................1681 HYDRAULIC CONTROL CIRCUITS...........................................................................................1681 OUTLINE..............................................................................................................1681 CONTROL SYSTEM DIAGRAM...............................................................................................1682 INDICATIONS OF 4WD WARNING LAMP......................................................................................1682 Location of Electrical Parts.............................................................................................1683 Circuit Diagram for Quick Pinpoint Check.................................................................................1684 Wiring Diagram - TF -....................................................................................................1685 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION.......................................................................................1695 Trouble Diagnosis without CONSULT........................................................................................1695 DESCRIPTION..........................................................................................................1695 SELF-DIAGNOSTIC PROCEDURE............................................................................................1696 INDICATIONS OF 4WD WARNING LAMP......................................................................................1697 Trouble Diagnosis with CONSULT...........................................................................................1698 SELF-DIAGNOSIS.......................................................................................................1698 SELF-DIAGNOSTIC ITEMS................................................................................................1699 DATA MONITOR.........................................................................................................1700 DATA MONITOR ITEMS...................................................................................................1701 REFERENCE VALUE IN DATA MONITOR MODE.................................................................................1703 WORK SUPPORT.........................................................................................................1704 CLUTCH FORCE RELEASE LIMIT ADJUSTMENT................................................................................1705 STARTING TORQUE OFFSET ADJUSTMENT....................................................................................1706 TROUBLE DIAGNOSIS - INTRODUCTION.............................................................................................1708 Introduction.............................................................................................................1708 DESCRIPTION..........................................................................................................1708 DIAGNOSTIC WORKSHEET.................................................................................................1708 Work Flow................................................................................................................1710 HOW TO PERFORM TROUBLE DIAGNOSES FOR QUICK AND ACCURATE REPAIR.......................................................1710 TROUBLE DIAGNOSIS - BASIC INSPECTION.........................................................................................1711 Listen to Customer Complaints............................................................................................1711 Transfer Fluid Check.....................................................................................................1711 Road Test................................................................................................................1711 PREPARATION FOR ROAD TEST............................................................................................1711 1. CHECK BEFORE ENGINE IS STARTED....................................................................................1712 2. CHECK AT IDLE.....................................................................................................1713 3. CRUISE TEST.......................................................................................................1715 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION......................................................................................1717 TCM Terminals and Reference Value........................................................................................1717 INSPECTION OF TCM....................................................................................................1717 TCM INSPECTION TABLE.................................................................................................1717 VEHICLE SPEED SENSOR (FRONT REVOLUTION SENSOR)...............................................................................1720 Diagnostic Procedure.....................................................................................................1720 4WD SOLENOID VALVE...........................................................................................................1722 Diagnostic Procedure.....................................................................................................1722 2-4WD SOLENOID VALVE AND 4WD SHIFT SWITCH....................................................................................1723 Diagnostic Procedure.....................................................................................................1723 TRANSFER MOTOR AND TRANSFER MOTOR RELAY......................................................................................1725 Diagnostic Procedure.....................................................................................................1725 TRANSFER FLUID TEMPERATURE SENSOR............................................................................................1727 Diagnostic Procedure.....................................................................................................1727 ATP SWITCH, WAIT DETECTION SWITCH AND NEUTRAL-4LO SWITCH.....................................................................1729 Diagnostic Procedure.....................................................................................................1729 CLUTCH PRESSURE SWITCH.......................................................................................................1731 Diagnostic Procedure.....................................................................................................1731 LINE PRESSURE SWITCH.........................................................................................................1733 Diagnostic Procedure.....................................................................................................1733 ABS OPERATION SIGNAL.........................................................................................................1735 Diagnostic Procedure.....................................................................................................1735 DATA ERASE/DISPLAY...........................................................................................................1737 Diagnostic Procedure.....................................................................................................1737 TROUBLE DIAGNOSES FOR SYMPTOMS...............................................................................................1738 Symptom 1. 4WD Shift Indicator Lamp Does Not Turn ON.....................................................................1738 Symptom 2. 4WD Warning Lamp Does Not Turn ON.............................................................................1739 Symptom 3. 4WD Shift Indicator Lamp Does Not Turn OFF....................................................................1741 Symptom 4. ATP Warning Lamp Does Not Turn ON.............................................................................1741 Symptom 5. 4LO Indicator Lamp Does Not Turn ON...........................................................................1742 Symptom 6. 4WD Shift Indicator Lamp Does Not Indicate "LOCK".............................................................1743 Symptom 7. 4WD Shift Indicator Lamp Repeats Flickering...................................................................1744 Symptom 8. Tight Corner Braking Symptom..................................................................................1745 Symptom 9. 4WD System Does Not Operate...................................................................................1745 COMPONENT INSPECTION.........................................................................................................1747 4WD Shift Switch.........................................................................................................1747 2-4WD Shift Solenoid Valve and Transfer Fluid Temperature Sensor.........................................................1747 4WD Solenoid Valve, Clutch Pressure Switch and Line Pressure Switch......................................................1747 Front Revolution Sensor..................................................................................................1748 Transfer Dropping Resistor...............................................................................................1748 ATP Switch, Neutral-4LO Switch and Wait Detection Switch.................................................................1748 Transfer Motor...........................................................................................................1749 Transfer Motor Relay.....................................................................................................1749 Transfer Sub-harness.....................................................................................................1749 FRONT REVOLUTION SENSOR SUB-HARNESS CONNECTOR........................................................................1749 TRANSFER SWITCH ASSEMBLY SUB-HARNESS CONNECTOR.......................................................................1750 TRANSFER TERMINAL CORD ASSEMBLY SUB-HARNESS CONNECTOR................................................................1750 Transfer Indicator Lamp Relay............................................................................................1750 ON-VEHICLE SERVICE...........................................................................................................1751 Replacing Oil Seal.......................................................................................................1751 FRONT CASE OIL SEAL..................................................................................................1751 SHIFT SHAFT OIL SEAL.................................................................................................1752 REAR OIL SEAL........................................................................................................1752 Transfer Motor...........................................................................................................1752 REMOVAL..............................................................................................................1752 INSTALLATION.........................................................................................................1752 Transfer Oil Filter......................................................................................................1753 REMOVAL..............................................................................................................1753 INSTALLATION.........................................................................................................1753 REMOVAL AND INSTALLATION.....................................................................................................1754 Removal..................................................................................................................1754 Installation.............................................................................................................1754 OVERHAUL.....................................................................................................................1755 Transfer Gear Control....................................................................................................1755 Transfer Components......................................................................................................1756 DISASSEMBLY..................................................................................................................1758 Rear Case................................................................................................................1758 DISASSEMBLY..........................................................................................................1758 Center Case..............................................................................................................1758 DISASSEMBLY..........................................................................................................1758 Front Case...............................................................................................................1768 DISASSEMBLY..........................................................................................................1768 REPAIR FOR COMPONENT PARTS...................................................................................................1772 Front case...............................................................................................................1772 INSPECTION...........................................................................................................1772 Center Case..............................................................................................................1773 INSPECTION...........................................................................................................1773 ASSEMBLY.....................................................................................................................1776 Front Case...............................................................................................................1776 ASSEMBLY.............................................................................................................1776 Center Case..............................................................................................................1780 ASSEMBLY.............................................................................................................1780 Final Assembly...........................................................................................................1788 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................................................1792 General Specifications...................................................................................................1792 Inner Gear and Outer Gear................................................................................................1792 SUB-OIL PUMP.........................................................................................................1792 MAIL OIL PUMP........................................................................................................1792 Control Valve............................................................................................................1792 VALVE................................................................................................................1792 SPRING...............................................................................................................1792 Clutch...................................................................................................................1793 DRIVE PLATE..........................................................................................................1793 RETURN SPRING........................................................................................................1793 RETAINING PLATE......................................................................................................1793 Seal Ring (Mainshaft side)...............................................................................................1793 Bearing Race (Thrust needle bearing side)................................................................................1794 Snap Ring (Sun gear side)................................................................................................1794
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