Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
1998 NISSAN PATHFINDER R50 Series Service Manual PDF DOWNLOAD
$24.95
1998 NISSAN PATHFINDER R50 Series Service Manual PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
1998 NISSAN PATHFINDER R50 Series Service Manual PDF DOWNLOAD
FILE DETAILS:
1998 NISSAN PATHFINDER R50 Series Service Manual PDF DOWNLOAD
Language : English
Pages : 1818
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
1998 NISSAN PATHFINDER R50 Series Service Manual PDF DOWNLOAD
fwd.............................................................................................................................. 1 QUICK REFERENCE INDEX........................................................................................................ 1 FOREWORD..................................................................................................................... 2 GI – General Information..................................................................................................... 0 MA – Maintenance............................................................................................................. 0 EM – Engine Mechanical....................................................................................................... 0 LC – Engine lubrication & Cooling Systems................................................................................... 0 EC – Engine Control Systems.................................................................................................. 0 FE – Accelerator Control, Fuel & Exhaust Systems............................................................................. 0 CL – Clutch.................................................................................................................. 0 MT – Manual Transmission..................................................................................................... 0 AT – Automatic Transmission.................................................................................................. 0 TF – Transfer................................................................................................................ 0 PD – Propeller Shaft & Differential Carrier.................................................................................. 0 AX – Front & Rear Axle....................................................................................................... 0 SU – Front & Rear Suspention................................................................................................. 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 QUICK REFERENCE CHART........................................................................................................ 4 GST Mode 6 - Test Value & Test Limit Chart................................................................................... 5 at............................................................................................................................... 6 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................ 6 TROUBLE DIAGNOSIS - INDEX.................................................................................................... 9 Alphabetical & P No. Index for DTC....................................................................................... 9 PRECAUTIONS.................................................................................................................. 11 Precautions for Supplemental Restraiant Sustem (SRS) "AIR BAG"........................................................... 11 Precautions for On Board Diagnostic (OBD) System of A/T and Engine....................................................... 11 Precautions.............................................................................................................. 11 Service Notice or Precautions............................................................................................ 13 Wiring Diagrams and Trouble Diagnosis.................................................................................... 14 PREPARATION.................................................................................................................. 15 Special Service Tools.................................................................................................... 15 OVERALL SYSTEM............................................................................................................... 17 A/T Electrical Parts Location............................................................................................ 17 Circuit Diagram.......................................................................................................... 18 Cross-sectional View..................................................................................................... 19 Hydraulic Control Circuit................................................................................................ 20 Shift Mechanism.......................................................................................................... 21 Control System........................................................................................................... 30 Control Mechanism........................................................................................................ 31 Control Valve............................................................................................................ 36 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION....................................................................................... 38 Introduction............................................................................................................. 38 OBD-II Function for A/T System........................................................................................... 38 One or Two Trip Detection Logic of OBD-II................................................................................ 38 OBD-II Diagnostic Trouble Code (DTC)..................................................................................... 38 Malfunction Indicator Lamp (MIL)......................................................................................... 42 CONSULT.................................................................................................................. 42 TROUBLE DIAGNOSIS - INTRODUCTION............................................................................................. 55 Introduction............................................................................................................. 55 Work Flow................................................................................................................ 59 TROUBLE DIAGNOSIS - BASIC INSPECTION......................................................................................... 61 A/T Fluid Check.......................................................................................................... 61 Stall Test............................................................................................................... 61 Line Pressure Test....................................................................................................... 64 Road Test................................................................................................................ 65 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION...................................................................................... 76 Symptom Chart............................................................................................................ 76 TCM Terminals and Reference Value........................................................................................ 87 TROUBLE DIAGNOSIS FOR POWER SUPPLY........................................................................................... 91 Wiring Diagram - AT - MAIN............................................................................................... 91 DTC P0705 INHIBITOR SWITCH................................................................................................... 93 Description.............................................................................................................. 93 Wiring Diagram - AT - INH/SW............................................................................................. 95 Diagnosis Procedure...................................................................................................... 96 Component Inspection..................................................................................................... 97 DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT............................................................................... 98 Description.............................................................................................................. 98 Wiring Diagram - AT - FTS................................................................................................ 100 Diagnostic Procedure..................................................................................................... 101 Component Inspection..................................................................................................... 102 DTC P0720 VEHICLE SPEED SENSOR-A/T (REVOLUTION SENSOR)....................................................................... 103 Description.............................................................................................................. 103 Wiring Diagram - AT - VSSA/T............................................................................................. 105 Diagnostic Procedure..................................................................................................... 106 Component Inspection..................................................................................................... 107 DTC P0725 ENGINE SPEED SIGNAL................................................................................................ 108 Description.............................................................................................................. 108 Wiring Diagram - AT - ENGSS.............................................................................................. 110 Diagnostic Procedure..................................................................................................... 111 DTC P0731 IMPROPER SHIFTING TO 1ST GEAR POSITION............................................................................. 112 Description.............................................................................................................. 112 Wiring Diagram - AT - 1ST................................................................................................ 115 Diagnostic Procedure..................................................................................................... 116 Component Inspection..................................................................................................... 117 DTC P0732 IMPROPER SHIFTING TO 2ND GEAR POSITION............................................................................. 118 Description.............................................................................................................. 118 Wiring Diagram - AT - 2ND................................................................................................ 121 Diagnostic Procedure..................................................................................................... 122 Component Inspection..................................................................................................... 122 DTC P0733 IMPROPER SHIFTING TO 3RD GEAR POSITION............................................................................. 124 Description.............................................................................................................. 124 Wiring Diagram - AT - 3RD................................................................................................ 127 Diagnostic Procedure..................................................................................................... 128 Component Inspection..................................................................................................... 128 DTC P0734 IMPROPER SHIFTING TO 4TH GEAR POSITION............................................................................. 130 Description.............................................................................................................. 130 Wiring Diagram - AT 4TH.................................................................................................. 134 Diagnostic Procedure..................................................................................................... 135 Component Inspection..................................................................................................... 138 DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE............................................................................. 139 Description.............................................................................................................. 139 Wiring Diagram - AT - TCV................................................................................................ 141 Diagnostic Procedure..................................................................................................... 142 Component Inspection..................................................................................................... 143 DTC P0744 IMPROPER LOCK-UP OPERATION......................................................................................... 144 Description.............................................................................................................. 144 Wiring Diagram - AT - TCCSIG............................................................................................. 147 Diagnostic Procedure..................................................................................................... 148 Component Inspection..................................................................................................... 151 DTC P0745 LINE RESSURE SOLENOID VALVE........................................................................................ 152 Description.............................................................................................................. 152 Wiring Diagram - AT - LPSV............................................................................................... 154 Diagnostic Procedure..................................................................................................... 155 Component Inspection..................................................................................................... 156 DTC P0750 SHIFT SOLENOID VALVE A............................................................................................. 158 Description.............................................................................................................. 158 Wiring Diagram - AT - SSV/A.............................................................................................. 160 Diagnostic Procedure..................................................................................................... 161 Component Inspection..................................................................................................... 162 DTC P0755 SHIFT SOLENOID VALVE B............................................................................................. 163 Description.............................................................................................................. 163 Wiring Diagram - AT - SSV/B.............................................................................................. 165 Diagnostic Procedure..................................................................................................... 166 Component Inspection..................................................................................................... 167 DTC P1705 THROTTLE POSITION SENSOR........................................................................................... 168 Description.............................................................................................................. 168 Wiring Diagram - AT - TPS................................................................................................ 171 Diagnostic Procedure..................................................................................................... 172 Component Inspection..................................................................................................... 174 DTC P1760 OVERRUN CLUTCH SOLENOID VALVE...................................................................................... 175 Description.............................................................................................................. 175 Wiring Diagram - AT - OVRCSV............................................................................................. 177 Diagnostic Procedure..................................................................................................... 178 Component Inspection..................................................................................................... 179 DTC BATT/FLUID TEMP SEN A/T FLUID TEMPERATURE SENSOR CIRCUIT AND TCM POWER SOURCE............................................ 180 Description.............................................................................................................. 180 Wiring Diagram - AT - BA/FTS............................................................................................. 182 Diagnostic Procedure..................................................................................................... 183 Component Inspection..................................................................................................... 184 VEHICLE SPEED SENSOR......................................................................................................... 185 Description.............................................................................................................. 185 Wiring Diagram - AT - VSSMTR............................................................................................. 187 Diagnotic Procedure...................................................................................................... 188 TROUBLE DIAGNOSES FOR SYMPTOMS............................................................................................... 189 Wiring Diagram - AT - NONDTC............................................................................................. 189 1. O/D OFF Indicator Lamp Does Not Come On............................................................................... 192 2. Engine Cannot Be Started in "P" and "N" Position...................................................................... 194 3. In "P" Postion, Vehicle Moves Forward Or Backward When Pushed......................................................... 195 4. In "P" Position, Vehicle Moves........................................................................................ 196 5. Large Shock. "N" - "R" Position....................................................................................... 198 6. Vehicle Does Not Creep Backward In "R" Position....................................................................... 199 7. Vehicle Does Not Creep Forward In "D", "2" Or "1" Position............................................................ 201 8. Vehicle Cannot Be Started From D1..................................................................................... 203 9. A/T Does Not Shift: D2 - D3 Or Does Not Kickdown: D4 - D2............................................................. 205 10. A/T Does Not Shift: D2 - D3.......................................................................................... 207 11. A/T Does Not Shift: D3 - D4.......................................................................................... 209 12. A/T Does Not Perform Lock-up......................................................................................... 211 13. A/T Does Not Hold Lock-up Condition.................................................................................. 212 14. Lock-up Is Not Released.............................................................................................. 213 15. Engine Speed Does Not Return To Idle (Light Braking D4- D3........................................................... 214 16. Vehicle Does Not Start From D1....................................................................................... 215 17. A/T Does Not Shift: D4 - D3, When Overdrive Control Switch "ON" - "OFF".............................................. 216 18. AT Does Not Shift: D3 - 2-2 When Selector Lever "D" - "2" Position................................................... 217 19. A/T Does Not Shift: 2-2 - 1-1, When Selector Lever "2" - "1" Position................................................ 218 20. Vehicle Does Not Decelerate By Engine Brake.......................................................................... 218 21. TCM Self-diagnosis Does Not Activate (Inhibitor, Overdrive Control and Throttle Position Switches Circuit Checks).... 219 A/T SHIFT LOCK SYSTEM........................................................................................................ 225 Description.............................................................................................................. 225 Wiring Diagram - SHIFT -................................................................................................. 226 Diagnostic Procedure..................................................................................................... 227 Component Check.......................................................................................................... 229 KEY INTERLOCK CABLE.......................................................................................................... 230 Components............................................................................................................... 230 Removal.................................................................................................................. 230 Installation............................................................................................................. 231 ON-VEHICLE SERVICE........................................................................................................... 232 Control Valve Assembly and Accumulators.................................................................................. 232 Revolution Sensor Replacement............................................................................................ 233 Rear Oil Seal Replacement................................................................................................ 233 Parking Components Inspection............................................................................................ 233 Inhibitor Switch Adjustment.............................................................................................. 234 Manual Control Linkage Adjustment........................................................................................ 234 REMOVAL AND INSTALLATION..................................................................................................... 235 Removal.................................................................................................................. 235 Installation............................................................................................................. 236 OVERHAUL..................................................................................................................... 238 Components............................................................................................................... 238 Oil Channel.............................................................................................................. 240 Locations of Needle Bearings, Thrust Washers and Snap Rings.............................................................. 241 DISASSEMBLY.................................................................................................................. 242 REPAIR FOR COMPONENT PARTS................................................................................................... 253 Oil Pump................................................................................................................. 253 Control Valve Assembly................................................................................................... 257 Control Valve Upper Body................................................................................................. 263 Control Valve Lower Body................................................................................................. 268 Reverse Clutch........................................................................................................... 270 High Clutch.............................................................................................................. 274 Forward and Overrun Clutches............................................................................................. 276 Low & Reverse Brake...................................................................................................... 280 Forward Clutch Drum Assembly............................................................................................. 284 Rear Internal Gear and Forward Clutch Hub................................................................................ 286 Band Servo Piston Assembly............................................................................................... 289 Parking Pawl Components.................................................................................................. 293 ASSEMBLY..................................................................................................................... 295 Assembly (1)............................................................................................................. 295 Adjustment............................................................................................................... 299 Assembly (2)............................................................................................................. 303 A/T FLUID COOLOR SYSTEM...................................................................................................... 313 A/T Fluid Cooler......................................................................................................... 313 Removal and Installation................................................................................................. 313 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................................................ 314 General Specifications................................................................................................... 314 Shift Schedule........................................................................................................... 314 Stall Revolution......................................................................................................... 314 Line Pressure............................................................................................................ 314 Return Springs........................................................................................................... 315 Accumulator O-ring....................................................................................................... 316 Clutches and Brakes...................................................................................................... 316 Oil Pump and Low One-way Clutch.......................................................................................... 318 Total End Play........................................................................................................... 318 Reverse Clutch Drum End Play............................................................................................. 319 Removal and Installation................................................................................................. 319 ax............................................................................................................................... 320 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................ 320 FRONT AXLE................................................................................................................... 320 Precautions.............................................................................................................. 321 PRECAUTIONS.......................................................................................................... 321 Preparation.............................................................................................................. 321 SPECIAL SERVICE TOOLS................................................................................................ 321 COMMERICAL SERVICE TOOLS............................................................................................. 321 Noise, Vibration and Harshness (NVH) Troubleshooting..................................................................... 322 Troubleshooting.......................................................................................................... 322 NVH TROUBLESHOOTING CHART............................................................................................ 322 On-vehicle Service....................................................................................................... 322 FRONT AXLE PARTS..................................................................................................... 322 FRONT WHEEL BEARING.................................................................................................. 323 DRIVE SHAFT.......................................................................................................... 324 Wheel Hub and Rotor Disc................................................................................................. 325 COMPONENTS........................................................................................................... 325 REMOVAL.............................................................................................................. 326 INSTALLATION......................................................................................................... 328 DISASSEMBLY.......................................................................................................... 328 INSPECTION........................................................................................................... 328 ASSEMBLY............................................................................................................. 329 Knuckle Spindle.......................................................................................................... 329 REMOVAL.............................................................................................................. 329 INSPECTION........................................................................................................... 330 INSTALLATION......................................................................................................... 330 Drive Shaft.............................................................................................................. 331 COMPONENTS........................................................................................................... 331 REMOVAL.............................................................................................................. 331 DISASSEMBLY.......................................................................................................... 332 INSPECTION........................................................................................................... 333 ASSEMBLY............................................................................................................. 333 INSTALLATION......................................................................................................... 335 REAR AXLE.................................................................................................................... 336 Precautions.............................................................................................................. 336 PRECAUTIONS.......................................................................................................... 336 Preparation.............................................................................................................. 336 SPECIAL SERVICE TOOLS................................................................................................ 336 COMMERCIAL SERVICE TOOLS............................................................................................. 337 Noice, Vibration and Harshness (NVH)..................................................................................... 337 Troubleshooting.......................................................................................................... 337 On-vehicle Service....................................................................................................... 337 REAR AXLE PARTS...................................................................................................... 337 REAR WHEEL BEARING................................................................................................... 337 Components............................................................................................................... 338 Removal.................................................................................................................. 338 Inspection............................................................................................................... 340 AXLE SHAFT........................................................................................................... 340 BEARING CAGE......................................................................................................... 340 REAR AXLE HOUSING.................................................................................................... 340 Installation............................................................................................................. 340 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................................................ 342 Wheel Bearing (Front).................................................................................................... 342 Drive Shaft (4WD)........................................................................................................ 342 DRIVE SHAFT END SNAP RING............................................................................................ 342 Wheel Bearing (Rear)..................................................................................................... 342 br............................................................................................................................... 343 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................ 343 PRECAUTIONS.................................................................................................................. 345 Supplemental Restraint System (SRS) "AIR BAG"............................................................................ 345 Precautions for Brake System............................................................................................. 345 Wiring Diagrams and Trouble Diagnosis.................................................................................... 345 PREPARATION.................................................................................................................. 346 Special Service Tools.................................................................................................... 346 Commercial Service Tools................................................................................................. 346 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING......................................................................... 347 NVH Troubleshooting Chart................................................................................................ 347 ON-VEHICLE SERVICE........................................................................................................... 348 Checking Brake Fluid Level............................................................................................... 348 Checking Brake Line...................................................................................................... 348 Changing Brake Fluid..................................................................................................... 348 Bleeding Brake System.................................................................................................... 349 BRAKE HYDRAULIC LINE......................................................................................................... 350 Hydraulic Circuit........................................................................................................ 350 Removal.................................................................................................................. 351 Inspection............................................................................................................... 351 Installation............................................................................................................. 351 PROPORTIONING VALVE (2WD).................................................................................................... 352 Inspection............................................................................................................... 352 Removal and Installation (Built-in type)................................................................................. 352 LOAD SENSING VALVE (4WD)..................................................................................................... 353 Inspection............................................................................................................... 353 Removal and Installation................................................................................................. 354 BRAKE PEDAL AND BRACKET...................................................................................................... 356 Removal and Installation................................................................................................. 356 Inspection............................................................................................................... 356 Adjustment............................................................................................................... 356 MASTER CYLINDER.............................................................................................................. 358 Removal.................................................................................................................. 358 Disassembly.............................................................................................................. 358 Inspection............................................................................................................... 359 Assembly................................................................................................................. 359 Installation............................................................................................................. 360 BRAKE BOOSTER................................................................................................................ 361 On-vehicle Service....................................................................................................... 361 OPERATING CHECK...................................................................................................... 361 AIRTIGHT CHECK....................................................................................................... 361 Removal.................................................................................................................. 361 Inspection............................................................................................................... 361 OUTPUT ROD LENGTH CHECK.............................................................................................. 361 Installation............................................................................................................. 362 VACUUM PIPING................................................................................................................ 363 Vacuum Hose.............................................................................................................. 363 Removal and Installation................................................................................................. 363 Inspection............................................................................................................... 363 HOSES AND CONNECTORS................................................................................................. 363 CHECK VALVE.......................................................................................................... 363 FRONT DISC BRAKE............................................................................................................. 364 Components............................................................................................................... 364 Pad Replacement.......................................................................................................... 364 Removal.................................................................................................................. 365 Disassembly.............................................................................................................. 366 Inspection............................................................................................................... 366 CALIPER.............................................................................................................. 366 ROTOR................................................................................................................ 366 Assembly................................................................................................................. 367 Installation............................................................................................................. 367 Brake Burnishing Procedure............................................................................................... 367 REAR DRUM BRAKE.............................................................................................................. 368 Components............................................................................................................... 368 Removal.................................................................................................................. 368 Inspection............................................................................................................... 369 WHEEL CYLINDER ...................................................................................................... 369 Wheel Cylinder Overhaul.................................................................................................. 370 Inspection............................................................................................................... 370 DRUM................................................................................................................. 370 LINING............................................................................................................... 370 Installation............................................................................................................. 370 PARKING BRAKE CONTROL........................................................................................................ 372 Components............................................................................................................... 372 Removal and Installation................................................................................................. 372 Inspection............................................................................................................... 372 Adjustment............................................................................................................... 373 ABS.......................................................................................................................... 374 DESCRIPTION.............................................................................................................. 374 Purpose.............................................................................................................. 374 Operation............................................................................................................ 374 ABS Hydraulic Circuit................................................................................................ 374 System Components.................................................................................................... 375 System Description................................................................................................... 375 SENSOR........................................................................................................... 375 CONTROL UNIT..................................................................................................... 375 G SENSOR (4WD MODELS ONLY)....................................................................................... 376 ACTUATOR......................................................................................................... 377 Component Parts and Harness Connector Location....................................................................... 378 Circuit Diagram for Quick Pinpoint Check............................................................................. 379 Wiring Diagram - ABS -............................................................................................... 380 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION................................................................................... 384 Self-diagnosis....................................................................................................... 384 FUNCTION......................................................................................................... 384 SELF-DIAGNOSIS PROCEDURE......................................................................................... 384 HOW TO READ SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES).......................................................... 385 HOW TO ERASE SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES)......................................................... 385 CONSULT.............................................................................................................. 386 CONSULT APPLICATION TO ABS....................................................................................... 386 ECU (ABS CONTROL UNIT) PART NUMBER MODE.......................................................................... 386 CONSULT Inspection Procedure......................................................................................... 387 SELF-DIAGNOSIS PROCEDURE......................................................................................... 387 SELF-DIAGNOSTIC RESULTS MODE..................................................................................... 388 DATA MONITOR PROCEDURE........................................................................................... 389 ACTIVE TEST PROCEDURE............................................................................................ 390 DATA MONITOR MODE................................................................................................ 391 ACTIVE TEST MODE................................................................................................. 391 TROUBLE DIAGNOSIS - INTRODUCTION......................................................................................... 392 How to Perform Trouble Diagnoses for Quick and Accurate Repair....................................................... 392 INTRODUCTION..................................................................................................... 392 TROUBLE DIAGNOSIS - BASIC INSPECTION..................................................................................... 393 Preliminary Check.................................................................................................... 393 Ground Circuit Check................................................................................................. 395 ACTUATOR MOTOR GROUND............................................................................................ 395 CONTROL UNIT GROUND.............................................................................................. 395 ACTUATOR GROUND.................................................................................................. 395 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION.................................................................................. 396 Malfunction Code/Symptom Chart....................................................................................... 396 WHEEL SENSOR OR ROTOR.................................................................................................... 397 Diagnostic Procedure................................................................................................. 397 ABS ACTUATOR SOLENOID VALVE.............................................................................................. 399 Diagnostic Procedure................................................................................................. 399 SOLENOID VALVE RELAY..................................................................................................... 401 Diagnostic Procedure................................................................................................. 401 MOTOR RELAY OR MOTOR..................................................................................................... 404 Diagnostic Procedure................................................................................................. 404 LOW VOLTAGE.............................................................................................................. 408 Diagnostic Procedure................................................................................................. 408 G SENSOR................................................................................................................. 409 Diagnostic Procedure................................................................................................. 409 Electrical Components Inspection..................................................................................... 411 G SENSOR......................................................................................................... 411 CONTROL UNIT............................................................................................................. 412 Diagnostic Procedure................................................................................................. 412 TROUBLE DIAGNOSES FOR SYMTOMS............................................................................................ 413 1. ABS Works Frequently.............................................................................................. 413 2. Unexpected Pedal Action........................................................................................... 413 3. Long Stopping Distance............................................................................................ 414 4. ABS Does Not Work................................................................................................. 415 5. Pedal Vibration and Noise......................................................................................... 415 6. Warning Lamp Does Not Come On When Ignition Switch Is Turned On................................................... 416 7. Warning Lamp Stays On When Ignition Switch Is Turned On........................................................... 419 Removal and Installation............................................................................................. 421 FRONT WHEEL SENSOR............................................................................................... 422 REAR WHEEL SENSOR................................................................................................ 422 FRONT SENSOR ROTOR............................................................................................... 422 REAR SENSOR ROTOR................................................................................................ 423 CONTROL UNIT..................................................................................................... 424 G SENSOR......................................................................................................... 424 ACTUATOR......................................................................................................... 425 ACTUATOR RELAYS.................................................................................................. 425 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................... 426 General Specifications............................................................................................... 426 Disc Brake........................................................................................................... 426 Drum Brake........................................................................................................... 426 Brake Pedal.......................................................................................................... 426 Parking Brake Control................................................................................................ 427 bt............................................................................................................................... 428 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................ 428 PRECAUTIONS.................................................................................................................. 429 Service Notice........................................................................................................... 429 Supplemental Restraint System (SRS) "AIR BAG"............................................................................ 429 CLIP AND FASTENER............................................................................................................ 430 Description.............................................................................................................. 430 BODY FRONT END............................................................................................................... 432 Removal and Installation................................................................................................. 432 FRONT BUMPER ASSEMBLY................................................................................................ 432 BODY REAR END AND OPENER..................................................................................................... 434 Removal and Installation................................................................................................. 434 REAR BUMPER ASSEMBLY................................................................................................. 434 FRONT DOOR................................................................................................................... 436 Overhaul................................................................................................................. 436 REAR DOOR.................................................................................................................... 437 Overhaul................................................................................................................. 437 INSTRUMENT PANEL ASSEMBLY.................................................................................................... 438 Removal and Installation................................................................................................. 438 SIDE AND FLOOR TRIM.......................................................................................................... 442 Removal and Installation................................................................................................. 442 DOOR TRIM.................................................................................................................... 444 Removal and Installation................................................................................................. 444 ROOF TRIM.................................................................................................................... 445 Removal and Installation................................................................................................. 445 BACK DOOR TRIM............................................................................................................... 445 Removal and Installation................................................................................................. 446 EXTERIOR..................................................................................................................... 447 Removal and Installation................................................................................................. 447 FRONT SEAT................................................................................................................... 453 Removal and Installation................................................................................................. 453 POWER SEAT........................................................................................................... 453 MANUAL SEAT.......................................................................................................... 454 HEATED SEAT.......................................................................................................... 455 REAR SEAT.................................................................................................................... 456 Removal and Installation................................................................................................. 456 SUNROOF...................................................................................................................... 457 Adjustment............................................................................................................... 457 Removal and Installation................................................................................................. 458 Trouble Diagnoses........................................................................................................ 461 DIAGNOSTIC TABLE..................................................................................................... 461 WIND DEFLECTOR....................................................................................................... 461 ADJUSTMENT........................................................................................................... 462 DRAIN HOSES.......................................................................................................... 463 WEATHERSTRIP......................................................................................................... 463 LINK AND WIRE ASSEMBLY............................................................................................... 464 WINDSHIELD AND WINDOWS....................................................................................................... 465 Removal and Installation................................................................................................. 465 REMOVAL.............................................................................................................. 465 INSTALLATION......................................................................................................... 465 WINDSHIELD........................................................................................................... 466 REAR SIDE WINDOW..................................................................................................... 467 DOOR MIRROR.................................................................................................................. 468 Removal and Installation................................................................................................. 468 BODY (ALIGNMENT)............................................................................................................. 469 Alignment................................................................................................................ 469 ENGINE COMPARTMENT................................................................................................... 470 UNDERBODY............................................................................................................ 472 cl............................................................................................................................... 474 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................ 474 PRECAUTIONS.................................................................................................................. 475 Precautions.............................................................................................................. 475 PREPARATION.................................................................................................................. 476 Special Service Tools.................................................................................................... 476 Commercial Service Tools................................................................................................. 476 NOISE, VIBRATION AND HARNESS (NVH) TROUBLESHOOTING........................................................................... 477 NVH Troubleshooting Chart................................................................................................ 477 CLUTCH SYSTEM - HYDRAULIC TYPE............................................................................................... 478 Components............................................................................................................... 478 Inspection and Adjustment................................................................................................ 479 ADJUSTING CLUTCH PEDAL............................................................................................... 479 AIR BLEEDING PROCEDURE............................................................................................... 480 CLUTCH MASTER CYLINDER....................................................................................................... 481 Components............................................................................................................... 481 Disassembly and Assembly................................................................................................. 481 Inspection............................................................................................................... 481 OPERATING CYLINDER........................................................................................................... 482 Components............................................................................................................... 482 Inspection............................................................................................................... 482 CLUTCH DAMPER................................................................................................................ 483 Components............................................................................................................... 483 Inspection............................................................................................................... 483 CLUTCH RELEASE MECHANISM..................................................................................................... 484 Components............................................................................................................... 484 Removal and Installation................................................................................................. 484 Inspection............................................................................................................... 485 Lubrication.............................................................................................................. 485 Waterproof - for 4WD Model............................................................................................... 485 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL....................................................................................... 486 Components............................................................................................................... 486 Inspection and Adjustment................................................................................................ 486 CLUTCH DISC.......................................................................................................... 486 CLUTCH COVER AND FLYWHEEL............................................................................................ 486 FLYWHEEL INSPECTION.................................................................................................. 487 Installation............................................................................................................. 487 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................................................ 488 Clutch Control System.................................................................................................... 488 Clutch Master Cylinder................................................................................................... 488 Clutch Operating Cylinder................................................................................................ 488 Clutch Damper............................................................................................................ 488 Clutch Disc.............................................................................................................. 488 Clutch Cover............................................................................................................. 488 Clutch Pedal............................................................................................................. 488 ec............................................................................................................................... 489 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................ 489 TROUBLE DIAGNOSIS - INDEX.................................................................................................... 496 Aplhabetical & P No. Index for DTC....................................................................................... 496 PRECAUTIONS.................................................................................................................. 502 Supplemental Restraint System (SRS) "AIR BAG"............................................................................ 502 Precautions for On Board Diagnostic (OBD) System of Engine and A/T....................................................... 502 Engine Fuel & Emission Control System.................................................................................... 503 Precautions.............................................................................................................. 504 Wiring Diagrams and Trouble Diagnosis.................................................................................... 505 PREPARATION.................................................................................................................. 506 Special Service Tools.................................................................................................... 506 Commercial Service Tools................................................................................................. 506 ENGINE AND EMISSION CONTROL OVERALL SYSTEM................................................................................... 508 ECCS Component Parts Location............................................................................................ 508 Circuit Diagram.......................................................................................................... 510 System Diagram........................................................................................................... 511 Vacuum Hose Drawing...................................................................................................... 512 System Chart............................................................................................................. 513 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION......................................................................... 514 Multiport Fuel Injection (MFI) System.................................................................................... 514 Distributor Ignition (DI) System......................................................................................... 516 Air Conditioning Cut Control............................................................................................. 517 Fuel Cut Control (at no load & high engine speed)........................................................................ 518 Evaporative Emission System.............................................................................................. 518 Positive Crankcase Ventilation........................................................................................... 524 BASIC SERVICE PROCEDURE...................................................................................................... 525 Fuel Pressure Release.................................................................................................... 525 Fuel Pressure Check...................................................................................................... 525 Fuel Pressure Regulator Check............................................................................................ 526 Injector................................................................................................................. 527 Fast Idle Cam (FIC)...................................................................................................... 528 Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment................................................................. 529 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION....................................................................................... 538 Introduction............................................................................................................. 538 Two Trip Detection Logic................................................................................................. 538 Emission-related Diagnostic Information.................................................................................. 539 Malfunction Indicator Lamp (MIL)......................................................................................... 551 OBD System Operation chart............................................................................................... 555 CONSULT.................................................................................................................. 560 Generic Scan Tool (GST).................................................................................................. 573 TROUBLE DIAGNOSIS - INTRODUCTION............................................................................................. 575 Introduction............................................................................................................. 575 Work Flow................................................................................................................ 577 TROUBLE DIAGNOSIS - BASIC INSPECTION......................................................................................... 579 Basis Inspection......................................................................................................... 579 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION...................................................................................... 581 DTC Inspection Priority Chart............................................................................................ 581 Fail-safe Chart.......................................................................................................... 582 Symptom Matrix Chart..................................................................................................... 583 CONSULT Reference Value in Data Monitor Mode............................................................................. 587 Major Sensor Reference Graph in Data Monitor Mode........................................................................ 589 ECM Terminals and Reference Value........................................................................................ 592 TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT.................................................................................. 601 Description.............................................................................................................. 601 Diagnostic Procedure..................................................................................................... 601 TROUBLE DIAGNOSIS FOR POWER SUPPLY........................................................................................... 602 Main Power Supply and Ground Circuit..................................................................................... 602 DTC P0100 MASS AIR FLOW SENSOR (MAFS)........................................................................................ 609 Component Description.................................................................................................... 609 CONSULT Reference Value in Data Monitor Mode............................................................................. 609 ECM Terminals and Reference Value........................................................................................ 609 On Board Diagnosis Logic................................................................................................. 609 DTC Confirmation Procedure............................................................................................... 610 Wiring Diagram........................................................................................................... 613 Diagnostic Procedure..................................................................................................... 614 Component Inspection..................................................................................................... 616 DTC P0105 ABSOLUTE PRESSURE SENSOR........................................................................................... 617 Component Description.................................................................................................... 617 On Board Diagnosis Logic................................................................................................. 617 DTC Confirmation Procedure............................................................................................... 617 Wiring Diagram........................................................................................................... 620 Diagnostic Procedure..................................................................................................... 621 Component Inspection..................................................................................................... 625 DTC P0110 INTAKE AIR TEMPERATURE SENSOR...................................................................................... 626 Component Description.................................................................................................... 626 On Board Diagnostic Logic................................................................................................ 626 DTC Confirmation Procedure............................................................................................... 626 Wiring Diagram........................................................................................................... 629 Diagnostic Procedure..................................................................................................... 630 Component Inspection..................................................................................................... 631 DTC P0115 ENGINE COOLANT TEMPERATURE SENSOR (ECTS) (CIRCUIT)................................................................. 632 Component Description.................................................................................................... 632 On Board Diagnosis Logic................................................................................................. 632 DTC Confirmation Procedure............................................................................................... 633 Wiring Diagram........................................................................................................... 634 Diagnostic Procedure..................................................................................................... 635 Component Inspection..................................................................................................... 636 DTC P0120 THROTTLE POSITION SENSOR........................................................................................... 637 Component Description.................................................................................................... 637 CONSULT Reference Value in Data Monitor Mode............................................................................. 637 ECM Terminals and Reference Value........................................................................................ 637 On Board Diagnosis Logic................................................................................................. 638 DTC Confirmation Procedure............................................................................................... 638 Wiring Diagram........................................................................................................... 643 Diagnostic Procedure..................................................................................................... 644 Component Inspection..................................................................................................... 646 DTC P0125 ENGINE COOLANT TEMPERATURE (ECT) SENSOR............................................................................ 647 Component Description.................................................................................................... 647 On Board Diagnosis Logic................................................................................................. 647 DTC Confirmation Procedure............................................................................................... 647 Wiring DIagram........................................................................................................... 650 Diagnostic Procedure..................................................................................................... 650 Component Inspection..................................................................................................... 651 DTC P0130 (RIGHT BANK, -B1), P0150 (LEFT BANK, -B2) FRONT HEATED OXYGEN SENSOR (FRONT HO2S) (CIRCUIT)........................ 652 Component Description.................................................................................................... 652 CONSULT Reference Value in Data Monitor Mode............................................................................. 652 ECM Terminals and Reference Value........................................................................................ 652 On Board Diagnosis Logic................................................................................................. 653 DTC Conformation Procedure............................................................................................... 653 Overall Function Check................................................................................................... 654 Wiring Diagram........................................................................................................... 655 Diagnostic Procedure..................................................................................................... 657 Component Inspection..................................................................................................... 658 DTC P0131 (RIGHT BANK, -B1), P0151 (LEFT BANK, -B2) FRONT HEATED OXYGEN SENSOR (FRONT HO2S) (LEAN SHIFT MONITORING).......... 660 Component Description.................................................................................................... 660 CONSULT Reference Value in Data Monitor Mode............................................................................. 660 ECM Terminals and Reference Value........................................................................................ 660 On Board Diagnosis Logic................................................................................................. 661 DTC Confirmation Procedure............................................................................................... 661 Overall Function Check................................................................................................... 662 Diagnostic Procedure..................................................................................................... 663 Component Inspection..................................................................................................... 664 DTC P0132 (RIGHT BANK, -B1), P0152 (LEFT BANK, -B2) FRONT HEATED OXYGEN SENSOR (FRONT HO2S) (RICH SHIFT MONITORING).......... 666 Component Description.................................................................................................... 666 CONSULT Reference Value in Data Monitor Mode............................................................................. 666 ECM Terminals and Reference Value........................................................................................ 666 On Board Diagnosis Logic................................................................................................. 667 DTC Confirmation Procedure............................................................................................... 667 Overall Function Check................................................................................................... 668 Diagnostic Procedure..................................................................................................... 669 Component Inspection..................................................................................................... 670 DTC P0133 (RIGHT BANK, -B1), P0153 (LEFT BANK, -B2) FRONT HEATED OXYGEN SENSOR (FRONT HO2S) (RESPONSE MONITORING)............ 672 Component Description.................................................................................................... 672 CONSULT Reference Value in Data Monitor Mode............................................................................. 672 ECM Terminals and Reference Value........................................................................................ 672 On Board Diagnosis Logic................................................................................................. 673 DTC Confirmation Procedure............................................................................................... 673 Overall Function Check................................................................................................... 674 Wiring Diagram........................................................................................................... 675 Diagnostic Procedure..................................................................................................... 677 Component Inspection..................................................................................................... 670 DTC P0134 (RIGHT BANK, -B1), P0154 (LEFT BANK, -B2) FRONT HEATED OXYGEN SENSOR (FRONT HO2S) (HIGH VOLTAGE)................... 681 Component Description.................................................................................................... 681 CONSULT Reference Value in Data Monitor Mode............................................................................. 681 ECM Terminals and Reference Value........................................................................................ 681 On Board Diagnosis Logic................................................................................................. 682 DTC Confirmation Procedure............................................................................................... 682 Wiring Diagram........................................................................................................... 683 Diagnostic Procedure..................................................................................................... 685 Component Inspection..................................................................................................... 686 DTC P0135 (RIGHT BANK, -B1), P0155 (LEFT BANK, -B2) FRONT HEATED OXYGEN SENSOR HEATER........................................ 688 Description.............................................................................................................. 688 CONSULT Reference Value in Data Monitor Mode............................................................................. 688 ECM Terminals and Reference Value........................................................................................ 688 On Board Diagnosis Logic................................................................................................. 688 DTC Confirmation Procedure............................................................................................... 689 Wiring Diagram........................................................................................................... 690 Diagnostic Procedure..................................................................................................... 692 Component Inspection..................................................................................................... 693 DTC P0137 (RIGHT BANK, -B1), P0157 (LEFT BANK, -B2) REAR HEATED OXYGEN SENSOR (REAR HO2S) (MIN. VOLTAGE MONITORING).......... 694 Component Description.................................................................................................... 694 CONSULT Reference Value in data Monitor Mode............................................................................. 694 ECM Terminals and Reference Value........................................................................................ 694 On Board Diagnosis Logic................................................................................................. 694 DTC Confirmation Procedure............................................................................................... 695 Overall Function Check................................................................................................... 696 Wiring Diagram........................................................................................................... 697 Diagnostic Procedure..................................................................................................... 699 Component Inspection..................................................................................................... 701 DTC P0138 (RIGHT BANK, -B1), P0158 (LEFT BANK, -B2) REAR HEATED OXYGEN SENSOR (REAR H02S) (MAX. VOLTAGE MONITORING).......... 702 Component Description.................................................................................................... 702 CONSULT Reference Value in Data Monitor Mode............................................................................. 702 ECM Terminals and Reference Value........................................................................................ 702 On Board Diagnosis Logic................................................................................................. 702 DTC Confirmation Procedure............................................................................................... 703 Overall Function Check................................................................................................... 704 Wiring Diagram........................................................................................................... 705 Diagnostic Procedure..................................................................................................... 707 Component Inspection..................................................................................................... 709 DTC P0139 (RIGHT BANK, -B1), P0159 (LEFT BANK, -B2) REAR HEATED OXYGEN SENSOR (REAR HO2S) (RESPONSE MONITORING).............. 710 Component Description.................................................................................................... 710 CONSULT Reference Value in Data Monitor Mode............................................................................. 710 ECM Terminals and Reference Value........................................................................................ 710 On Board Diagnosis Logic................................................................................................. 710 DTC Confirmation Procedure............................................................................................... 711 Overall Function Check................................................................................................... 712 Wiring Diagram........................................................................................................... 713 Diagnostic Procedure..................................................................................................... 715 Component Inspection..................................................................................................... 716 DTC P0140 (RIGHT BANK, -B1), P0160 (LEFT BANK, -B2) REAR HEATED OXYGEN SENSOR (REAR HO2S) (HIGH VOLTAGE)..................... 718 Component Description.................................................................................................... 718 CONSULT Reference Value in Data Monitor Mode............................................................................. 718 ECM Terminals and Reference Value........................................................................................ 718 On Board Diagnosis Logic................................................................................................. 719 DTC Confirmation Procedure............................................................................................... 719 Overall Function check................................................................................................... 719 Wiring Diagram........................................................................................................... 720 Diagnostic Procedure..................................................................................................... 722 Component Inspection..................................................................................................... 723 DTC P0141 (RIGHT BANK, -B1), P0161 (LEFT BANK -B2) REAR HEATED OXYGEN SENSOR HEATER.......................................... 725 Description.............................................................................................................. 725 CONSULT Reference Value in Data Monitor Mode............................................................................. 725 ECM Terminals and Reference Value........................................................................................ 725 On Board Diagnosis Logic................................................................................................. 725 DTC Confirmation Procedure............................................................................................... 726 Wiring Diagram........................................................................................................... 727 Diagnostic Procedure..................................................................................................... 729 Component Inspection..................................................................................................... 730 DTC P0171 (RIGHT BANK, -B1), P0174 (LEFT BANK, -B2) FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE)............................... 731 On Board Diagnosis Logic................................................................................................. 731 DTC Confirmation Procedure............................................................................................... 731 Wiring Diagram........................................................................................................... 733 Diagnostic Procedure..................................................................................................... 735 DTC P0172 (RIGHT BANK, -B1), P0175 (LEFT BANK, -B2) FUEL INJECTION SYSTEM FUNCTION (RICH SIDE)............................... 738 On Board Diagnosis Logic................................................................................................. 738 DTC Confirmation Procedure............................................................................................... 738 Wiring Diagram........................................................................................................... 740 Diagnostic Procedure..................................................................................................... 742 DTC P0180 TANK FUEL TEMPERATURE SENSOR....................................................................................... 745 Component Description.................................................................................................... 745 On Board Diagnosis Logic................................................................................................. 745 DTC Confirmation Procedure............................................................................................... 745 Wiring Diagram........................................................................................................... 747 Diagnostic Procedure..................................................................................................... 748 Component Inspection..................................................................................................... 748 DTC P0300 - P0306 NO. 6 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE...................................................... 749 On Board Diagnosis Logic................................................................................................. 749 DTC Confirmation Procedure............................................................................................... 749 Diagnostic Procedure..................................................................................................... 750 Component Inspection..................................................................................................... 753 DTC P0325 KNOCK SENSOR (KS).................................................................................................. 754 Component Description.................................................................................................... 754 ECM Terninals and Reference Value........................................................................................ 754 On Board Diagnosis Logic................................................................................................. 754 DTC Confirmation Procedure............................................................................................... 754 Wiring Diagram........................................................................................................... 755 Diagnostic Procedure..................................................................................................... 756 Component Inspection..................................................................................................... 757 DTC P0335 CRANKSHAFT POSITION SENSOR (CKPS) (OBD)............................................................................ 758 Component Description.................................................................................................... 758 ECM Terminals and Reference Value........................................................................................ 758 On Board Diagnosis Logic................................................................................................. 758 DTC Confirmation Procedure............................................................................................... 759 Wiring Diagram........................................................................................................... 760 Diagnostic Procedure..................................................................................................... 761 Component Inspection..................................................................................................... 762 DTC P0340 CAMSHAFT POSITION SENSOR (CMPS).................................................................................... 763 Component Description.................................................................................................... 763 ECM Terminals and Reference Value........................................................................................ 763 On Board Diagnosis Logic................................................................................................. 764 DTC Confirmation Procedure............................................................................................... 764 Wiring Diagram........................................................................................................... 766 Diagnostic Procedure..................................................................................................... 767 Component Inspection..................................................................................................... 768 DTC P0400 EGR FUNCTION (CLOSE)............................................................................................... 770 Description.............................................................................................................. 770 On Board Diagnosis Logic................................................................................................. 771 DTC Confirmation Procedure............................................................................................... 772 Overall Function Check................................................................................................... 773 Wiring Diagram........................................................................................................... 774 Diagnostic Procedure..................................................................................................... 775 Component Inspection..................................................................................................... 777 DTC P0402 EGRC-BPT VALVE FUNCTION............................................................................................ 778 Description.............................................................................................................. 778 On Board Diagnosis Logic................................................................................................. 778 DTC Confirmation Procedure............................................................................................... 779 Overall Function check................................................................................................... 780 Diagnostic Procedure..................................................................................................... 780 Component Inspection..................................................................................................... 781 DTC P0420 (RIGHT BANK, -B1), P0430 (LEFT BANK, -B2) THREE WAY CATALYST FUNCTION.............................................. 782 On Board diagnosis Logic................................................................................................. 782 DTC Confirmation Procedure............................................................................................... 782 Overall Function check................................................................................................... 783 Diagnostic Procedure..................................................................................................... 784 DTC P0440 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM (SMALL LEAK) (NEGATIVE PRESSURE)........................................ 786 On Board Diagnosis Logic................................................................................................. 786 DTC Confirmation Procedure............................................................................................... 787 Diagnostic Procedure..................................................................................................... 788 DTC P0443 EVAPORATIVE EMISSION (EVAP) CANISTER PURGE VOLUME CONTROL SOLENOID VALVE........................................... 793 Description.............................................................................................................. 793 CONSULT Reference Value in Data Monitor Mode............................................................................. 793 ECM Terminals and Reference Value........................................................................................ 794 On Board Diagnosis Logic................................................................................................. 794 DTC Confirmation Procedure............................................................................................... 794 Wiring Diagram........................................................................................................... 796 Diagnostic Procedure..................................................................................................... 797 Component Inspection..................................................................................................... 798 DTC P0446 EVAPORATIVE EMISSION (EVAP) CANISTER VENT CONTROL VALVE............................................................ 799 Component Description.................................................................................................... 799 CONSULT Reference Value in Data Monitor Mode............................................................................. 799 ECM Terminals and Reference Value........................................................................................ 799 On Board Diagnosis Logic................................................................................................. 799 DTC Confirmation Procedure............................................................................................... 799 Wiring Diagram........................................................................................................... 801 Diagnostic Procedure..................................................................................................... 802 Component Inspection..................................................................................................... 803 DTC P0450 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM PRESSURE SENSOR......................................................... 805 Component Description.................................................................................................... 805 CONSULT Reference Value in Data Monitor Mode............................................................................. 805 ECM Terminals and Reference Value........................................................................................ 805 On Board Diagnosis Logic................................................................................................. 806 DTC Confirmation Procedure............................................................................................... 806 Wiring Diagram........................................................................................................... 808 Diagnostic Procedure..................................................................................................... 809 Component Inspection..................................................................................................... 811 DTC P0500 VEHICLE SPEED SENSOR (VSS)......................................................................................... 813 Component Description.................................................................................................... 813 ECM Terminals and Reference Value........................................................................................ 813 On Board Diagnosis Logic................................................................................................. 813 DTC Confirmation Procedure............................................................................................... 813 Overall Function Check................................................................................................... 814 Wiring Diagram........................................................................................................... 815 Diagnostic Procedure..................................................................................................... 816 DTC P0505 IDLE AIR CONTROL VALVE (IACV) - AUSILIARY AIR CONTROL (AAC) VALVE.................................................. 817 Description.............................................................................................................. 817 CONSULT Reference Value in Data Monitor Mode............................................................................. 818 ECM Terminals and Reference Value........................................................................................ 818 On Board Diagnosis Logic................................................................................................. 818 DTC Confirmation Procedure............................................................................................... 818 Wiring Diagram........................................................................................................... 820 Diagnostic Procedure..................................................................................................... 821 Component Inspection..................................................................................................... 822 DTC P0510 CLOSED THROTTLE POSITION SWITCH.................................................................................... 823 Component Description.................................................................................................... 823 ECM Terminals and Reference Value........................................................................................ 823 On Board Diagnosis Logic................................................................................................. 823 DTC Confirmation Procedure............................................................................................... 823 Overall Functiion Check.................................................................................................. 824 Wiring Diagram........................................................................................................... 825 Diagnostic Procedure..................................................................................................... 826 Component Inspection..................................................................................................... 827 DTC P0600 A/T CONTROL........................................................................................................ 828 System Description....................................................................................................... 828 ECM Terminals and Reference Value........................................................................................ 828 On Board Diagnosis Logic................................................................................................. 828 DTC Confirmation Procedure............................................................................................... 828 Overall Function Check................................................................................................... 828 Wiring Diagram........................................................................................................... 829 Diagnostic Procedure..................................................................................................... 830 DTC P0605 ENGINE CONROL MODULE (ECM) - ECCS CONTROL MODULE................................................................... 831 Component Description.................................................................................................... 831 On Board Diagnosis Logic................................................................................................. 831 DTC Confirmation Procedure............................................................................................... 831 Diagnostic Procedure..................................................................................................... 832 DTC P1105 MANIFOLD ABSOLUTE PRESSURE (MAP)/BAROMETRIC PRESSURE (BARO) SWITCH SOLENOID VALVE.................................. 833 Description.............................................................................................................. 833 CONSULT Reference Value in Data Monidor Mode............................................................................. 833 ECM Terminals and Reference Value........................................................................................ 834 On board Diagnosis Logic................................................................................................. 834 DTC Confirmation Procedure............................................................................................... 834 Wiring Diagram........................................................................................................... 836 Diagnostic Procedure..................................................................................................... 837 Component Inspection..................................................................................................... 841 DTC P1148 (RIGHT BANK, -B1), P1168 (LEFT BANK, -B2) CLOSED LOOP CONTROL...................................................... 842 On Board Diagnosis Logic................................................................................................. 842 DTC Confirmation Procedure............................................................................................... 842 Overall Function check................................................................................................... 843 Diagnostic Procedure..................................................................................................... 843 DTC P1320 IGNITION SIGNAL.................................................................................................... 844 Component Description.................................................................................................... 844 CONSULT Reference Value In Data Monitor Mode............................................................................. 844 ECM Terminals and Reference Value........................................................................................ 844 On Board Diagnosis Logic................................................................................................. 845 DTC Confirmation Procedure............................................................................................... 845 Wiring Diagram........................................................................................................... 847 Diagnostic Procedure..................................................................................................... 848 Component Inspection..................................................................................................... 850 DTC P1336 CRANKSHAFT POSITION SENSOR (CKPS) (OBD) (COG)...................................................................... 851 Component Description.................................................................................................... 851 ECM Terminals and Reference Value........................................................................................ 851 On Board Diagnosis Logic................................................................................................. 851 DTC Confirmation Procedure............................................................................................... 852 Wiring Diagram........................................................................................................... 853 Diagnostic Procedure..................................................................................................... 854 Component Inspection..................................................................................................... 855 DTC P1400 EGRC-SOLENOID VALVE................................................................................................ 856 Component Description.................................................................................................... 856 CONSULT Reference Value in Data Monitor Mode............................................................................. 856 ECM Terminals and Reference Value........................................................................................ 856 On Board Diagnosis Logic................................................................................................. 856 DTC Confirmation Procedure............................................................................................... 856 Wiring Diagram........................................................................................................... 858 Diagnostic Procedure..................................................................................................... 859 Component Inspection..................................................................................................... 859 DTC P1401 EGR TEMPERATURE SENSORE............................................................................................ 861 Component Description.................................................................................................... 861 On Board Diagnosis Logic................................................................................................. 861 DTC Confirmation Procedure............................................................................................... 862 Overall Function Check................................................................................................... 863 Wiring Diagram........................................................................................................... 864 Diagnostic Procedure..................................................................................................... 865 Component Inspection..................................................................................................... 866 DTC P1402 EGR FUNCTION (OPEN)................................................................................................ 867 Description.............................................................................................................. 867 On Board Diagnosis Logic................................................................................................. 868 DTC Confirmation Procedure............................................................................................... 868 Wiring Diagram........................................................................................................... 870 Diagnostic Procedure..................................................................................................... 871 Component Inspection..................................................................................................... 872 DTC P1440 EVAPORATIVE EMISSION (EVAP) CONROL SYSTEM (SMALL LEAK) (POSITIVE PRESSURE)......................................... 874 On Board Diagnosis Logic................................................................................................. 874 DTC Confirmation Procedure............................................................................................... 875 Diagnostic Procedure..................................................................................................... 876 DTC P1444 EVAPORATIVE EMISSION (EVAP) CANISTER PURGE VOLUME CONTROL SOLENOID VALVE........................................... 881 Description.............................................................................................................. 881 CONSULT Reference Value in Data Monitor Mode............................................................................. 881 ECM Terminals and Reference Value........................................................................................ 882 On Board Diagnosis Logic................................................................................................. 882 DTC Confirmation Procedure............................................................................................... 883 Wiring Diagram........................................................................................................... 884 Diagnostic Procedure..................................................................................................... 885 Component Inspection..................................................................................................... 887 DTC P1446 EVAPORATIVE EMISSION (EVAP) CANISTER VENT CONTROL VALVE (CLOSE).................................................... 888 Component Description.................................................................................................... 888 CONSULT Reference Value in Data Monitor Mode............................................................................. 888 ECM Terminals and Reference Value........................................................................................ 888 On Board Diagnosis Logic................................................................................................. 888 DTC Confirmation Procedure............................................................................................... 889 Wiring Diagram........................................................................................................... 890 Component Inspection..................................................................................................... 892 DTC P1447 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM PURGE FLOW MONITORING................................................... 893 System Description....................................................................................................... 893 On Board Diagnosis Logic................................................................................................. 893 DTC Confirmation Procedure............................................................................................... 894 Overall Function Check................................................................................................... 894 Diagnostic Procedure..................................................................................................... 895 DTC P1448 EVAPORATIVE EMISSION (EVAP) CANISTER VENT CONTROL VALVE (OPEN)..................................................... 898 Component Description.................................................................................................... 898 CONSULT Reference Value in Data Monitor Mode............................................................................. 898 ECM Terminals and Reference Value........................................................................................ 898 On Board Diagnosis Logic................................................................................................. 898 DTC Confirmation Procedure............................................................................................... 899 Overall Function Check................................................................................................... 900 Wiring Diagram........................................................................................................... 901 Diagnostic Procedure..................................................................................................... 902 Component Inspection..................................................................................................... 903 DTC P1490 VACUUM CUT VALVE BYPASS VALVE (CIRCUIT)............................................................................ 904 Description.............................................................................................................. 904 CONSULT Reference Value in Data Monitor Mode............................................................................. 904 ECM Terminals and Reference Value........................................................................................ 904 On Board Diagnosis Logic................................................................................................. 905 DTC Confirmation Procedure............................................................................................... 905 Wiring Diagram........................................................................................................... 906 Diagnostic Procedure..................................................................................................... 907 Component Inspection..................................................................................................... 908 DTC P1491 VACUUM CUT VALVE BYPASS VALVE...................................................................................... 909 Description.............................................................................................................. 909 CONSULT Reference Value in Data Monitor Mode............................................................................. 909 ECM Terminals and Reference Value........................................................................................ 909 On Board Diagnosis Logic................................................................................................. 910 DTC Confirmation Procedure............................................................................................... 910 Overall Function Check................................................................................................... 911 Wiring Diagram........................................................................................................... 912 Diagnostic Procedure..................................................................................................... 913 Component Inspection..................................................................................................... 915 DTC P1605 A/T DIAGNOSIS COMMUNICATION LINE................................................................................... 916 Component Description.................................................................................................... 916 ECM Terminals and Reference Value........................................................................................ 916 On Board Diagnosis Logic................................................................................................. 916 DTC Confirmation Procedure............................................................................................... 916 Wiring Diagram........................................................................................................... 917 Diagnostic Procedure..................................................................................................... 918 DTC P1706 PARK/NEUTRAL POSITION SWITCH....................................................................................... 919 Component Description.................................................................................................... 919 CONSULT Reference Value in Data Monitor Mode............................................................................. 919 ECM Terminals and Reference Value........................................................................................ 919 On Board Diagnosis Logic................................................................................................. 919 DTC Confirmation Procedure............................................................................................... 919 Overall Function Check................................................................................................... 920 Wiring Diagram........................................................................................................... 921 Diagnostic Procedure for A/T Models...................................................................................... 922 Diagnostic Procedure for M/T Models...................................................................................... 923 INJECTOR..................................................................................................................... 924 Wiring Diagram........................................................................................................... 924 Component Description.................................................................................................... 925 ECM Terminals and Reference Value........................................................................................ 925 Diagnostic Procedure..................................................................................................... 926 Component Inspection..................................................................................................... 929 START SIGNAL................................................................................................................. 930 Wiring Diagram........................................................................................................... 930 CONSULT Reference Value in data Monitor Mode............................................................................. 931 ECM Terminals and Reference Value........................................................................................ 931 Diagnostic Procedure..................................................................................................... 931 FUEL PUMP.................................................................................................................... 934 Description.............................................................................................................. 934 CONSULT Reference Value in Data Monitor Mode............................................................................. 934 ECM Terminals and Reference Value........................................................................................ 935 Wiring Diagram........................................................................................................... 936 Diagnostic Procedure..................................................................................................... 937 Component Inspection..................................................................................................... 939 POWER STEERING OIL PRESSURE SWITCH........................................................................................... 940 Wiring Diagram........................................................................................................... 940 Component Description.................................................................................................... 941 CONSULT Reference Value in Data Monitor Mode............................................................................. 941 ECM Terminals and Reference Value........................................................................................ 941 Diagnostic Procedure..................................................................................................... 942 Component Inspection..................................................................................................... 943 IACV-FICD SOLENOID VALVE..................................................................................................... 944 Wiring Diagram........................................................................................................... 944 Component Description.................................................................................................... 945 ECM Terminals and Reference Value........................................................................................ 945 Diagnostic Procedure..................................................................................................... 946 Component Inspection..................................................................................................... 947 MIL & DATA LINK CONNECTORS................................................................................................... 949 Wiring Diagram........................................................................................................... 949 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................................................ 950 Fuel Pressure Regulator.................................................................................................. 950 Idle Speed and Ignition Timing........................................................................................... 950 Ignition Coil............................................................................................................ 950 Mass Air Flow Sensor..................................................................................................... 950 Engine Coolant Temperature Sensor........................................................................................ 950 EGR Temperature Sensor................................................................................................... 950 Front Heated Oxygen Sensor Heater........................................................................................ 950 Fuel Pump................................................................................................................ 951 IACV-AAC Valve........................................................................................................... 951 Injector................................................................................................................. 951 Resistor................................................................................................................. 951 Throttle Position Sensor................................................................................................. 951 Calculated Load Value.................................................................................................... 951 Intake Air Temperature Sensor............................................................................................ 951 Rear Heated Oxygen Sensor Heater......................................................................................... 951 Crankshaft Position Sensor (OBD)......................................................................................... 951 Tank Fuel Temperature Sensor............................................................................................. 951 el............................................................................................................................... 952 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................ 952 PRECAUTIONS.................................................................................................................. 955 Supplemental Restraint System (SRS) "AIR BAG"............................................................................ 955 Wiring Diagrams and Trouble Diagnosis.................................................................................... 955 HARNESS CONNECTOR............................................................................................................ 956 Description.............................................................................................................. 956 STANDARDIZED RELAY........................................................................................................... 957 Description.............................................................................................................. 957 POWER SUPPLY ROUTING......................................................................................................... 959 Schematic................................................................................................................ 959 Wiring Diagram - POWER -................................................................................................. 960 Inspection............................................................................................................... 966 GROUND....................................................................................................................... 967 Ground Distribution...................................................................................................... 967 COMBINATION SWITCH........................................................................................................... 971 Check.................................................................................................................... 971 Replacement.............................................................................................................. 972 STEERING SWITCH.............................................................................................................. 973 Check.................................................................................................................... 973 HEADLAMP (FOR USA)........................................................................................................... 974 System Description....................................................................................................... 974 Wiring Diagram - H/LAMP -................................................................................................ 975 Trouble Diagnoses........................................................................................................ 976 Bulb Replacement......................................................................................................... 976 Aiming Adjustment........................................................................................................ 977 HEADLAMP (FOR CANADA) - DAYTIME LIGHT SYSTEM - .............................................................................. 979 System Description....................................................................................................... 979 Schematic................................................................................................................ 981 Wiring Diagram - DTRL -.................................................................................................. 982 Trouble Diagnoses........................................................................................................ 985 Bulb Replacement......................................................................................................... 986 Aiming Adjustment........................................................................................................ 986 PARKING, LICENSE AND TAIL LAMPS.............................................................................................. 987 Wiring Diagram - TAIL/L -................................................................................................ 987 STOP LAMP.................................................................................................................... 989 Wiring Diagram - STOP/L -................................................................................................ 989 BACK-UP LAMP................................................................................................................. 991 Wiring Diagram - BACK/L -................................................................................................ 991 FRONT FOG LAMP............................................................................................................... 992 System Description....................................................................................................... 992 Wiring Diagram - F/FOG - ................................................................................................ 993 Aiming Adjustment........................................................................................................ 994 TURN SIGNAL AND HAZARD WARNING LAMPS......................................................................................... 995 System Description....................................................................................................... 995 Wiring Diagram - TURN -.................................................................................................. 997 Trouble Diagnoses........................................................................................................ 999 Electrical Components Inspection......................................................................................... 999 ILLUMINATION.................................................................................................................1000 System Description.......................................................................................................1000 Schematic................................................................................................................1001 Wiring Diagram - ILL -...................................................................................................1002 INTERIOR, SPOT, VANITY MIRROR AND LUGGAGE ROOM LAMPS.........................................................................1006 System Description.......................................................................................................1006 Schematic................................................................................................................1007 Wiring Diagram - INT/L -.................................................................................................1008 METER AND GAUGES.............................................................................................................1012 Component Parts and Harness Connector Location...........................................................................1012 System Description.......................................................................................................1012 Combination Meter........................................................................................................1014 Wiring Diagram - METER -.................................................................................................1015 Meter/Gauge Operation and Odc/Trip Meter Segment Check In Diagnosis Mode.................................................1016 Flexible Print Circuit (FPC).............................................................................................1017 Trouble Diagnoses........................................................................................................1018 Electrical Components Inspection.........................................................................................1023 COMPASS AND THERMOMETER......................................................................................................1025 System Description.......................................................................................................1025 Wiring Diagram - COMPAS - ...............................................................................................1026 Trouble Diagnoses........................................................................................................1027 Calibration Procedure for Compass........................................................................................1028 WARNING LAMPS................................................................................................................1029 Schematic................................................................................................................1029 Wiring Diagram - WARN -..................................................................................................1030 Electrical Components Inspection.........................................................................................1037 WARNING CHIME................................................................................................................1038 Component Parts and Harness Connector Location...........................................................................1038 System Description.......................................................................................................1038 Wiring Diagram - CHIME -.................................................................................................1040 Trouble Diagnoses........................................................................................................1042 FRONT WIPER AND WASHER.......................................................................................................1046 System Description.......................................................................................................1046 Wiring Diagram - WIPER -.................................................................................................1048 Trouble Diagnoses........................................................................................................1050 Removal and Installation.................................................................................................1052 Washer Nozzle Adjustment.................................................................................................1053 Washer Tube Layout.......................................................................................................1054 REAR WIPER AND WASHER........................................................................................................1055 System Description.......................................................................................................1055 Schematic................................................................................................................1057 Wiring Diagram - WIP/R -.................................................................................................1058 Trouble Diagnoses........................................................................................................1061 Removal and Installation.................................................................................................1061 Washer Nozzle Adjustment.................................................................................................1062 Washer Tube Layout.......................................................................................................1062 Check Valve..............................................................................................................1062 HORN.........................................................................................................................1063 Wiring diagram - HORN - .................................................................................................1063 CIGARETTE LIGHTER............................................................................................................1064 Wiring Diagram - CIGAR -.................................................................................................1064 REAR WINDOW DEFOGGER.........................................................................................................1065 Component Parts and Harness Connector Location...........................................................................1065 System Description.......................................................................................................1065 Wiring Diagram - DEF - ..................................................................................................1067 Trouble Diagnoses........................................................................................................1069 Electrical Components Inspection.........................................................................................1071 Filament Check...........................................................................................................1071 Filament Repair..........................................................................................................1072 AUDIO........................................................................................................................1074 System Description.......................................................................................................1074 Wiring Diagram - AUDIO - /Base System....................................................................................1075 Schematic/BOSE System....................................................................................................1077 Wiring Diagram - AUDIO - /BOSE System....................................................................................1078 Trouble Diagnoses........................................................................................................1082 Inspection...............................................................................................................1083 AUDIO ANTENNA................................................................................................................1084 System Description.......................................................................................................1084 Wiring Diagram - P/ANT -.................................................................................................1085 Trouble Diagnoses........................................................................................................1086 Location of Antenna......................................................................................................1086 Antenna Rod Replacement..................................................................................................1086 POWER SUNROOF................................................................................................................1088 Wiring Diagram - SROOF...................................................................................................1088 DOOR MIRROR..................................................................................................................1089 Wiring Diagram - MIRROR..................................................................................................1089 POWER SEAT...................................................................................................................1090 Wiring Diagram - SEAT -..................................................................................................1090 HEATED SEAT..................................................................................................................1092 Wiring Diagram - HSEAT...................................................................................................1092 AUTOMATIC SPEED CONTROL DEVICE (ASCD)........................................................................................1093 Component Parts and Harness Connector Location...........................................................................1093 System Description.......................................................................................................1094 Schematic/M/T Models.....................................................................................................1096 Schematic/A/T Models.....................................................................................................1097 Wiring Diagram - ASCD - .................................................................................................1098 Fail Safe System.........................................................................................................1103 Trouble Diagnoses........................................................................................................1104 Electrical Component Inspection..........................................................................................1113 ASCD Wire Adjustment.....................................................................................................1114 POWER WINDOW.................................................................................................................1115 System Description.......................................................................................................1115 Schematic................................................................................................................1117 Wiring Diagram - WINDOW -................................................................................................1118 Trouble Diagnoses........................................................................................................1122 POWER DOOR LOCK..............................................................................................................1123 Component Parts and Harness Connector Location...........................................................................1123 System Description.......................................................................................................1123 Schematic................................................................................................................1125 Wiring Diagram - D/LOCK -................................................................................................1126 Trouble Diagnoses........................................................................................................1129 MULTI-REMOTE CONTROL SYSTEM..................................................................................................1132 Component Parts and Harness Connector Location...........................................................................1132 System Description.......................................................................................................1132 Schematic................................................................................................................1134 Wiring Diagram - MULTI -.................................................................................................1135 Trouble Diagnoses........................................................................................................1139 ID Code Entry Procedure..................................................................................................1147 Remote Controller Battery Replacement....................................................................................1148 THEFT WARNING SYSTEM.........................................................................................................1149 Component Parts and Harness Connector Location...........................................................................1149 System Description.......................................................................................................1150 Schematic................................................................................................................1153 Wiring Diagram - THEFT -.................................................................................................1155 Trouble Diagnoses........................................................................................................1161 SMART ENTRANCE CONTROL UNIT..................................................................................................1174 Description..............................................................................................................1174 Schematic................................................................................................................1175 Smart Entrance Control Unit Inspection Table.............................................................................1177 INTEGRATED HOMELINK TRANSMITTER..............................................................................................1178 Wiring Diagram - TRNSMT -................................................................................................1178 Trouble Diagnoses........................................................................................................1179 ELECTRICAL UNITS LOCATION....................................................................................................1180 Engine Compartment.......................................................................................................1180 Passenger Compartment....................................................................................................1181 HARNESS LAYOUT...............................................................................................................1183 How to Read Harness Layout...............................................................................................1183 Outline..................................................................................................................1184 Main Harness.............................................................................................................1185 Engine Room Harness......................................................................................................1187 Engine Control Harness...................................................................................................1189 Body Harness LH..........................................................................................................1191 Engine Harness RH........................................................................................................1192 Back Door Harness........................................................................................................1193 Engine and Transmission Harness..........................................................................................1194 Room Lamp................................................................................................................1195 Air Bag Harness..........................................................................................................1196 Front Door Harness.......................................................................................................1197 Rear Door Harness........................................................................................................1198 BULB SPECIFICATIONS..........................................................................................................1199 Headlamp.................................................................................................................1199 Exterior Lamp............................................................................................................1199 Interior Lamp............................................................................................................1199 WIRING DIAGRAM CODES (CEL CODES).............................................................................................1200 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.................................................................................................... 3 Terminal Arrangement..................................................................................................... 3 ELECTRICAL UNITS............................................................................................................. 4 Terminal Arrangement..................................................................................................... 4 em...............................................................................................................................1202 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................1202 PRECAUTIONS..................................................................................................................1204 Parts Requiring Angular Tightening.......................................................................................1204 Liquid Gasket Application Procedure......................................................................................1204 PREPARATION..................................................................................................................1205 Special Service Tools....................................................................................................1205 Commercial Service Tools.................................................................................................1207 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING.........................................................................1209 NVH Troubleshooting Chart - Engine Noise.................................................................................1210 OUTER COMPONENT PARTS........................................................................................................1211 Removal and Installation.................................................................................................1211 WARM-UP THREE WAY CATALYST LH (FOR 4WD MODEL)........................................................................1213 MEASUREMENT OF COMPRESSION PRESSURE..........................................................................................1214 OIL PAN......................................................................................................................1215 Removal..................................................................................................................1215 Installation.............................................................................................................1216 TIMING BELT..................................................................................................................1218 Components...............................................................................................................1218 Removal..................................................................................................................1219 Inspection...............................................................................................................1220 BELT TENSIONER AND TENSIONER SPRING..................................................................................1221 Installation.............................................................................................................1221 BELT TENSION CHECK...................................................................................................1223 OIL SEAL.....................................................................................................................1224 Replacement..............................................................................................................1224 VALVE OIL SEAL.......................................................................................................1224 OIL SEAL INSTALLING DIRECTION........................................................................................1224 CAMSHAFT OIL SEAL....................................................................................................1225 FRONT OIL SEAL.......................................................................................................1225 REAR OIL SEAL........................................................................................................1225 CYLINDER HEAD................................................................................................................1226 Components...............................................................................................................1226 Removal..................................................................................................................1227 Disassembly..............................................................................................................1229 Inspection...............................................................................................................1230 CYLINDER HEAD DISTORTION.............................................................................................1230 CAMSHAFT VISUAL CHECK................................................................................................1230 CAMSHAFT RUNOUT......................................................................................................1230 CAMSHAFT CAM HEIGHT..................................................................................................1230 CAMSHAFT JOURNAL CLEARANCE...........................................................................................1231 CAMSHAFT END PLAY....................................................................................................1231 CAMSHAFT SPROCKET RUNOUT.............................................................................................1232 VALVE GUIDE CLEARANCE................................................................................................1232 VALVE GUIDE REPLACEMENT..............................................................................................1232 VALVE SEATS..........................................................................................................1233 REPLACING VALVE SEAT FOR SERVICE PARTS...............................................................................1233 VALVE DIMENSIONS.....................................................................................................1234 VALVE SPRING.........................................................................................................1234 ROCKER SHAFT AND ROCKER ARM..........................................................................................1235 HYDRAULIC VALVE LIFTER...............................................................................................1235 Assembly.................................................................................................................1236 Installation.............................................................................................................1236 ENGINE ASSEMBLY..............................................................................................................1241 Removal and Installation.................................................................................................1241 REMOVAL..............................................................................................................1242 CYLINDER BLOCK...............................................................................................................1244 Components...............................................................................................................1244 CYLINDER BLOCK HEATER................................................................................................1245 Removal and Installation.................................................................................................1245 Disassembly..............................................................................................................1246 PISTON AND CRANKSHAFT................................................................................................1246 Inspection...............................................................................................................1246 PISTON AND PISTON PIN CLEARANCE......................................................................................1246 PISTON RING SIDE CLEARANCE...........................................................................................1247 PISTON RING END GAP..................................................................................................1247 CONNECTING ROD BEND AND TORSION......................................................................................1247 CYLINDER BLOCK DISTORTION AND WEAR...................................................................................1248 PISTON-TO-BORE CLEARANCE.............................................................................................1248 CRANKSHAFT...........................................................................................................1250 BEARING CLEARANCE....................................................................................................1250 CONNECTING ROD BUSHING CLEARANCE (SMALL END).........................................................................1252 FLYWHEEL/DRIVE PLATE RUNOUT..........................................................................................1253 Assembly.................................................................................................................1253 PISTON...............................................................................................................1253 CRANKSHAFT...........................................................................................................1254 REPLACING PILOT BUSHING (M/T) OR PILOT CONVERTER (A/T)...............................................................1255 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................................................1256 General Specifications...................................................................................................1256 Cylinder Head............................................................................................................1257 Valve....................................................................................................................1257 VALVE................................................................................................................1257 VALVE SPRING.........................................................................................................1258 HYDRAULIC VALVE LIFTER...............................................................................................1258 VALVE GUIDE..........................................................................................................1258 ROCKER SHAFT AND ROCKER ARM..........................................................................................1258 Valve Seat...............................................................................................................1259 INTAKE VALVE SEAT....................................................................................................1259 EXHAUST VALVE SEAT...................................................................................................1260 Camshaft and Camshaft Bearing............................................................................................1261 Cylinder Block...........................................................................................................1262 Piston, Piston Ring and Piston Pin.......................................................................................1263 AVAILABLE PISTON.....................................................................................................1263 PISTON RING..........................................................................................................1263 PISTON PIN...........................................................................................................1264 Connecting Rod...........................................................................................................1264 Crankshaft...............................................................................................................1264 Available Main Bearing...................................................................................................1265 NO. 1 MAIN BEARING...................................................................................................1265 NO. 2 AND 3 MAIN BEARING.............................................................................................1265 NO. 4 MAIN BEARING...................................................................................................1265 UNDER SIZE...........................................................................................................1265 Available Connecting Rod Bearing.........................................................................................1266 CONNECTING ROD BEARING UNDERSIZE.....................................................................................1266 Miscellaneous Components.................................................................................................1266 BEARING CLEARANCE....................................................................................................1266 fe...............................................................................................................................1267 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................1267 PREPARATION..................................................................................................................1268 Special Service Tools....................................................................................................1268 ACCELERATOR CONTROL SYSTEM...................................................................................................1269 Removal and Installation.................................................................................................1269 Adjusting Accelerator Wire...............................................................................................1269 FUEL SYSTEM..................................................................................................................1270 Removal and Installation.................................................................................................1270 FUEL TANK............................................................................................................1271 FUEL PUMP AND GUAGE..................................................................................................1272 EXHAUSE SYSTEM...............................................................................................................1274 Removal and Installation.................................................................................................1274 foldout..........................................................................................................................1279 QUICK REFERENCE INDEX........................................................................................................ 0 SUPER MULTIPLE JUNCTION (SMJ)................................................................................................1279 Installation.............................................................................................................1279 Terminal Arrangement.....................................................................................................1280 FUSE BLOCK – JUNCTION BOX (J/B)..............................................................................................1281 Terminal Arrangement.....................................................................................................1281 FUSE AND FUSIBLE LINK BOX....................................................................................................1282 Terminal Arrangement.....................................................................................................1282 ELECTRICAL UNITS.............................................................................................................1283 Terminal arrangement.....................................................................................................1283 gi...............................................................................................................................1284 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................1284 PRECAUTIONS..................................................................................................................1286 Precautions..............................................................................................................1286 PRECAUTIONS FOR SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) "AIR BAG".......................................................1286 GENERAL PRECAUTIONS..................................................................................................1286 PRECAUTIONS FOR MULTIPORT FUEL INJECTION SYSTEM OR ECCS ENGINE.......................................................1288 PRECAUTIONS FOR THREE WAY CATALYST...................................................................................1288 PRECAUTIONS FOR ENGINE OILS..........................................................................................1288 PRECAUTIONS FOR FUEL.................................................................................................1289 PRECAUTIONS FOR AIR CONDITIONING.....................................................................................1289 HOW TO USE THIS MANUAL.......................................................................................................1290 HOW TO READ WIRING DIAGRAMS..................................................................................................1292 Sample/Wiring Diagram - EXAMPL -.........................................................................................1292 OPTIONAL SPLICE......................................................................................................1293 Description..............................................................................................................1294 CONNECTOR SYMBOLS....................................................................................................1301 HARNESS INDICATION...................................................................................................1297 COMPONENT INDICATION.................................................................................................1297 SWITCH POSITIONS.....................................................................................................1297 DETECTABLE LINES AND NON-DETECTABLE LINES............................................................................1298 MULTIPLE SWITCH......................................................................................................1299 FOLDOUT PAGE.........................................................................................................1300 HOW TO CHECK TERMINAL........................................................................................................1301 Connector and Terminal Pin Kit...........................................................................................1301 How to Probe Connectors..................................................................................................1301 PROBING FROM HARNESS SIDE............................................................................................1301 PROBING FROM TERMINAL SIDE...........................................................................................1301 How to Check Enlarged Contact Spring of Terminal.........................................................................1302 Waterproof Connector Inspection..........................................................................................1303 RUBBER SEAL INSPECTION...............................................................................................1303 WIRE SEAL INSPECTION.................................................................................................1303 Terminal Lock Inspection.................................................................................................1303 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT................................................................1304 Work Flow................................................................................................................1304 Incident Simulation Tests................................................................................................1305 INTRODUCTION.........................................................................................................1305 VEHICLE VIBRATION....................................................................................................1305 HEAT SENSATIVE.......................................................................................................1306 FREEZING.............................................................................................................1306 WATER INTRUSION......................................................................................................1307 ELECTRICAL LOAD......................................................................................................1307 COLD OR HOT START UP.................................................................................................1307 Circuit Inspection.......................................................................................................1307 INTRODUCTION.........................................................................................................1307 TESTING FOR "OPENS" IN THE CIRCUIT...................................................................................1308 TESTING FOR "SHORTS" IN THE CIRCUIT..................................................................................1309 GROUND INSPECTION....................................................................................................1310 VOLTAGE DROP TESTS...................................................................................................1310 CONTROL UNIT CIRCUIT TEST............................................................................................1312 HOW TO FOLLOW TROUBLE DIAGNOSES..............................................................................................1314 How to Follow Test Groups in Trouble Diagnoses...........................................................................1315 Key to Symbols Signifying Measurements or Procedures.....................................................................1316 CONSULT CHECKING SYSTEM......................................................................................................1318 Function and System Application..........................................................................................1318 Lithium Battery Replacement..............................................................................................1318 Checking Equipment.......................................................................................................1318 Loading Procedure........................................................................................................1319 CONSULT Data Link Connector (DLC) Circuit................................................................................1319 INSPECTION PROCEDURE.................................................................................................1319 IDENTIFICATION INFORMATION...................................................................................................1320 Model Variation..........................................................................................................1320 2-WHEEL DRIVE........................................................................................................1320 4-WHEEL DRIVE........................................................................................................1320 Identification Number....................................................................................................1320 VEHICLE IDENTIFICATION NUMBER ARRANGEMENT............................................................................1321 IDENTIFICATION PLATE.................................................................................................1322 ENGINE SERIAL NUMBER.................................................................................................1322 MANUAL TRANSMISSION NUMBER...........................................................................................1322 AUTOMATIC TRANSMISSION NUMBER........................................................................................1322 TRANSFER SERIAL NUMBER...............................................................................................1323 Dimensions...............................................................................................................1323 Wheels & Tires...........................................................................................................1323 FOR U.S.A............................................................................................................1323 FOR CANADA...........................................................................................................1323 LIFTING POINTS AND TOW TRUCK TOWING..........................................................................................1324 Screw Jack...............................................................................................................1324 Garage Jack and Safety Stand.............................................................................................1325 2-pole Lift..............................................................................................................1326 Tow Truck Towing.........................................................................................................1326 2-WHEEL DRIVE MODELS.................................................................................................1327 4-WHEEL DRIVE MODELS.................................................................................................1327 VEHICLE RECOVERY.....................................................................................................1328 TIGHTENING TORQUE OF STANDARD BOLTS..........................................................................................1329 SAE J1930 TERMINOLOGY LIST...................................................................................................1330 SAE J1930 Terminology List...............................................................................................1330 ha...............................................................................................................................1334 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................1334 AUTO.........................................................................................................................1336 PRECAUTIONS..............................................................................................................1336 Supplemental Restraint System (SRS) "AIR BAG"........................................................................1336 Precautions for Working with HFC-134a (R-134a).......................................................................1336 General Refrigerant Precautions......................................................................................1336 Precautions for Regrigerant Connection...............................................................................1337 Precautions for Servicing Compressor.................................................................................1339 Precautions for Service Equipment....................................................................................1339 Wiring Diagram and Trouble Diagnosis.................................................................................1341 PREPARATION..............................................................................................................1342 Special Service Tools................................................................................................1342 HFC-134a (R-134a) Service Tools and Equipment........................................................................1343 Equipment............................................................................................................1343 DESCRIPTION..............................................................................................................1345 Refrigeration System.................................................................................................1345 V-6 Variable Displacement Compressor.................................................................................1346 Component Layout.....................................................................................................1352 Introduction.........................................................................................................1353 Features.............................................................................................................1353 Overview of Control System...........................................................................................1353 Control Operation....................................................................................................1354 Discharge Air Flow...................................................................................................1356 TROUBLE DIAGNOSIS........................................................................................................1357 Harness Layout.......................................................................................................1357 Circuit Diagram - Auto Air Conditioner...............................................................................1359 Wiring Diagram - A/C, A -............................................................................................1360 How to Perform Trouble Diagnoses for Quick and Accurate Repair.......................................................1365 Operational Check....................................................................................................1366 A/C System...........................................................................................................1368 Intake Door..........................................................................................................1370 Blower Motor.........................................................................................................1377 Magnet Clutch........................................................................................................1386 Insufficient Cooling.................................................................................................1391 Insufficient Heating.................................................................................................1399 Starting Fan Speed Control...........................................................................................1400 Setting Temp. on PTC and In-vehicle Temp.............................................................................1402 Air Mix Door.........................................................................................................1405 Noise................................................................................................................1410 Ambient Sensor.......................................................................................................1411 In-vehicle Sensor....................................................................................................1413 Sunload Sensor.......................................................................................................1416 SERVICE PROCEDURE........................................................................................................1419 HFC-134a (R-134a) Service Procedure..................................................................................1419 Maintenance of Lubricant Quantity in Compressor......................................................................1421 Compressor...........................................................................................................1421 Compressor Clutch....................................................................................................1424 Refrigerant Lines....................................................................................................1427 Belt.................................................................................................................1431 Fast Idle Control Device (FICD)......................................................................................1431 MANUAL.......................................................................................................................1432 PRECAUTIONS..............................................................................................................1432 Supplemental Restraint System (SRS) "AIR BAG"........................................................................1432 Precautions for Working with HFC-134a (R-134a).......................................................................1432 General Refrigerant Precautions......................................................................................1432 Precautions for Refrigerant Connection...............................................................................1433 Precautions for Servicing Compressor.................................................................................1435 Precautions for Service Equipment....................................................................................1435 Wiring Diagrams and Trouble Diagnosis................................................................................1437 PREPARATION..............................................................................................................1438 Special Service Tools................................................................................................1438 HFC-134a (R-134a) Service Tools and Equipment........................................................................1439 DESCRIPTION..............................................................................................................1441 Refrigeration System.................................................................................................1441 V-6 Variable Displacement Compressor.................................................................................1442 Component Layout.....................................................................................................1448 Control Operation....................................................................................................1449 Discharge Air Flow...................................................................................................1450 System Description...................................................................................................1451 TROUBLE DIAGNOSES........................................................................................................1452 Harness Layout.......................................................................................................1452 Wiring Diagram - HEATER -............................................................................................1454 Circuit Diagram - Air Conditioner....................................................................................1455 Wiring Diagram - A/C, M -............................................................................................1456 How to Perform Trouble Diagnoses for Quick and Accurate Repair.......................................................1459 Operational check....................................................................................................1460 Intake Door..........................................................................................................1462 Blower Motor.........................................................................................................1467 Insufficient Cooling.................................................................................................1472 Insufficient Heating.................................................................................................1480 Air Outlet...........................................................................................................1482 Magnet Clutch........................................................................................................1484 Noise................................................................................................................1489 SERVICE PROCEDURE........................................................................................................1490 HFC-134a (R-134a) Service Procedure..................................................................................1490 Maintenance of Lubricant Quantity in Compressor......................................................................1492 Compresssor..........................................................................................................1494 Compressor Clutch....................................................................................................1495 Refrigerant Lines....................................................................................................1498 Belt.................................................................................................................1502 Fast Idle Control Device (FICD)......................................................................................1502 SERVICE DATA AND SPECIFICATIONS (SDS)....................................................................................1503 Auto.................................................................................................................1503 Manual...............................................................................................................1503 idx..............................................................................................................................1505 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................1505 lc...............................................................................................................................1514 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................1514 ENGINE LUBRICATION SYSTEM....................................................................................................1515 Precautions..............................................................................................................1515 LIQUID GASKET APPLIATION PROCEDURE...................................................................................1515 Preparation..............................................................................................................1515 SPECIAL SERVICE TOOLS................................................................................................1515 Lubrication Circuit......................................................................................................1516 Oil Pressure Check.......................................................................................................1516 Oil Pump.................................................................................................................1517 REMOVAL AND INSTALLATION.............................................................................................1517 DISASSEMBLY AND ASSEMBLY.............................................................................................1517 INSPECTION...........................................................................................................1518 REGULATOR VALVE INSPECTION...........................................................................................1518 OIL FILTER...........................................................................................................1518 OIL FILTER BRACKET...................................................................................................1519 ENGINE COOLING SYSTEM........................................................................................................1520 Precautions..............................................................................................................1520 LIQUID GASKET APPLICATION PROCEDURE..................................................................................1520 Preparation..............................................................................................................1520 SPECIAL SERVICE TOOLS................................................................................................1520 Cooling Circuit..........................................................................................................1521 System Check.............................................................................................................1521 CHECKING COOLING SYSTEM HOSES........................................................................................1521 CHECKING RADIATOR CAP................................................................................................1521 CHECKING COOLING SYSTEM FOR LEAKS....................................................................................1522 Water Pump...............................................................................................................1522 REMOVAL AND INSTALLATION.............................................................................................1522 INSPECTION...........................................................................................................1523 Thermostat...............................................................................................................1523 REMOVAL..............................................................................................................1523 INSPECTION...........................................................................................................1524 INSTALLATION.........................................................................................................1524 Radiator.................................................................................................................1525 REMOVAL AND INSTALLATION.............................................................................................1525 COMPONENTS...........................................................................................................1525 PREPARATION..........................................................................................................1526 DISASSEMBLY..........................................................................................................1526 ASSEMBLY.............................................................................................................1527 INSPECTION...........................................................................................................1528 Cooling Fan (Crankshaft driven)..........................................................................................1529 REMOVAL AND INSTALLATION.............................................................................................1529 INSPECTION...........................................................................................................1529 Refilling Engine Coolant.................................................................................................1530 Overheating Cause Analysis...............................................................................................1530 SERVICE DATA AND SPECIFICATIONS..............................................................................................1532 Oil Pressure.............................................................................................................1532 Regulator Valve..........................................................................................................1532 Oil Pump.................................................................................................................1532 Thermostat...............................................................................................................1532 Radiator.................................................................................................................1532 ma...............................................................................................................................1533 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................1533 PRECAUTIONS..................................................................................................................1534 Precautions for Supplemental Restraint System (SRS) "Air Bag"............................................................1534 PREPARATION..................................................................................................................1535 Special Service Tools....................................................................................................1535 GENERAL MAINTENTANCE.........................................................................................................1536 PERIODIC MAINTENANCE.........................................................................................................1538 Schedule 1...............................................................................................................1539 EMISSION CONTROL SYSTEM MAINTENANCE..................................................................................1539 CHASSIS AND BODY MAINTENANCE.........................................................................................1542 Schedule 2...............................................................................................................1541 EMISSION CONTROL SYSTEM MAINTENANCE..................................................................................1541 CHASSIS AND BODY MAINTENANCE.........................................................................................1542 RECOMMENDED FLUIDS AND LUBRICANTS............................................................................................1543 Fluids and Lubricants....................................................................................................1543 SAE Viscosity Number.....................................................................................................1544 GASOLINE ENGINE OIL..................................................................................................1544 GEAR OIL.............................................................................................................1544 Anti-freeze Coolant Mixture Ratio........................................................................................1544 ENGINE MAINTENANCE...........................................................................................................1545 Checking Drive Belts.....................................................................................................1545 Checking Engine Coolant..................................................................................................1546 Checking Fuel Lines......................................................................................................1548 Checking Fuel Filter.....................................................................................................1548 WITH CONSULT.........................................................................................................1548 WITHOUT CONSULT......................................................................................................1548 Changing Air Cleaner Filter..............................................................................................1549 VISCOUS PAPER TYPE...................................................................................................1549 Changing Engine Oil......................................................................................................1549 Changing Oil Filter......................................................................................................1550 Changing Spark Plugs.....................................................................................................1550 Checking EVAP Vapor Lines................................................................................................1552 CHASSIS AND BODY MAINTENANCE.................................................................................................1553 Checking Exhaust System..................................................................................................1553 Checking Clutch Fluid Level and Leaks....................................................................................1553 Checking M/T Oil.........................................................................................................1553 Changing M/T Oil.........................................................................................................1553 Checking Water Entry - For 4WD models with M/T...........................................................................1554 Checking A/T Fluid.......................................................................................................1554 Changing A/T Fluid.......................................................................................................1554 Checking Transfer Fluid..................................................................................................1555 Changing Transfer Fluid..................................................................................................1555 Checking Propeller Shaft.................................................................................................1556 Greasing Propeller Shaft.................................................................................................1556 Checking Differential Gear Oil...........................................................................................1556 Changing Differential Gear Oil...........................................................................................1557 LIMITED-SLIP DIFFERENTIAL GEAR.......................................................................................1557 Balancing Wheels.........................................................................................................1557 Tire Rotation............................................................................................................1557 Checking Brake Fluid Level and Leaks.....................................................................................1558 Checking Brake Lines and Cables..........................................................................................1558 Checking Disc Brake......................................................................................................1558 ROTOR................................................................................................................1558 CALIPER..............................................................................................................1558 PAD..................................................................................................................1558 Checking Drum Brake......................................................................................................1559 WHEEL CYLINDER.......................................................................................................1559 DRUM.................................................................................................................1559 LINING...............................................................................................................1559 TEMPORARY METHOD FOR CHECKING LINING WEAR............................................................................1559 Checking Steering Gear, Linkage and Transfer Gear........................................................................1559 STEERING GEAR........................................................................................................1559 STEERING LINKAGE.....................................................................................................1559 STEERING TRANSFER GEAR...............................................................................................1559 Checking Power Steering Fluid and Lines..................................................................................1560 CHECKING FLUID LEVEL.................................................................................................1560 CHECKING LINES.......................................................................................................1560 Lubricating Locks, Hinges and Hood Latches...............................................................................1560 Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters..........................................................1561 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................................................1562 Engine Maintenance.......................................................................................................1562 DRIVE BELT DEFLECTION................................................................................................1562 SPARK PLUG TYPE......................................................................................................1562 Chassis and Body Maintenance.............................................................................................1562 WHEEL BALANCE........................................................................................................1562 mt...............................................................................................................................1563 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................1563 PREPARATION..................................................................................................................1564 Special Service Tools....................................................................................................1564 Commercial Service Tool..................................................................................................1566 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING.........................................................................1567 NVH Troubleshooting Chart................................................................................................1567 MANUAL TRANSMISSION..................................................................................................1567 ON-VEHICLE SERVICE...........................................................................................................1568 Replacing Rear Oil Seal - 2WD Model......................................................................................1568 REMOVAL..............................................................................................................1568 INSTALLATION.........................................................................................................1568 Position Switch Check....................................................................................................1568 DESCRIPTION..................................................................................................................1569 Cross-sectional View - 2WD Model.........................................................................................1569 Cross-sectional View - 4WD Model.........................................................................................1570 REMOVAL AND INSTALLATION.....................................................................................................1571 Removal..................................................................................................................1571 2WD MODEL............................................................................................................1571 4WD MODEL............................................................................................................1572 Installation.............................................................................................................1573 OVERHAUL.....................................................................................................................1574 Case Components..........................................................................................................1574 Gear Components..........................................................................................................1575 Shift Control Components.................................................................................................1577 DISASSEMBLY..................................................................................................................1578 Case Components..........................................................................................................1578 DISASSEMBLY..........................................................................................................1578 Shift Control Components.................................................................................................1579 DISASSEMBLY..........................................................................................................1579 Gear Components..........................................................................................................1580 DISASSEMBLY..........................................................................................................1580 INSPECTION...................................................................................................................1584 Shift Control Components.................................................................................................1584 INSPECTION...........................................................................................................1584 Gear Components..........................................................................................................1584 INSPECTION...........................................................................................................1584 ASSEMBLY.....................................................................................................................1586 Gear Components..........................................................................................................1586 ASSEMBLY.............................................................................................................1586 Shift Control Components.................................................................................................1594 ASSEMBLY.............................................................................................................1594 Case Components..........................................................................................................1595 ASSEMBLY.............................................................................................................1595 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................................................1597 General Specifications...................................................................................................1597 Gear End Play............................................................................................................1597 Clearance Between Baulk Ring and Gear....................................................................................1597 2ND AND 3RD BAULK RING...............................................................................................1598 Distance between Rear Surface of Reverse Cone and Reverse Baulk Ring.....................................................1598 Available Snap Ring......................................................................................................1598 MAIN DRIVE GEAR SNAP RING............................................................................................1598 MAINSHAFT FRONT SNAP RING............................................................................................1598 COUNTER GEAR REAR SNAP RING..........................................................................................1599 Available C-ring.........................................................................................................1599 MAINSHAFT C-RING.....................................................................................................1599 Available Shim and Washer................................................................................................1599 TABLE FOR SELECTING PROPER COUNTER GEAR FRONT BEARING THRUST WASHER..................................................1599 REVERSE IDLER REAR THRUST WASHER.....................................................................................1599 pd...............................................................................................................................1600 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................1600 PROPELLER SHAFT..............................................................................................................1602 Preparation..............................................................................................................1602 SPECIAL SERVICE TOOLS................................................................................................1602 Noise, Vibration and Harshness (NVH) Troubleshooting.....................................................................1603 NVH TROUBLESHOOTING CHART............................................................................................1603 Components...............................................................................................................1604 FRONT PROPELLER SHAFT................................................................................................1604 REAR PROPELLER SHAFT.................................................................................................1605 On-vehicle Service.......................................................................................................1606 PROPELLER SHAFT VIBRATION............................................................................................1606 APPEARANCE CHECKING..................................................................................................1606 Removal and Installation.................................................................................................1606 Inspection...............................................................................................................1607 Disassembly..............................................................................................................1607 CENTER BEARING - 2WD -...............................................................................................1607 JOURNAL (71H AND 80B)................................................................................................1608 Assembly.................................................................................................................1609 CENTER BEARING - 2WD -...............................................................................................1609 JOURNAL (71H AND 90B)................................................................................................1609 R200A........................................................................................................................1611 FRONT FINAL DRIVE........................................................................................................1611 Preparation..........................................................................................................1611 SPECIAL SERVICE TOOLS............................................................................................1611 Noise, Vibration and Harshness (NVH) Troubleshooting.................................................................1613 On-vehicle Service...................................................................................................1613 FRONT OIL SEAL REPLACEMENT.......................................................................................1613 REAR COVER GASKET REPLACEMENT....................................................................................1614 Components...........................................................................................................1615 Removal and Installation.............................................................................................1616 REMOVAL..........................................................................................................1616 INSTALLATION.....................................................................................................1616 Disassembly..........................................................................................................1616 PRE-INSPECTION...................................................................................................1616 FINAL DRIVE HOUSING..............................................................................................1616 DIFFERENTIAL CASE................................................................................................1619 DIFFERENTIAL SIDE SHAFT..........................................................................................1620 Inspection...........................................................................................................1621 RING GEAR AND DRIVE PINION.......................................................................................1621 DIFFERENTIAL CASE ASSEMBLY.......................................................................................1621 BEARING..........................................................................................................1621 Adjustment...........................................................................................................1622 SIDE BEARING PRELOAD.............................................................................................1622 PINION GEAR HEIGHT AND PINION BEARING PRELOAD....................................................................1623 TOOTH CONTACT....................................................................................................1627 Assembly.............................................................................................................1628 DIFFERENTIAL SIDE SHAFT..........................................................................................1628 DIFFERENTIAL CASE................................................................................................1629 FINAL DRIVE HOUSING..............................................................................................1630 H223B........................................................................................................................1635 REAR FINAL DRIVE.........................................................................................................1635 Preparation..........................................................................................................1635 SPECIAL SERVICE TOOLS............................................................................................1635 Noise, Vibration and Harshness (NVH) Troubleshooting.................................................................1637 On-vehicle Service...................................................................................................1637 FRONT OIL SEAL REPLACEMENT.......................................................................................1637 Components...........................................................................................................1639 Removal and Installation.............................................................................................1640 REMOVAL..........................................................................................................1640 INSTALLATION.....................................................................................................1640 Disassembly..........................................................................................................1640 PRE-INSPECTION...................................................................................................1640 DIFFERENTIAL CARRIER.............................................................................................1641 DIFFERENTIAL CASE................................................................................................1643 Inspection...........................................................................................................1644 RING GEAR AND DRIVE PINION.......................................................................................1644 DIFFERENTIAL CASE ASSEMBLY.......................................................................................1644 BEARING..........................................................................................................1644 Limited Slip Differential............................................................................................1644 PREPARATION FOR DISASSEMBLY......................................................................................1644 DISASSEMBLY......................................................................................................1645 INSPECTION.......................................................................................................1646 ADJUSTMENT.......................................................................................................1647 ASSEMBLY.........................................................................................................1648 Adjustment...........................................................................................................1650 PINION GEAR HEIGHT...............................................................................................1650 TOOTH CONTACT....................................................................................................1653 Assembly.............................................................................................................1654 DIFFERENTIAL CASE................................................................................................1654 DIFFERENTIAL CARRIER.............................................................................................1655 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................................................1659 General Specifications...................................................................................................1659 2WD MODEL............................................................................................................1659 4WD MODEL............................................................................................................1659 Service Data.............................................................................................................1659 Snap Ring (80B)..........................................................................................................1659 Snap Ring (71H)..........................................................................................................1660 R200A....................................................................................................................1660 GENERAL SPECIFICATIONS...............................................................................................1660 RING GEAR RUNOUT.....................................................................................................1660 SIDE GEAR ADJUSTMENT.................................................................................................1660 SIDE BEARING ADJUSTMENT..............................................................................................1661 TOTAL PRELOAD ADJUSTMENT.............................................................................................1661 DRIVE PINION HEIGHT ADJUSTMENT.......................................................................................1661 DRIVE PINION PRELOAD ADJUSTMENT......................................................................................1662 H233B....................................................................................................................1662 GENERAL SPECIFICATIONS...............................................................................................1662 RING GEAR RUNOUT.....................................................................................................1663 SIDE GEAR ADJUSTMENT.................................................................................................1663 DIFFERENTIAL TORQUE ADJUSTMENT (LSD MODELS)..........................................................................1663 TOTAL PRELOAD ADJUSTMENT.............................................................................................1663 DRIVE PINION HEIGHT ADJUSTMENT.......................................................................................1664 DRIVE PINION PRELOAD ADJUSTMENT......................................................................................1664 rs...............................................................................................................................1665 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................1665 SEAT BELTS...................................................................................................................1666 Precautions..............................................................................................................1666 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) "AIR BAG"........................................................................1666 PRECAUTION FOR SEAT BELT SERVICE.....................................................................................1666 Front Seat Belt..........................................................................................................1667 REMOVAL AND INSTALLATION.............................................................................................1667 Rear Seat Belt...........................................................................................................1668 REMOVAL AND INSTALLATION.............................................................................................1668 Seat Belt Inspection.....................................................................................................1669 AFTER A COLLISION....................................................................................................1669 PRELIMINARY CHECKS...................................................................................................1669 SEAT BELT RETRACTOR ON-VEHICLE CHECK.................................................................................1669 SEAT BELT RETRACTOR OFF-VEHICLE CHECK................................................................................1670 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)..........................................................................................1672 Precautions..............................................................................................................1672 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) "AIR BAG"........................................................................1672 PRECAUTIONS FOR SRS "AIR BAG" SERVICE................................................................................1672 WIRING DIAGRAMS AND TROUBLE DIAGNOSIS................................................................................1672 Preparation..............................................................................................................1673 SPECIAL SERVICE TOOLS................................................................................................1673 Description..............................................................................................................1674 SRS Component Parts Location.............................................................................................1674 Maintenance Items........................................................................................................1675 Diagnosis Sensor Unit....................................................................................................1675 REMOVAL AND INSTALLATION.............................................................................................1675 Driver Air Bag Module and Spiral Cable...................................................................................1676 REMOVAL AND INSTALLATION.............................................................................................1676 REMOVAL..............................................................................................................1676 INSTALLATION.........................................................................................................1678 Front Passenger Air Bag Module...........................................................................................1678 REMOVAL..............................................................................................................1678 INSTALLATION.........................................................................................................1679 Disposal of Air bag Module...............................................................................................1680 CHECKING DEPLOYMENT TOOL.............................................................................................1680 DEPLOYMENT PROCEDURES FOR AIR BAG MODULE (OUTSIDE OF VEHICLE.........................................................1681 DEPLOYMENT OF AIR BAG MODULE WHILE MOUNTED IN VEHICLE................................................................1683 DISPOSING OF AIR BAG MODULE..........................................................................................1684 Trouble Diagnoses Intrucuction...........................................................................................1684 DIAGNOSIS FUNCTION...................................................................................................1684 DIAGNOSIS MODE FOR CONSULT...........................................................................................1684 HOW TO CHANGE SELF-DIAGNOSIS MODE WITH CONSULT.......................................................................1685 HOW TO CHANGE SELF-DIAGNOSIS MODE WITHOUT CONSULT....................................................................1686 HOW TO ERASE SELF-DIAGNOSIS RESULTS..................................................................................1686 How to Perform Trouble Diagnoses for Quick and Accurate Repair...........................................................1687 INFORMATION FROM CUSTOMER............................................................................................1687 PRELIMINARY CHECK....................................................................................................1687 WORK FLOW............................................................................................................1687 Schematic................................................................................................................1688 Wiring Diagram - SRS -...................................................................................................1689 SRS Operation Check......................................................................................................1691 DIAGNOSTIC PROCEDURE 1...............................................................................................1691 Trouble Diagnoses with CONSULT...........................................................................................1692 DIAGNOSTIC PROCEDURE 2...............................................................................................1692 DIAGNOSTIC PROCEDURE 3...............................................................................................1694 DIAGNOSTIC PROCEDURE 4 (CONTINUED FROM DIAGNOSTIC PROCEDURE 2).......................................................1696 DIAGNOSTIC PROCEDURE 5...............................................................................................1696 Trouble Diagnoses without CONSULT........................................................................................1700 DIAGNOSTIC PROCEDURE 6...............................................................................................1700 DIAGNOSTIC PROCEDURE 7...............................................................................................1701 DIAGNOSTIC PROCEDURE 8 (CONTINUED FROM DIAGNOSTIC PROCEDURE 6).......................................................1703 Trouble Diagnoses: "AIR BAG" Warning Lamp Does Not Turn Off..............................................................1704 DIAGNOSTIC PROCEDURE 9...............................................................................................1704 Trouble Diagnoses: "AIR BAG" Warning Lamp Does Not Turn On...............................................................1705 DIAGNOSTIC PROCEDURE 10..............................................................................................1706 Trouble Diagnoses: SRS Does Not Enter Diagnosis Mode Using Door Switch...................................................1706 DIAGNOSTIC PROCEDURE 11..............................................................................................1706 Collision Diagnosis......................................................................................................1707 SRS INSPECTION.......................................................................................................1707 sc...............................................................................................................................1709 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................1709 PRECAUTIONS..................................................................................................................1710 Supplemental Restraint System (SRS) "AIR BAG"............................................................................1710 Wiring Diagram and Trouble Diagnosis.....................................................................................1710 BATTERY......................................................................................................................1711 How to Handle Battery....................................................................................................1711 METHODS OF PREVENTING OVER-DISCHARGE.................................................................................1711 CHECKING ELECTROLYTE LEVEL...........................................................................................1711 SPECIFIC GRAVITY CHECK...............................................................................................1712 CHARGING THE BATTERY.................................................................................................1713 STARTING SYSTEM..............................................................................................................1714 System Description.......................................................................................................1714 WITH M/T.............................................................................................................1714 WITH A/T.............................................................................................................1715 Wiring Diagram - START - /With M/T.......................................................................................1716 Wiring Diagram - START - /With A/T.......................................................................................1717 Construction.............................................................................................................1718 Removal and Installation.................................................................................................1718 Pinion/Clutch Check......................................................................................................1718 CHARGING SYSTEM..............................................................................................................1719 System Description.......................................................................................................1719 Wiring Diagram - CHARGE-.................................................................................................1720 Trouble Diagnoses........................................................................................................1721 WITH IC REGULATOR....................................................................................................1721 MALFUNCTION INDICATOR................................................................................................1721 Construction.............................................................................................................1722 Removal and Installation.................................................................................................1722 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................................................1723 Battery..................................................................................................................1723 Starter..................................................................................................................1723 Alternator...............................................................................................................1723 st...............................................................................................................................1724 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................1724 PRECAUTIONS..................................................................................................................1725 Supplemental Restraint System (SRS) "AIR BAG"............................................................................1725 Precautions for Steering System..........................................................................................1725 PREPARATION..................................................................................................................1726 Special Service Tools....................................................................................................1726 Commercial Service Tools.................................................................................................1728 NOISE, VIBRATION AND HARSHNESS (NVH) TROUGLESHOOTING.........................................................................1729 NVH Troubleshooting Chart................................................................................................1729 ON-VEHICLE SERVICE...........................................................................................................1730 Checking Steering Wheel Play.............................................................................................1730 Checking Neutral Position on Steering Wheel..............................................................................1730 PRE-CHECKING.........................................................................................................1730 CHECKING.............................................................................................................1730 Front Wheel Turning Angle................................................................................................1730 Checking Gear Housing Movement...........................................................................................1731 Adjusting Rack Retainer..................................................................................................1731 Checking and Adjusting Drive Belts.......................................................................................1731 Checking Fluid Level.....................................................................................................1731 Cjeclomg Fluid Leakage...................................................................................................1731 Bleeding Hydraulic System................................................................................................1732 Checking Steering Wheel Turning Force....................................................................................1732 Checking Hydraulic System................................................................................................1733 STEERING WHEEL AND STEERING COLUMN...........................................................................................1734 Components...............................................................................................................1734 Removal and Installation.................................................................................................1734 STEERING WHEEL.......................................................................................................1734 STEERING COLUMN......................................................................................................1735 Disassembly and Assembly.................................................................................................1736 Inspection...............................................................................................................1737 TILT MECHANISM.......................................................................................................1737 STEERING TRANSFER GEAR.......................................................................................................1738 Components...............................................................................................................1738 Removal..................................................................................................................1739 Installation.............................................................................................................1740 Disassembly..............................................................................................................1740 OUTPUT SHAFT SIDE....................................................................................................1740 INPUT SHAFT SIDE.....................................................................................................1741 Inspection...............................................................................................................1742 Assembly.................................................................................................................1742 POWER STEERING GEAR AND LINKAGE..............................................................................................1747 Components...............................................................................................................1747 Removal and Installation.................................................................................................1748 Disassembly..............................................................................................................1749 Inspection...............................................................................................................1750 BOOT.................................................................................................................1750 RACK.................................................................................................................1750 PINION ASSEMBLY......................................................................................................1750 GEAR HOUSING CYLINDER................................................................................................1750 TIE-ROD OUTER AND INNER SOCKETS......................................................................................1751 Assembly.................................................................................................................1751 Adjustment...............................................................................................................1754 POWER STEERING OIL PUMP......................................................................................................1757 Components...............................................................................................................1757 Pre-disassembly Inspection...............................................................................................1757 Disassembly..............................................................................................................1758 Inspection...............................................................................................................1759 Assembly.................................................................................................................1759 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................................................1761 General Specifications...................................................................................................1761 Steering Wheel...........................................................................................................1761 Steering Column..........................................................................................................1761 Steering Transfer Gear...................................................................................................1761 Steering Gear and Linkage................................................................................................1762 Power Steering...........................................................................................................1762 su...............................................................................................................................1763 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................1763 FRONT SUSPENSION.............................................................................................................1764 Precautions..............................................................................................................1764 PRECAUTIONS..........................................................................................................1764 Preparation..............................................................................................................1764 SPECIAL SERVICE TOOLS................................................................................................1764 COMMERCIAL SERVICE TOOLS.............................................................................................1764 Noise, Vibration and Harshness (NVH) Troubleshooting.....................................................................1765 NVH TROUBLESHOOTING CHART............................................................................................1765 Components...............................................................................................................1766 2WD..................................................................................................................1766 4WD..................................................................................................................1767 On-vehicle Service.......................................................................................................1768 FRONT SUSPENSION PARTS...............................................................................................1768 FRONT WHEEL ALIGNMENT................................................................................................1769 Coil Spring and Strut Assembly...........................................................................................1771 COMPONENTS...........................................................................................................1771 REMOVAL..............................................................................................................1773 DISASSEMBLY..........................................................................................................1773 INSPECTION...........................................................................................................1773 ASSEMBLY.............................................................................................................1774 Stabilizer Bars..........................................................................................................1774 REMOVAL AND INSTALLATION.............................................................................................1774 INSPECTION...........................................................................................................1775 Transverse Link and Lower Ball Joint.....................................................................................1775 REMOVAL AND INSTALLATION.............................................................................................1775 INSPECTION...........................................................................................................1776 REAR SUSPENSION..............................................................................................................1777 Precautions..............................................................................................................1777 PRECAUTIONS..........................................................................................................1777 Preparation..............................................................................................................1777 COMMERCIAL SERVICE TOOLS.............................................................................................1777 Noise, Vibration and Harshness (NVH) Troubleshooting.....................................................................1777 Components...............................................................................................................1778 On-vehicle Service.......................................................................................................1778 REAR SUSPENSION PARTS................................................................................................1778 Removal and Installation.................................................................................................1779 Coil Spring and Shock Absorber...........................................................................................1781 COMPONENTS...........................................................................................................1781 REMOVAL AND INSTALLATION.............................................................................................1782 INSPECTION...........................................................................................................1782 Upper Link, Lower Link and Panhard Rod...................................................................................1782 INSPECTION...........................................................................................................1782 BUSHING REPLACEMENT..................................................................................................1782 INSTALLATION.........................................................................................................1783 Stabilizer Bar...........................................................................................................1783 REMOVAL AND INSTALLATION.............................................................................................1783 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................................................1784 General Specifications (Front)...........................................................................................1784 Wheel Alignment: (Unladen *1)............................................................................................1784 Lower Ball Joint.........................................................................................................1784 Wheelarch Height (Unladen*)..............................................................................................1785 Wheel Runout Average*....................................................................................................1785 General Specifications (Rear)............................................................................................1785 tf...............................................................................................................................1786 QUICK REFERENCE INDEX........................................................................................................ 0 TABLE OF CONTENTS............................................................................................................1786 PREPARATION..................................................................................................................1787 Special Service Tools....................................................................................................1787 Commercial Service Tools.................................................................................................1788 DESCRIPTION..................................................................................................................1790 Cross-sectional View.....................................................................................................1790 ON- VEHICLE SERVICE..........................................................................................................1791 Replacing Oil Seal.......................................................................................................1791 CENTER CASE OIL SEAL.................................................................................................1791 SHIFT SHAFT OIL SEAL.................................................................................................1791 REAR OIL SEAL........................................................................................................1792 Position Switch Check....................................................................................................1792 REMOVAL AND INSTALLATION.....................................................................................................1793 Removal .................................................................................................................1793 Installation.............................................................................................................1793 M/T MODEL............................................................................................................1793 A/T MODEL............................................................................................................1793 OVERHAUL.....................................................................................................................1794 Transfer Gear Control....................................................................................................1794 Case Components..........................................................................................................1795 Gear Components..........................................................................................................1796 Shift Control Components.................................................................................................1797 DISASSEMBLY..................................................................................................................1798 REPAIR FOR COMPONENT PARTS...................................................................................................1802 Mainshaft................................................................................................................1802 DISASSEMBLY..........................................................................................................1802 INSPECTION...........................................................................................................1803 ASSEMBLY.............................................................................................................1803 Front Drive Shaft........................................................................................................1804 DISASSEMBLY..........................................................................................................1804 INSPECTION...........................................................................................................1804 ASSEMBLY.............................................................................................................1804 Counter Gear.............................................................................................................1804 DISASSEMBLY..........................................................................................................1804 INSPECTION...........................................................................................................1804 ASSEMBLY.............................................................................................................1805 Main Gear................................................................................................................1805 DISASSEMBLY..........................................................................................................1805 INSPECTION...........................................................................................................1806 ASSEMBLY.............................................................................................................1806 Front Case...............................................................................................................1806 REMOVAL..............................................................................................................1807 INSTALLATION.........................................................................................................1807 Front Case Cover.........................................................................................................1807 REMOVAL..............................................................................................................1807 INSTALLATION.........................................................................................................1807 Bearing Retainer ........................................................................................................1807 REMOVAL..............................................................................................................1807 INSTALLATION ........................................................................................................1807 Rear Case................................................................................................................1808 REMOVAL..............................................................................................................1808 INSTALLATION.........................................................................................................1808 Shift Control Components.................................................................................................1808 INSPECTION ..........................................................................................................1808 ASSEMBLY.....................................................................................................................1810 SERVICE DATA AND SPECIFICATIONS (SDS)........................................................................................1817 General Specifications...................................................................................................1817 Gear End Play............................................................................................................1817 Available Snap Ring .....................................................................................................1817 MAINSHAFT FRONT BEARING .............................................................................................1817 MAINSHAFT REAR BEARING...............................................................................................1817 MAIN GEAR BEARING....................................................................................................1817 Available Shim...........................................................................................................1818 COUNTER GEAR REAR BEARING............................................................................................1818
DESCRIPTION:
1998 NISSAN PATHFINDER R50 Series Service Manual PDF DOWNLOAD
FOREWORD
- This manual contains maintenance and repair procedures for the 1998 Nissan PATHFINDER.
- In order to assure your safety and the efficient functioning of the vehicle, this manual should be read thoroughly.
- It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task.
- All information in this manual is based on the latest product information at the time of publication. The right is reserved to make changes in specifications and methods at any time without notice.
Important safety notice:
- The proper performance of service is essential for both the safety of the technician and the efficient functioning of the vehicle.
- The service methods in this Service Manual are described in such a manner that the service may be performed safely and accurately.
- Service varies with the procedures used, the skills of the technician and the tools and parts available.
- Accordingly, anyone using service procedures, tools or parts which are not specifically recommended by NISSAN must first completely satisfy himself that neither his safety nor the vehicle’s safety will be jeopardized by the service method selected .
Questions? Email us: [email protected]
https://vimeo.com/853939011?share=copy
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
G.P
