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1999 INFINITI G20 P10 Series Service Manual PDF DOWNLOAD
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Description
1999 INFINITI G20 P10 Series Service Manual PDF DOWNLOAD
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1999 INFINITI G20 P10 Series Service Manual PDF DOWNLOAD
Language : English
Pages : 1799
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
1999 INFINITI G20 P10 Series Service Manual PDF DOWNLOAD
fwd....................................................................................................................... 1 QUICK REFERENCE INDEX................................................................................................. 1 FOREWORD.............................................................................................................. 2 GI - General Information.............................................................................................. 0 MA - Maintenance...................................................................................................... 0 EM - Engine Mechanical................................................................................................ 0 LC - Engine Lubrication & Cooling Systems............................................................................. 0 EC - Engine Control System............................................................................................ 0 FE - Accelerator Control, Fuel & Exhaust Systems...................................................................... 0 CL - Clutch........................................................................................................... 0 MT - Manual Transaxle................................................................................................. 0 AT - Automatic Transaxle.............................................................................................. 0 AX - Front & Rear Axle................................................................................................ 0 SU - Front & Rear Suspension.......................................................................................... 0 BR - Brake System..................................................................................................... 0 ST - Steering System.................................................................................................. 0 RS - Restraint System................................................................................................. 0 BT - Body & Trim...................................................................................................... 0 HA - Heater & Air Conditioner......................................................................................... 0 SC - Starting & Changing System....................................................................................... 0 EL - Electrical System................................................................................................ 0 IDX - Alphabetical Index.............................................................................................. 1 Foldout............................................................................................................... 0 Comment Sheet......................................................................................................... 3 Inch to Metric Conversion Chart....................................................................................... 4 Quick Reference Chart................................................................................................. 5 GST Mode 6 - Test Value & Test Limit ................................................................................. 6 at........................................................................................................................ 7 QUICK REFERENCE INDEX................................................................................................. 0 TABLE OF CONTENTS..................................................................................................... 7 TROUBLE DIAGNOSIS - INDEX............................................................................................. 10 Alphabetical & P No. Index for DTC................................................................................ 10 PRECAUTIONS........................................................................................................... 12 Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONERÆ....................... 12 Precautions for On Board Diagnostic (OBD)......................................................................... 12 System of A/T and Engine.......................................................................................... 12 Precautions....................................................................................................... 12 Service Notice or Precautions..................................................................................... 14 Wiring Diagram and Trouble Diagnosis.............................................................................. 15 PREPARATION........................................................................................................... 16 Special Service Tools............................................................................................. 16 Commercial Service Tools.......................................................................................... 18 OVERALL SYSTEM........................................................................................................ 20 A/T Electrical Parts Location..................................................................................... 20 Circuit Diagram................................................................................................... 21 Cross-sectional View - RE4F03A.................................................................................... 22 Cross-sectional View - RE4F03V.................................................................................... 23 Hydraulic Control Circuit......................................................................................... 24 Shift Mechanism................................................................................................... 25 Control System.................................................................................................... 34 Control Mechanism................................................................................................. 35 Control Valve..................................................................................................... 40 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION................................................................................ 42 Introduction...................................................................................................... 42 OBD-II Function fo A/T System..................................................................................... 42 One or Two Trip Detection Logic of OBD-II......................................................................... 42 OBDII Diagnostic Trouble Code (DTC)............................................................................... 42 Malfunction Indicator Lamp (MIL).................................................................................. 46 CONSULT........................................................................................................... 46 TROUBLE DIAGNOSIS - INTRODUCTION...................................................................................... 60 Introduction...................................................................................................... 60 Work Flow......................................................................................................... 64 TROUBLE DIAGNOSIS - BASIC INSPECTION.................................................................................. 66 A/T Fluid Check................................................................................................... 66 Stall Test........................................................................................................ 66 Line Pressure Test................................................................................................ 70 Road Test......................................................................................................... 71 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION............................................................................... 83 Symptom Chart..................................................................................................... 83 TCM Terminals and Reference Value................................................................................. 93 TROUBLE DIAGNOSIS FOR POWER SUPPLY.................................................................................... 98 Wiring Diagram - AT - MAIN........................................................................................ 98 DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH.......................................................................... 100 Description....................................................................................................... 100 Wiring Diagram - AT - PNP/SW...................................................................................... 102 Diagnostic Procedure.............................................................................................. 103 Component Inspection.............................................................................................. 104 DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT........................................................................ 105 Description....................................................................................................... 105 Wiring Diagram - AT - FTS......................................................................................... 107 Diagnostic Procedure.............................................................................................. 108 Component Inspection.............................................................................................. 110 DTC P0720 VEHICLE SPEED SENSOR - A/T (REVOLUTION SENSOR).............................................................. 111 Description....................................................................................................... 111 Wiring Diagram - AT - VSSA/T...................................................................................... 113 Diagnostic Procedure.............................................................................................. 114 Component Inspection.............................................................................................. 115 DTC P0725 ENGINE SPEED SIGNAL......................................................................................... 116 Description....................................................................................................... 116 Wiring Diagram - AT - ENGSS....................................................................................... 118 Diagnostic Procedure.............................................................................................. 119 DTC P0731 A/T 1ST GEAR FUNCTION....................................................................................... 120 Description....................................................................................................... 120 Wiring Diagram - AT - 1ST......................................................................................... 123 Diagnostic Procedure.............................................................................................. 124 Component Inspection.............................................................................................. 125 DTC P0732 A/T 2ND GEAR FUNCTION....................................................................................... 126 Description....................................................................................................... 126 Wiring Diagram - AT - 2ND......................................................................................... 129 Diagnostic Procedure.............................................................................................. 130 Component Inspection.............................................................................................. 131 DTC P0733 A/T 3RD GEAR FUNCTION....................................................................................... 132 Description....................................................................................................... 132 Wiring Diagram - AT - 3RD......................................................................................... 135 Diagnostic Procedure.............................................................................................. 136 Component Inspection.............................................................................................. 137 DTC P0734 A/T 4TH GEAR FUNCTION....................................................................................... 138 Description....................................................................................................... 138 Wiring Diagram - AT - 4TH......................................................................................... 142 Diagnostic Procedure.............................................................................................. 143 Component Inspection.............................................................................................. 146 DTC P0740 TORQUE CONVERTER CLTUCH SOLENOID VALVE...................................................................... 147 Description....................................................................................................... 147 Wiring Diagram - AT - TCV......................................................................................... 149 Diagnostic Procedure.............................................................................................. 150 Component Inspection.............................................................................................. 151 DTC P0744 A/T TCC S/V FUNCTION (LOCK-UP).............................................................................. 152 Description....................................................................................................... 152 Wiring Diagram - AT - TCCSIG...................................................................................... 155 Diagnostic Procedure.............................................................................................. 156 Component Inspection.............................................................................................. 159 DTC P0745 LINE PRESSURE SOLENOID VALVE................................................................................ 160 Description....................................................................................................... 160 Wiring Diagram - AT - LPSV........................................................................................ 162 Diagnostic Procedure.............................................................................................. 163 Component Inspection.............................................................................................. 165 DTC P0750 SHIFT SOLENOID VALVE A...................................................................................... 166 Description....................................................................................................... 166 Wiring Diagram - AT - SSV/A....................................................................................... 168 Diagnostic Procedure.............................................................................................. 169 Component Inspection.............................................................................................. 170 DTC P0755 SHIFT SOLENOID VALVE B...................................................................................... 171 Description....................................................................................................... 171 Wiring Diagram - AT - SSV/B....................................................................................... 173 Diagnostic Procedure.............................................................................................. 174 Component Inspection.............................................................................................. 175 DTC P1705 THROTTLE POSITION SENSOR.................................................................................... 176 Description....................................................................................................... 176 Wiring Diagram - AT - TPS......................................................................................... 179 Diagnostic Procedure.............................................................................................. 180 Component Inspection.............................................................................................. 183 DTC P1760 OVERRUN CLUTCH SOLENOID VALVE............................................................................... 184 Description....................................................................................................... 184 Wiring Diagram - AT - OVRCSV...................................................................................... 186 Diagnostic Procedure.............................................................................................. 187 Component Inspection.............................................................................................. 188 DTC BATT/FLUID TEMP SEN A/T FLUID TEMPERATURE SENSOR CIRCUIT AND TCM POWER SOURCE..................................... 189 Description....................................................................................................... 189 Wiring Diagram - AT - BA/FTS...................................................................................... 191 Diagnostic Procedure.............................................................................................. 192 Component Inspection.............................................................................................. 194 DTC VHCL SPEED SEN - MTR VEHICLE SPEED SENSOR - MTR................................................................... 195 Description....................................................................................................... 195 Wiring Diagram - AT - VSSMTR...................................................................................... 197 Diagnostic Procedure.............................................................................................. 198 DTC CONTROL UNIT (RAM), CONTROL UNIT (ROM)............................................................................ 199 Description....................................................................................................... 199 Diagnostic Procedure.............................................................................................. 199 TROUBLE DIAGNOSES FOR SYMPTOMS........................................................................................ 201 Wiring Diagram - AT - NONDTC...................................................................................... 201 1. A/D OFF Indicator Lamp Does Not Come On........................................................................ 203 2. Engine Cannot Be Started In "P" and "N" Position............................................................... 205 3. In "P" Position, Vehicle Moves Forward Or Backward When Pushed................................................. 206 4. In "N" Position, Vehicle Moves................................................................................. 207 5. Large Shock, "N" - "R" Position................................................................................ 208 6. Vehicle Does Not Creep Backward In "R" Position................................................................ 209 7. Vehicle Does Not Creep Forward In "D", "2" Or "1" Position..................................................... 211 8. Vehicle Cannot Be Started From D1.............................................................................. 213 9. A/T Does Not Shift: D1 - D2 Or Does Not Kickdown: D4 - D2...................................................... 215 10. A/T Does Not Shift: D2 - D3................................................................................... 217 11. A/T Does Not Shift: D3 - D4................................................................................... 219 12. A/T Does Not Perform Lock-up.................................................................................. 221 13. A/T Does Not Hold Lock-up Condition........................................................................... 222 14. Lock-up Is Not Released....................................................................................... 223 15. Engine Speed Does Not Return To Idle (Light Braking D4 - D3).................................................. 224 16. Vehicle Does Not Start From D1................................................................................ 225 17. A/T Does Not Shift: D4 - D3, When Overdrive Control Switch "ON" - "OFF"....................................... 226 18. A/T Does Not Shift: D3 - s2, When Selector Lever "D" - "2" Position........................................... 227 19. A/T Does Not Shift: 22 - 11, When Selector lever "2" - "1" Position........................................... 228 20. Vehicle Does Not Decelerate By Engine Brake................................................................... 229 21. TCM Self-diagnosis Does Not Activate (PNP, Overdrive Control and Throtte Position Switches Circuit Checks).... 229 A/T SHIFT LOCK SYSTEM................................................................................................. 235 Description....................................................................................................... 235 Shift Lock System Electrical Parts Location....................................................................... 235 Wiring Diagram - SHIFT -.......................................................................................... 236 Diagnostic Procedure.............................................................................................. 237 Component Check................................................................................................... 238 KEY INTERLOCK CABLE................................................................................................... 240 Components........................................................................................................ 240 Removal........................................................................................................... 240 Installation...................................................................................................... 241 ON-VEHICLE SERVICE.................................................................................................... 242 Control Valve Assembly and Accumulators........................................................................... 242 Control Cable Adjustment.......................................................................................... 243 Park/Neutral Positioin (PNP) Switch Adjustment.................................................................... 243 Differential Side Oil Seal Replacement............................................................................ 244 Revolution Sensor Replacement..................................................................................... 244 REMOVAL AND INSTALLATION.............................................................................................. 245 Removal........................................................................................................... 245 Installation...................................................................................................... 246 OVERHAUL.............................................................................................................. 248 Components........................................................................................................ 248 Oil Channel....................................................................................................... 251 Locations of Adjusting Shims, Needle Bearings, Thrust Washers and Snap Rings...................................... 252 DISASSEMBLY........................................................................................................... 253 REPAIR FOR COMPONENT PARTS............................................................................................ 267 Manual Shaft...................................................................................................... 267 Oil Pump.......................................................................................................... 270 Control Valve Assembly............................................................................................ 274 Control Valve Upper Body.......................................................................................... 283 Control Valve Lower Body.......................................................................................... 287 Reverse Clutch.................................................................................................... 289 High Clutch....................................................................................................... 293 Forward Clutch and Overrun Clutch................................................................................. 298 Low & Reverse Brake............................................................................................... 305 Rear Internal Gear, Forward Clutch Hub and Overrrun Clutch Hub.................................................... 309 Output shaft, Idler Gear, Reduction pinion Gear and Bearing Retainer.............................................. 313 Band Servo Piston Assembly........................................................................................ 318 Final Drive....................................................................................................... 323 ASSEMBLY.............................................................................................................. 330 Assembly (1)...................................................................................................... 330 Adjustment (1) ................................................................................................... 331 Assembly (2)...................................................................................................... 336 Adjustment (2).................................................................................................... 340 Assembly (3)...................................................................................................... 344 Assembly (4)...................................................................................................... 346 SERVICE DATA AND SPECIFICATIONS (SDS)................................................................................. 351 General Specifications............................................................................................ 351 Shift Schedule.................................................................................................... 351 Stall Revolution.................................................................................................. 351 Line Pressure..................................................................................................... 351 Control Valves.................................................................................................... 352 Clutch and Brakes................................................................................................. 352 Clutch and Brake Return Springs................................................................................... 354 Oil Pump.......................................................................................................... 354 Input Shaft....................................................................................................... 355 Planetary Carrier................................................................................................. 355 Final Drive....................................................................................................... 355 Reduction Pinion Gear............................................................................................. 358 Output Shaft...................................................................................................... 360 Bearing Retainer.................................................................................................. 360 Total End Play.................................................................................................... 361 Reverse Clutch End Play........................................................................................... 361 Accumulator....................................................................................................... 361 Band Servo........................................................................................................ 361 Removal and Installation.......................................................................................... 361 ax........................................................................................................................ 362 QUICK REFERENCE INDEX................................................................................................. 0 TABLE OF CONTENTS..................................................................................................... 362 FRONT AXLE............................................................................................................ 363 Precautions....................................................................................................... 363 PRECAUTIONS................................................................................................... 363 Preparation....................................................................................................... 363 SPECIAL SERVICE TOOLS......................................................................................... 363 COMMERCIAL SERVICE TOOLS...................................................................................... 363 Noise, Vibration and Harshness (NVH) Troubleshooting.............................................................. 364 NVH TROUBLESHOOTING CHART..................................................................................... 364 On-Vehicle Service................................................................................................ 364 FRONT AXLE PARTS.............................................................................................. 364 FRONT WHEEL BEARING........................................................................................... 365 DRIVE SHAFT................................................................................................... 365 Wheel Hub and Knuckle............................................................................................. 366 COMPONENTS.................................................................................................... 366 REMOVAL....................................................................................................... 366 INSTALLATION.................................................................................................. 367 DISASSEMBLY................................................................................................... 368 INSPECTION.................................................................................................... 369 ASSEMBLY...................................................................................................... 369 Drive Shaft....................................................................................................... 371 COMPONENTS.................................................................................................... 371 REMOVAL....................................................................................................... 372 INSTALLATION.................................................................................................. 373 DISASSEMBLY................................................................................................... 374 INSPECTION.................................................................................................... 376 ASSEMBLY...................................................................................................... 376 REAR AXLE............................................................................................................. 381 Precautions....................................................................................................... 381 PRECAUTIONS................................................................................................... 381 Preparation....................................................................................................... 381 COMMERCIAL SERVICE TOOLS...................................................................................... 381 Noise, Vibration and Harshness (NVH) Troubleshooting.............................................................. 381 On-vehicle Service................................................................................................ 381 REAR AXLE PARTS............................................................................................... 381 REAR WHEEL BEARING............................................................................................ 382 Wheel Hub......................................................................................................... 382 COMPONENTS.................................................................................................... 382 REMOVAL....................................................................................................... 382 INSTALLATION.................................................................................................. 383 SERVICE DATA AND SPECIFICATIONS (SDS)................................................................................. 384 Drive Shaft....................................................................................................... 384 Wheel Bearing (Front)............................................................................................. 384 Wheel Bearing (Rear).............................................................................................. 384 br........................................................................................................................ 385 QUICK REFERENCE INDEX................................................................................................. 0 TABLE OF CONTENTS..................................................................................................... 385 PRECAUTIONS........................................................................................................... 387 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"....................................... 387 Precautions for Brake Sysem....................................................................................... 387 Wiring Diagrams and Trouble Diagnosis............................................................................. 388 PREPARATION........................................................................................................... 389 Commercial Service Tools.......................................................................................... 389 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOTING................................................................... 390 NVH Troubleshooting Chart......................................................................................... 390 ON-VEHICLE SERVICE.................................................................................................... 391 Checking Brake Fluid Level........................................................................................ 391 Checking Brake Line............................................................................................... 391 Changing Brake Fluid.............................................................................................. 391 Brake Burnishing Procedure........................................................................................ 391 Bleeding Brake System............................................................................................. 392 BRAKE HYDRAULIC LINE.................................................................................................. 393 Hydraulic Circuit................................................................................................. 393 Removal........................................................................................................... 393 Inspection........................................................................................................ 393 Installation...................................................................................................... 394 DUAL PROPORTIONING VALVE.............................................................................................. 395 Inspection........................................................................................................ 395 BRAKE PEDAL AND BRACKET............................................................................................... 396 Removal and Installation.......................................................................................... 396 Inspection........................................................................................................ 396 Adjustment........................................................................................................ 396 MASTER CYLINDER....................................................................................................... 398 Removal........................................................................................................... 398 Disassembly....................................................................................................... 398 Inspection........................................................................................................ 399 Assembly.......................................................................................................... 399 Installation...................................................................................................... 400 BRAKE BOOSTER......................................................................................................... 401 On-vehicle Service................................................................................................ 401 OPERATING CHECK............................................................................................... 401 AIRTIGHT CHECK................................................................................................ 401 Removal........................................................................................................... 401 Inspection........................................................................................................ 401 OUTPUT ROD LENGTH CHECK....................................................................................... 401 Installation...................................................................................................... 402 VACUUM HOSE........................................................................................................... 403 Removal and Installation.......................................................................................... 403 Inspection........................................................................................................ 403 HOSES AND CONNECTORS.......................................................................................... 403 CHECK VALVE................................................................................................... 403 FRONT DISC BRAKE...................................................................................................... 404 Component......................................................................................................... 404 Pad Replacement................................................................................................... 404 Removal........................................................................................................... 405 Disassembly....................................................................................................... 405 Inspection........................................................................................................ 405 CALIPER....................................................................................................... 405 ROTOR......................................................................................................... 406 Assembly.......................................................................................................... 407 Installation...................................................................................................... 407 REAR DISC BRAKE....................................................................................................... 408 Component......................................................................................................... 408 Pad Replacement................................................................................................... 408 Removal........................................................................................................... 410 Disassembly....................................................................................................... 411 Inspection........................................................................................................ 412 CALIPER....................................................................................................... 412 ROTOR......................................................................................................... 412 Assembly.......................................................................................................... 413 Installation...................................................................................................... 415 PARKING BRAKE CONTROL................................................................................................. 416 Components........................................................................................................ 416 Removal and Installation.......................................................................................... 416 Inspection........................................................................................................ 417 Adjustment........................................................................................................ 417 ABS................................................................................................................... 418 DESCRIPTION....................................................................................................... 418 Purpose....................................................................................................... 418 Operatioin.................................................................................................... 418 ABS Hydraulic Circuit......................................................................................... 418 System Components............................................................................................. 419 System Description............................................................................................ 419 SENSOR.................................................................................................... 419 CONTROL UNIT.............................................................................................. 419 ACTUATOR.................................................................................................. 420 Component Parts and Harness Connector Location................................................................ 421 Schematic..................................................................................................... 422 Wiring Diagram - ABS -........................................................................................ 423 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION............................................................................ 426 Self-Diagnosis................................................................................................ 426 FUNCTION.................................................................................................. 426 SELF-DIAGNOSIS PROCEDURE.................................................................................. 426 HOW TO READ SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES)................................................... 426 HOW TO ERASE SELF-DIAGNOSTIC RESULTS (MALFUNCTION CODES).................................................. 427 CONSULT....................................................................................................... 428 CONSULT APPLICATION TO ABS................................................................................ 428 ECU (ABS CONTROL UNIT) PART NUMBER MODE................................................................... 428 CONSULT Inspection Procedure.................................................................................. 428 SELF-DIAGNOSIS PROCEDURE.................................................................................. 428 SELF-DIAGNOSTIC RESULTS MODE.............................................................................. 430 DATA MONITOR PROCEDURE.................................................................................... 431 ACTIVE TEST PROCEDURE..................................................................................... 432 DATA MONITOR MODE......................................................................................... 433 ACTIVE TEST MODE.......................................................................................... 434 TROUBLE DIAGNOSIS - INTRODUCTION.................................................................................. 435 How to Perform Trouble Diagnoses for Quick and Accurate Repari................................................ 435 INTRODUCTION.............................................................................................. 435 TROUBLE DIAGNOSIS - BASIC INSPECTION.............................................................................. 436 Preliminary Check............................................................................................. 436 Ground Circuit Check.......................................................................................... 437 ACTUATOR MOTOR GROUND..................................................................................... 437 CONTROL UNIT GROUND....................................................................................... 438 ABS SOLENOID VALVE RELAY GROUND........................................................................... 438 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION........................................................................... 439 Malfunction Code/Symptom Chart................................................................................ 439 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS....................................................................... 440 Wheel Sensor or Rotor......................................................................................... 440 DIAGNOSTIC PROCEDURE...................................................................................... 440 ABS Actuator Solenoid Valve................................................................................... 442 DIAGNOSTIC PROCEDURE...................................................................................... 442 Solenoid Valve Relay.......................................................................................... 444 DIAGNOSTIC PROCEDURE...................................................................................... 444 Motor Relay or Motor.......................................................................................... 447 DIAGNOSTIC PROCEDURE...................................................................................... 447 Low Voltage................................................................................................... 450 DIAGNOSTIC PROCEDURE...................................................................................... 450 Control Unit.................................................................................................. 451 DIAGNOSTIC PROCEDURE...................................................................................... 451 TROUBLE DIAGNOSES FOR SYMPTOMS.................................................................................... 453 1. ABS Works Frequently....................................................................................... 453 2. Unexpected Pedal Action.................................................................................... 453 3. Long Stopping Distance..................................................................................... 454 4. ABS Does Not Work.......................................................................................... 454 5. Pedal Vibration and Noise.................................................................................. 455 6. Warning Lamp Does Not Come On When Ignition Switch Is Turned On............................................ 456 7. Warning Lamp Stays On When Ignition Switch Is Turned On.................................................... 458 REMOVAL AND INSTALLATION.......................................................................................... 461 Wheel Sensors................................................................................................. 461 Sensor Rotor.................................................................................................. 461 REMOVAL .................................................................................................. 461 INSTALLATION.............................................................................................. 462 Control Unit.................................................................................................. 462 Actuator...................................................................................................... 463 REMOVAL .................................................................................................. 463 INSTALLATION.............................................................................................. 463 SERVICE DATA AND SPECIFICATIONS (SDS)................................................................................. 464 General Specifications............................................................................................ 464 Disc Brake........................................................................................................ 464 Brake Pedal....................................................................................................... 464 Parking Brake..................................................................................................... 464 bt........................................................................................................................ 465 QUICK REFERENCE INDEX................................................................................................. 0 TABLE OF CONTENTS..................................................................................................... 465 PRECAUTIONS........................................................................................................... 466 Service Notice.................................................................................................... 466 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"....................................... 466 CLIP AND FASTENER..................................................................................................... 467 Description....................................................................................................... 467 BODY FRONT END........................................................................................................ 469 Removal and Installation.......................................................................................... 469 FRONT BUMPER ASSEMBLY......................................................................................... 469 BODY REAR END AND OPENER.............................................................................................. 472 Removal and Installation.......................................................................................... 472 REAR BUMPER ASSEMBLY.......................................................................................... 472 FRONT DOOR............................................................................................................ 475 Overhaul.......................................................................................................... 475 REAR DOOR............................................................................................................. 476 Overhaul.......................................................................................................... 476 INSTRUMENT PANEL ASSEMBLY............................................................................................. 477 Removal and Installation.......................................................................................... 477 SIDE AND FLOOR TRIM................................................................................................... 481 Removal and Installation.......................................................................................... 481 DOOR TRIM............................................................................................................. 483 Removal and Installation.......................................................................................... 483 ROOF TRIM............................................................................................................. 485 Removal and Installation.......................................................................................... 485 TRUNK ROOM TRIM....................................................................................................... 487 Removal and Installation.......................................................................................... 487 EXTERIOR.............................................................................................................. 488 Removal and Installation.......................................................................................... 488 FRONT SEAT............................................................................................................ 493 Removal and Installation.......................................................................................... 493 POWER SEAT ................................................................................................... 494 HEATED SEAT................................................................................................... 495 REAR SEAT............................................................................................................. 496 Removal and Installation.......................................................................................... 496 FOLDING SEAT.................................................................................................. 496 SUNROOF............................................................................................................... 497 Adjustment........................................................................................................ 497 Removal and Installation.......................................................................................... 498 Trouble Diagnoses................................................................................................. 502 DIAGNOSTIC TABLE.............................................................................................. 502 WIND DEFLECTOR................................................................................................ 502 ADJUSTMENT.................................................................................................... 503 DRAIN HOSES................................................................................................... 504 WEATHERSTRIP.................................................................................................. 504 LINK AND WIRE ASSEMBLY........................................................................................ 505 WINDSHIELD AND WINDOWS................................................................................................ 506 Removal and Installation.......................................................................................... 506 REMOVAL....................................................................................................... 506 INSTALLATION.................................................................................................. 506 WINDSHIELD.................................................................................................... 507 DOOR MIRROR........................................................................................................... 508 Removal and Installation.......................................................................................... 508 BODY(ALIGNMENT)....................................................................................................... 509 Alignment......................................................................................................... 509 ENGINE COMPARTMENT............................................................................................ 510 UNDERBODY..................................................................................................... 512 cl........................................................................................................................ 514 QUICK REFERENCE INDEX................................................................................................. 0 TABLE OF CONTENTS..................................................................................................... 514 PRECAUTIONS........................................................................................................... 515 Precautions....................................................................................................... 515 PREPARATION........................................................................................................... 516 Special Service Tools............................................................................................. 516 Commercial Service Tools.......................................................................................... 516 NOISE, VIBRATION AND AHRSHNESS (NVH) TROUBLESHOOTING.................................................................. 517 NVH Troubleshooting Chart......................................................................................... 517 CLUTCH SYSTEM......................................................................................................... 518 Components........................................................................................................ 518 Inspection and Adjustment......................................................................................... 519 ADJUSTING CLUTCH PEDAL........................................................................................ 515 BLEEDING PROCEDURE............................................................................................ 520 CLUTCH MASTER CYLINDER................................................................................................ 521 Components........................................................................................................ 521 Removal........................................................................................................... 521 Installation...................................................................................................... 522 Disassembly....................................................................................................... 522 Inspection........................................................................................................ 522 Assembly.......................................................................................................... 522 CLUTCH DAMPER......................................................................................................... 524 Components........................................................................................................ 524 Removal........................................................................................................... 524 Disassembly....................................................................................................... 524 Inspection........................................................................................................ 525 Assembly.......................................................................................................... 525 Installation...................................................................................................... 525 OPERATING CYLINDER ................................................................................................... 526 Components........................................................................................................ 526 Removal........................................................................................................... 526 Disassembly....................................................................................................... 526 Inspection........................................................................................................ 527 Assembly.......................................................................................................... 527 Installation...................................................................................................... 527 PIPING................................................................................................................ 528 Removal........................................................................................................... 528 Installation...................................................................................................... 528 CLUTCH RELEASE MECHANISM.............................................................................................. 529 Components........................................................................................................ 529 Removal........................................................................................................... 529 Inspection........................................................................................................ 529 Installation...................................................................................................... 529 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL................................................................................ 532 Components........................................................................................................ 532 Inspection and Adjustment......................................................................................... 532 CLUTCH DISC................................................................................................... 532 CLUTCH COVER AND FLYWHEEL..................................................................................... 532 FLYWHEEL INSPECTION........................................................................................... 533 Installation...................................................................................................... 533 SERVICE DATA AND SPECIFICATIONS (SDS)................................................................................. 534 Clutch Control System............................................................................................. 534 Clutch Master Cylinder............................................................................................ 534 Clutch Operating Cylinder......................................................................................... 534 Clutch Damper..................................................................................................... 534 Clutch Disc....................................................................................................... 534 Clutch Cover...................................................................................................... 534 Clutch Pedal...................................................................................................... 534 ec........................................................................................................................ 535 QUICK REFERENCE INDEX................................................................................................. 0 TABLE OF CONTENTS..................................................................................................... 535 TROUBLE DIAGNOSIS - INDEX............................................................................................. 542 Alphabetical & P No. Index for DTC................................................................................ 542 PRECAUTIONS........................................................................................................... 547 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"....................................... 547 Precautions for On Board Diagnostic (OBD) System of Engine and A/T................................................ 547 Engine Fuel & Emission Control System............................................................................. 548 Precautions....................................................................................................... 549 Wiring Diagrams and Trouble Diagnosis............................................................................. 550 PREPARATION........................................................................................................... 551 Special Service Tools............................................................................................. 551 Commercial Service Tools.......................................................................................... 551 ENGINE AND EMISSION CONTROL OVERALL SYSTEM............................................................................ 553 Engine Control Component Parts Location........................................................................... 553 Circuit Diagram................................................................................................... 558 System Diagram.................................................................................................... 560 Vacuum Hose Drawing............................................................................................... 561 System Chart...................................................................................................... 562 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION.................................................................. 563 Multiport Fuel Injection (MFI) system............................................................................. 563 Distributor Ignition (DI) System.................................................................................. 565 Air Conditioning Cut Control...................................................................................... 566 Fuel Cut Control (at no load & high engine speed)................................................................. 567 Evaporative Emission System....................................................................................... 567 Positive Crankcase Ventilation.................................................................................... 573 BASIC SERVICE PROCEDURE............................................................................................... 574 Fuel Pressure Release............................................................................................. 574 Fuel Pressure Check............................................................................................... 574 Fuel Pressure Regulator Check..................................................................................... 575 Injector.......................................................................................................... 575 Idle speed/Ignition Timing/Idle Mixture Ratio Adjustment.......................................................... 576 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTON................................................................................. 584 Introduction...................................................................................................... 584 Two Trip Detection Logic.......................................................................................... 584 Emission-related Diagnostic Information........................................................................... 585 Malfunction Indicator Lamp (MIL).................................................................................. 595 OBD System Operation Chart ....................................................................................... 599 CONSULT........................................................................................................... 604 Generic Scan Tool (GST)........................................................................................... 617 TROUBLE DIAGNOSIS - INTRODUCTION...................................................................................... 619 Introduction...................................................................................................... 619 Work Flow......................................................................................................... 621 TROUBLE DIAGNOSIS - BASIC INSPECTION.................................................................................. 623 Basic Inspection.................................................................................................. 623 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION............................................................................... 630 DTC Inspection Priority Chart..................................................................................... 630 Fail-safe Chart................................................................................................... 631 Symptom Matrix Chart.............................................................................................. 632 CONSULT Reference Value in Data Monitor Mode...................................................................... 636 Major Sensor Reference Graph in Data Monitor Mode................................................................. 638 ECM Terminals and Reference Value................................................................................. 641 TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT........................................................................... 650 Description....................................................................................................... 650 Diagnostic Procedure.............................................................................................. 650 TROUBLE DIAGNOSIS FOR POWER SUPPLY.................................................................................... 651 Main Power Supply and Ground Circuit.............................................................................. 651 DTC P0100 MASS AIR FLOW SENSOR (MAFS)................................................................................. 656 Component Description............................................................................................. 656 CONSULT Reference Value in Data Monitor Mode...................................................................... 656 ECM Terminals and Reference Value................................................................................. 656 On Board Diagnosis Logic.......................................................................................... 657 DTC Confirmation Procedure........................................................................................ 657 Overall Function Check............................................................................................ 660 Wiring Diagram.................................................................................................... 661 Diagnostic Procedure.............................................................................................. 662 Component Inspection.............................................................................................. 664 DTC P0105 ABSOLUTE PRESSURE SENSOR.................................................................................... 665 Component Description............................................................................................. 665 On Board Diagnosis Logic.......................................................................................... 665 DTC Confirmation Procedure........................................................................................ 665 Overall Function Check............................................................................................ 667 Wiring Diagram.................................................................................................... 668 Diagnostic Procedure.............................................................................................. 669 Component Inspection.............................................................................................. 673 DTC P0110 INTAKE AIR TEMPERATURE SENSOR............................................................................... 674 Component Description............................................................................................. 674 On Board Diagnosis Logic.......................................................................................... 674 DTC Confirmation Procedure........................................................................................ 674 Wiring Diagram.................................................................................................... 677 Diagnostic Procedure.............................................................................................. 678 Component Inspection.............................................................................................. 679 DTC P0115 ENGINE COOLANT TERMPERATURE SENSOR (ECTS) (CIRCUIT)......................................................... 680 Component Description............................................................................................. 680 CONSULT Reference Value in Data Monitor Mode...................................................................... 680 On Board Diagnosis Logic.......................................................................................... 680 DTC Confirmation Procedure........................................................................................ 681 Wiring Diagram.................................................................................................... 682 Diagnostic Procedure.............................................................................................. 683 Component Inspection.............................................................................................. 684 DTC P0120 THROTTLE POSITION SENSOR.................................................................................... 685 Component Description............................................................................................. 685 CONSULT Reference Value in Data Monitor Mode...................................................................... 685 ECM Terminals and Reference Value................................................................................. 685 On Board Diagnoses Logic.......................................................................................... 686 DTC Confirmation Procedure........................................................................................ 686 Wiring Diagram.................................................................................................... 692 Diagnostic Procedure.............................................................................................. 693 Component Inspection.............................................................................................. 695 DTC P0125 ENGINE COOLANT TEMPERATURE (ECT) SENSOR..................................................................... 696 Component Description............................................................................................. 696 CONSULT Reference Value in Data Monitor Mode...................................................................... 696 On Board Diagnosis Logic.......................................................................................... 696 DTC Confirmation Procedure........................................................................................ 696 Wiring Diagram.................................................................................................... 698 Diagnostic Procedure.............................................................................................. 699 Component Inspection.............................................................................................. 700 DTC P0130 FRONT HEATED OXYGEN SENSOR (FRONT HO2S) (CIRCUIT)........................................................... 701 Component Description............................................................................................. 701 CONSULT Reference Value in Data Monitor Mode...................................................................... 701 ECM Terminals and Reference Value................................................................................. 701 On Board Diagnosis Logic.......................................................................................... 702 DTC Confirmation Procedure........................................................................................ 702 Overall Function Check............................................................................................ 703 Wiring Diagram.................................................................................................... 704 Diagnostic Procedure.............................................................................................. 705 Component Inspection.............................................................................................. 706 DTC P0131 FRONT HEATED OXYGEN SENSOR (FRONT HO2S) (LEAN SHIFT MONITORING)............................................. 707 Component Description............................................................................................. 707 CONSULT Reference Value in Data Monitor Mode...................................................................... 707 ECM Terminals and Reference Value................................................................................. 707 On Board Diagnosis Logic.......................................................................................... 708 DTC Confirmation Procedure........................................................................................ 708 Overall Function Check............................................................................................ 709 Diagnostic Procedure.............................................................................................. 709 Component Inspection.............................................................................................. 711 DTC P0132 FRONT HEATED OXYGEN SENSOR (FRONT HO2S) (RICH SHIFT MONITORING)............................................. 712 Component Description............................................................................................. 712 CONSULT Reference Value in Data Monitor Mode...................................................................... 712 ECM Terminals and Reference Value................................................................................. 712 On Board Diagnosis Logic.......................................................................................... 713 DTC Confirmation Procedure........................................................................................ 713 Overall Function Check............................................................................................ 714 Diagnostic Procedure.............................................................................................. 714 Component Inspection.............................................................................................. 716 DTC P0133 FRONT HEATED OXYGEN SENSOR (FRONT HO2S) (RESPONSE MONITORING)............................................... 717 Component Description............................................................................................. 717 CONSULT Reference Value in Data Monitor Mode...................................................................... 717 ECM Terminals and Reference Value................................................................................. 717 On Board Diagnosis Logic.......................................................................................... 718 DTC Confirmation Procedure........................................................................................ 718 Overall Function Check............................................................................................ 719 Wiring Diagram.................................................................................................... 720 Diagnostic Procedure.............................................................................................. 721 Component Inspection.............................................................................................. 723 DTC P0134 FRONT HEATED OXYGEN SENSOR (FRONT HO2S) (HIGH VOLTAGE)...................................................... 724 Component Description............................................................................................. 724 CONSULT Reference Value in Data Monitor Mode...................................................................... 724 ECM Terminals and Reference Value................................................................................. 724 On Board Diagnosis Logic.......................................................................................... 725 DTC Confirmation Procedure........................................................................................ 725 Wiring Diagram.................................................................................................... 727 Diagnostic Procedure.............................................................................................. 728 Component Inspection.............................................................................................. 729 DTC P0135 FRONT HEATED OXYGEN SENSOR HEATER........................................................................... 730 Description....................................................................................................... 730 CONSULT Reference Value in Data Monitor Mode...................................................................... 730 ECM Terminals and Reference Value................................................................................. 730 On Board Diagnosis Logic.......................................................................................... 730 DTC Confirmation Procedure........................................................................................ 731 Wiring Diagram.................................................................................................... 732 Diagnostic Procedure.............................................................................................. 733 Component Inspection.............................................................................................. 733 DTC P0137 REAR HEATED OXYGEN SENSOR (REAR HO2S) (MIN. VOLTAGE MONITORING)............................................. 735 Component Description............................................................................................. 735 CONSULT Reference Value in Data Monitor Mode...................................................................... 735 ECM Terminals and Reference Value................................................................................. 735 On Board Diagnosis Logic.......................................................................................... 735 DTC Confirmation Procedure........................................................................................ 736 Overall Function Check............................................................................................ 737 Wiring Diagram.................................................................................................... 738 Diagnostic Procedure.............................................................................................. 739 Component Inspection.............................................................................................. 741 DTC P0138 REAR HEATED OXYGEN SENSOR (REAR HO2S) (MAX. VOLTAGE MONITORING)............................................. 743 Component Description............................................................................................. 743 CONSULT Reference Value in Data Monitor Mode...................................................................... 743 ECM Terminals and Reference Value................................................................................. 743 On Board Diagnosis Logic.......................................................................................... 743 DTC Confirmation Procedure........................................................................................ 744 Overall Function Check............................................................................................ 745 Wiring Diagram.................................................................................................... 746 Diagnostic Procedure.............................................................................................. 747 Component Inspection.............................................................................................. 749 DTC P0139 REAR HEATED OXYGEN SENSOR (REAR HO2S) (RESPONSE MONITORING)................................................. 750 Component Description............................................................................................. 750 CONSULT Reference Value in Data Monitor Mode...................................................................... 750 ECM Terminals and Reference Value................................................................................. 750 On Board Diagnosis Logic.......................................................................................... 750 DTC Confirmation Procedure........................................................................................ 751 Overall Function Check............................................................................................ 752 Wiring Diagram.................................................................................................... 753 Diagnostic Procedure.............................................................................................. 754 Component Inspection.............................................................................................. 756 DTC P0140 REAR HEATED OXYGEN SENSOR (REAR HO2S) (HIGHT VOLTAGE"....................................................... 758 Component Description............................................................................................. 758 CONSULT Reference Value in Data Monitor Mode...................................................................... 758 ECM Terminals and Reference Value................................................................................. 758 On Board Diagnosis Logic.......................................................................................... 758 DTC Confirmation Procedure........................................................................................ 759 Overall Function Check............................................................................................ 759 Wiring Diagram.................................................................................................... 760 Diagnostic Procedure.............................................................................................. 761 Component Inspection.............................................................................................. 762 DTC P0141 REAR HEATED OXYGEN SENSOR HEATER............................................................................ 764 Description....................................................................................................... 764 CONSULT Reference Value in Data Monitor Mode...................................................................... 764 ECM Terminals and Reference Value................................................................................. 764 On Board Diagnosis Logic.......................................................................................... 764 DTC Confirmation Procedure........................................................................................ 765 Wiring Diagram.................................................................................................... 766 Diagnostic Procedure.............................................................................................. 767 Component Inspection.............................................................................................. 768 DTC P0171 FUEL IINJECTION SYSTEM FUNCTION (LEAN SIDE)................................................................. 769 On Board Diagnosis Logic.......................................................................................... 769 DTC Confirmation Procedure........................................................................................ 769 Wiring Diagram.................................................................................................... 771 Diagnostic Procedure.............................................................................................. 772 DTC P0172 FUEL INJECTION SYSTEM FUNCTION (RICH SIDE).................................................................. 775 On Board Diagnosis Logic.......................................................................................... 775 DTC Confirmation Procedure........................................................................................ 775 Wiring Diagram.................................................................................................... 777 Diagnostic Procedure.............................................................................................. 778 DTC P0180 TANK FUEL TEMPERATURE SENSOR................................................................................ 781 Component Description............................................................................................. 781 On Board Diagnosis Logic.......................................................................................... 781 DTC Confirmation Procedure........................................................................................ 781 Wiring Diagram.................................................................................................... 783 Diagnostic Procedure.............................................................................................. 784 Component Inspection.............................................................................................. 784 DTC P0300 - P0304 NO. 4 - 1 CYLINDER MISFURE, MULTIPLE CYLINDER MISFIRE............................................... 785 On Board Diagnosis Logic.......................................................................................... 785 DTC Confirmation Procedure........................................................................................ 785 Diagnostic Procedure.............................................................................................. 786 Component Inspection.............................................................................................. 789 DTC P0325 KNOCK SENSOR (KS)........................................................................................... 790 Component Description............................................................................................. 790 ECM Terminals and Reference Value................................................................................. 790 On Board Diagnosis Logic.......................................................................................... 790 DTC Confirmation Procedure........................................................................................ 790 Wiring Diagram.................................................................................................... 792 Diagnostic Procedure.............................................................................................. 793 Component Inspection.............................................................................................. 794 DTC P0335 CRANKSHAFT POSITION SENSOR (CKPS) (OBD)..................................................................... 795 Component Description............................................................................................. 795 ECM Terminals and Reference Value................................................................................. 795 On Board Diagnosis Logic.......................................................................................... 795 DTC Confirmation Procedure........................................................................................ 796 Wiring Diagram.................................................................................................... 797 Diagnostic Procedure.............................................................................................. 798 Component Inspection.............................................................................................. 799 DTC P0340 CAMSHAFT POSITION SENSOR (CMPS)............................................................................. 800 Component Description............................................................................................. 800 ECM Terminals and Reference Value................................................................................. 800 On Board Diagnosis Logic.......................................................................................... 801 DTC Confirmation Procedure........................................................................................ 801 Wiring Diagram.................................................................................................... 803 Diagnostic Procedure.............................................................................................. 804 Component Inspection.............................................................................................. 806 DTC P0400 EGR FUNCTION (CLOSE)........................................................................................ 807 Description....................................................................................................... 807 On Board Diagnosis Logic.......................................................................................... 808 DTC Confirmation Procedure........................................................................................ 809 Overall Function Check............................................................................................ 810 Wiring Diagram.................................................................................................... 811 Diagnostic Procedure.............................................................................................. 812 Component Inspection.............................................................................................. 814 DTC P0402 EGRC-BPT VALVE FUNCTION..................................................................................... 815 Description....................................................................................................... 815 On Board Diagnosis Logic.......................................................................................... 815 DTC Confirmation Procedure........................................................................................ 816 Overall Function Check............................................................................................ 817 Diagnostic Procedure.............................................................................................. 817 Component Inspection.............................................................................................. 818 DTC P0420 THREE WAY CATLYST FUNCTION.................................................................................. 819 On Board Diagnosis Logic.......................................................................................... 819 DTC Confirmation Procedure........................................................................................ 819 Overall Function Check............................................................................................ 820 Diagnostic Procedure.............................................................................................. 821 DTC P0440 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM (SMALL LEAK) (NEGATIVE PRESSURE)................................. 823 On Board Diagnosis Logic.......................................................................................... 823 DTC Confirmation Procedure........................................................................................ 824 Diagnostic Procedure.............................................................................................. 826 DTC P0443 EVAPORATIVE EMISSION (EVAP) CANISTER PURGE VOLUME CONTROL VALVE (CIRCUIT)................................... 831 Description....................................................................................................... 831 CONSULT Reference Value in Data Monitor Mode...................................................................... 831 ECM Terminals and Reference Value................................................................................. 832 On Board Diagnosis Logic.......................................................................................... 832 DTC Confirmation Procedure........................................................................................ 832 Wiring Diagram.................................................................................................... 833 Diagnostic Procedure.............................................................................................. 834 Component Inspection.............................................................................................. 835 DTC P0446 EVAPORATIVE EMISSION (EVAP) CANISTER VENT CONTROL VALVE (CIRCUIT)........................................... 836 Component Description............................................................................................. 836 CONSULT Reference Value in Data Monitor Mode...................................................................... 836 ECM Terminals and Reference Value................................................................................. 836 On Board Diagnosis Logic.......................................................................................... 836 DTC Confirmation Procedure........................................................................................ 837 Wiring Diagram.................................................................................................... 838 Diagnostic Procedure.............................................................................................. 839 Component Inspection.............................................................................................. 840 DTC P0450 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM PRESSURE SENSOR.................................................. 842 Component Description............................................................................................. 842 CONSULT Reference Value in Data Monitor Mode...................................................................... 842 ECM Terminals and Reference Value................................................................................. 842 On Board Diagnosis Logic.......................................................................................... 843 DTC Confirmation Procedure........................................................................................ 843 Wiring Diagram.................................................................................................... 845 Diagnostic Procedure.............................................................................................. 846 Component Inspection.............................................................................................. 848 DTC P0500 VEHICLE SPEED SENSOR (VSS).................................................................................. 850 Component Description............................................................................................. 850 ECM Terminals and Reference Value................................................................................. 850 On Board Diagnosis Logic.......................................................................................... 850 DTC Confirmation Procedure........................................................................................ 850 Overall Function Check............................................................................................ 852 Wiring Diagram.................................................................................................... 853 Diagnostic Procedure.............................................................................................. 854 DTC P0505 IDLE AIR CONTROL VALVE (IACB) - AUXILIARY AIR CONTROL (AAC) VALVE........................................... 855 Description....................................................................................................... 855 CONSULT Reference Value in Data Monitor Mode...................................................................... 855 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 P0510 CLOSED THROTTLE POSITION SWITCH............................................................................. 860 Component Description............................................................................................. 860 ECM Terminals and Reference Value................................................................................. 860 On Board Diagnosis Logic.......................................................................................... 860 DTC Confirmation Procedure........................................................................................ 860 Overall Function Check............................................................................................ 861 Wiring Diagram.................................................................................................... 862 Diagnostic Procedure.............................................................................................. 863 Component Inspection.............................................................................................. 864 DTC P0600 A/T CONTROL................................................................................................. 865 System Description................................................................................................ 865 ECM Terminals and Reference Value................................................................................. 865 On Board Diagnosis Logic.......................................................................................... 865 DTC Confirmation Procedure........................................................................................ 865 Overall Function Check............................................................................................ 866 Wiring Diagram.................................................................................................... 867 Diagnostic Procedure.............................................................................................. 868 DTC P0605 ECM......................................................................................................... 869 Component Description............................................................................................. 869 On Board Diagnosis Logic.......................................................................................... 869 DTC Confirmation Procedure........................................................................................ 869 Diagnostic Procedure.............................................................................................. 870 DTC P1105 MANIFOLD ABSOLUTE PRESSURE (MAP)BA/BAROMETRIC PRESSURE (BARO) SWITCH SOLENOID VALVE......................... 871 Description....................................................................................................... 871 CONSULT Reference Value in Data Monitor Mode...................................................................... 871 ECM Terminals and Reference Value................................................................................. 872 On Board Diagnosis Logic.......................................................................................... 872 DTC Confirmation Procedure........................................................................................ 872 Wiring Diagram.................................................................................................... 875 Diagnostic Procedure.............................................................................................. 876 Component Inspection.............................................................................................. 880 DTC P1148 CLOSED LOOP CONTROL......................................................................................... 881 On Board Diagnosis Logic.......................................................................................... 881 DTC Confirmation Procedure........................................................................................ 881 Overall Function Check............................................................................................ 882 Diagnostic Procedure.............................................................................................. 882 DTC P1320 IGNITION SIGNAL............................................................................................. 883 Component Description............................................................................................. 883 CONSULT Reference Value in Data Monitor Mode...................................................................... 883 ECM Terminals and Reference Value................................................................................. 883 On Board Diagnosis Logic.......................................................................................... 884 DTC Confirmation Procedure........................................................................................ 884 Wiring Diagram.................................................................................................... 886 Diagnostic Procedure.............................................................................................. 887 Component Inspection.............................................................................................. 888 DTC P1336 CRANKSHAFT POSITION SENSOR (CKPS) (OBD) (COG)............................................................... 890 Component Description............................................................................................. 890 ECM Terminals and Reference Value................................................................................. 890 On Board Diagnosis Logic.......................................................................................... 890 DTC Confirmation Procedure........................................................................................ 891 Wiring Diagram.................................................................................................... 892 Diagnostic Procedure.............................................................................................. 893 Component Inspection.............................................................................................. 894 DTC P1400 EGRC-SOLENOID VALVE......................................................................................... 895 Component Description............................................................................................. 895 CONSULT Reference Value in Data Monitor Mode...................................................................... 895 ECM Terminals and Reference Value................................................................................. 895 On Board Diagnosis Logic.......................................................................................... 895 DTC Confirmation Procedure........................................................................................ 895 Wiring Diagram.................................................................................................... 897 Diagnostic Procedure.............................................................................................. 898 Component Inspection.............................................................................................. 899 DTC P1401 EGR TEMPERATURE SENSOR...................................................................................... 900 Component Description............................................................................................. 900 On Board Diagnosis Logic.......................................................................................... 900 DTC Confirmation Porcedure........................................................................................ 901 Overall Function Check............................................................................................ 902 Wiring Diagram.................................................................................................... 903 Diagnostic Procedure.............................................................................................. 904 Component Inspection.............................................................................................. 905 DTC P1402 EGR FUNCTION (OPEN)......................................................................................... 906 Description....................................................................................................... 906 On Board Diagnosis Logic.......................................................................................... 907 DTC Confirmation Procedure........................................................................................ 907 Wiring Diagram.................................................................................................... 909 Diagnostic Procedure.............................................................................................. 910 Component Inspection.............................................................................................. 911 DTC P1440 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM (SMALL LEAK) (POSITIVE PRESSURE)................................. 912 On Board Diagnosis Logic.......................................................................................... 912 DTC Confirmation Procedure........................................................................................ 913 Diagnostic Procedure.............................................................................................. 914 DTC P1444 EVAPORATIVE EMISSION (EVAP) CANISTER PURGE VOLUME CONTROL VALVE............................................. 920 Description....................................................................................................... 920 CONSULT Reference Value in Data Monitor Mode...................................................................... 920 ECM Terminals and Reference Value................................................................................. 921 On Board Diagnosis Logic.......................................................................................... 921 DTC Confirmation Procedure........................................................................................ 921 Diagnostic Procedure.............................................................................................. 924 Component Inspection.............................................................................................. 925 DTC P1446 EVAPORATIVE EMISSION (EVAP) CANISTER VENT CONTROL VALVE (CLOSE)............................................. 926 Component Description............................................................................................. 926 CONSULT Reference Value in Data Monitor Mode...................................................................... 926 ECM Terminals and Reference Value................................................................................. 926 On Board Diagnosis Logic.......................................................................................... 926 DTC Confirmation Procedure........................................................................................ 927 Diagnostic Procedure.............................................................................................. 928 Component Inspection.............................................................................................. 929 DTC P1447 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM PURGE FLOW MONITORING............................................ 930 System Description................................................................................................ 930 On Board Diagnosis Logic.......................................................................................... 930 DTC Confirmaion Procedure......................................................................................... 931 Overall Function Check............................................................................................ 932 Diagnostic Procedure.............................................................................................. 933 Component Inspection.............................................................................................. 936 DTC P1448 EVAPORATIVE EMISSION (EVAP) CANISTER VENT CONTROL VALVE (OPEN).............................................. 937 Component Description............................................................................................. 937 CONSULT Reference Value in Data Monitor Mode...................................................................... 937 ECM Terminals and Reference Value................................................................................. 937 On Board Diagnosis Logic.......................................................................................... 937 DTC Confirmation Procedure........................................................................................ 938 Overall Function Check............................................................................................ 939 Diagnostic Procedure.............................................................................................. 939 Component Inspection.............................................................................................. 941 DTC P1490 VACUUM CUT VALVE BYPASS VALVE (CIRCUIT)..................................................................... 942 Description....................................................................................................... 942 CONSULT Reference Value in Data Monitor Mode...................................................................... 942 ECM Terminals and Reference Value................................................................................. 942 On Board Diagnosis Logic.......................................................................................... 943 DTC Confirmation Procedure........................................................................................ 943 Wiring Diagram.................................................................................................... 944 Diagnostic Procedure.............................................................................................. 945 Component Inspection.............................................................................................. 946 DTC P1491 VACUUM CUT VALVE BYPASS VALVE............................................................................... 947 Description....................................................................................................... 947 CONSULT Reference Value in Data Monitor Mode...................................................................... 947 ECM Terminals and Reference Value................................................................................. 947 On Board Diagnosis Logic.......................................................................................... 948 DTC Confirmation Procedure........................................................................................ 948 Overall Function Check............................................................................................ 950 Diagnostic Procedure.............................................................................................. 950 Component Inspection.............................................................................................. 953 DTC P1492 EVAPORATIVE EMISSION (EVAP) CANISTER PUGE CONTROL VALVE/SOLENOID VALVE (CIRCUIT)............................ 954 Description....................................................................................................... 954 CONSULT Reference Value in Data Monitor Mode...................................................................... 955 ECM Terminals and Reference Value................................................................................. 955 On Board Diagnosis Logic.......................................................................................... 955 DTC Confirmation Procedure........................................................................................ 956 Wiring Diagram.................................................................................................... 957 Diagnostic Procedure.............................................................................................. 958 Component Inspection.............................................................................................. 959 DTC P1493 EVAPORATIVE EMISSION (EVAP) CANISTER PURGE CONTROL VALVE/SOLENOID VALVE..................................... 960 Description....................................................................................................... 960 CONSULT Reference Value in Data Monitor Mode...................................................................... 961 ECM Terminals and Reference Value................................................................................. 961 On Board Diagnosis Logic.......................................................................................... 962 DTC Confirmation Procedure........................................................................................ 962 Diagnostic Procedure.............................................................................................. 964 Component Inspection.............................................................................................. 967 DTC P1605 A/T DIAGNOSIS COMMUNICATION LINE............................................................................ 968 System Description................................................................................................ 968 ECM Terminals and Reference Value................................................................................. 968 On Board Diagnosis Logic.......................................................................................... 968 DTC Confirmation Procedure........................................................................................ 968 Wiring Diagram.................................................................................................... 969 Diagnostic Procedure.............................................................................................. 970 DTC P1706 PARK/NEUTRAL POSITION (PNP) SWITCH.......................................................................... 971 Component Description............................................................................................. 971 CONSULT Reference Value in Data Monitor Mode...................................................................... 971 ECM Terminals and Reference Value................................................................................. 971 On Board Diagnosis Logic.......................................................................................... 971 DTC Confirmation Procedure........................................................................................ 971 Overall Function Check............................................................................................ 972 Wiring diagram.................................................................................................... 973 Diagnostic Procedure For M/T Models............................................................................... 974 Diagnostic Procedure For A/T Models............................................................................... 975 TROUBLE DIAGNOSES FOR OVERHEAT (COOLING SYSTEM)....................................................................... 976 System Description................................................................................................ 976 CONSULT Reference Value in Data Monitor Mode...................................................................... 976 ECM Terminals and Reference Value................................................................................. 977 On Board Diagnosis Logic.......................................................................................... 977 Overall Function Check............................................................................................ 978 Wiring Diagram.................................................................................................... 979 Diagnostic Procedure.............................................................................................. 980 Main 12 Causes of Overheating..................................................................................... 988 Component Inspection.............................................................................................. 989 INJECTOR.............................................................................................................. 990 Component Description............................................................................................. 990 CONSULT Reference Value in Data Monitor Mode...................................................................... 990 ECM Terminals and Reference Value................................................................................. 990 Wiring Diagram.................................................................................................... 991 Diagnostic Procedure.............................................................................................. 992 Component Inspection.............................................................................................. 993 START SIGNAL.......................................................................................................... 994 CONSULT Reference Value in Data Monitor Mode...................................................................... 994 ECM Terminals and Reference Value................................................................................. 994 Wiring Diagram.................................................................................................... 995 Diagnostic Procedure.............................................................................................. 996 FUEL PUMP............................................................................................................. 997 System Description................................................................................................ 997 Component Description............................................................................................. 997 CONSULT Reference Value in Data Monitor Mode...................................................................... 997 ECM Terminals and Reference Value................................................................................. 997 Wiring Diagram.................................................................................................... 998 Diagnostic Procedure.............................................................................................. 999 Component Inspection..............................................................................................1000 POWER STEERING OIL PRESSURE SWITCH....................................................................................1001 Component Description.............................................................................................1001 CONSULT Reference Value in Data Monitor Mode......................................................................1001 ECM Terminals and ReferenceValue..................................................................................1001 Wiring Diagram....................................................................................................1002 Diagnostic Procedure..............................................................................................1003 Component Inspection..............................................................................................1004 IACV-AIR REGULATOR....................................................................................................1005 Description.......................................................................................................1005 ECM Terminals and Reference Value.................................................................................1005 Wiring Diagram....................................................................................................1006 Diagnostic Procedure..............................................................................................1007 Component Inspection..............................................................................................1008 IACV-FICD SOLENOID VALVE..............................................................................................1009 Component Description.............................................................................................1009 ECM Terminals and Reference Value.................................................................................1009 Wiring Diagram....................................................................................................1010 Diagnostic Procedure..............................................................................................1011 Component Inspection..............................................................................................1014 MIL & DATA LINK CONNECTORS............................................................................................1015 Wiring Diagram....................................................................................................1015 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................1016 Fuel Pressure Regulator...........................................................................................1016 Idle Speed and Ignition Timing....................................................................................1016 Ignition Coil.....................................................................................................1016 Mass Air Flow Sensor..............................................................................................1016 Engine Coolant Temperature Sensor.................................................................................1016 EGR Temperature Sensor............................................................................................1016 Fuel Pump.........................................................................................................1016 IACV-AAC Valve....................................................................................................1017 Injector..........................................................................................................1017 Throttle Position Sensor..........................................................................................1017 Front Heated Oxygen Sensor Heater.................................................................................1017 Calculated Load Value.............................................................................................1017 Intake Air Temperature Sensor.....................................................................................1017 EVAP Canister Purge Volume Control Valve..........................................................................1017 Rear Heated Oxygen Sensor Heater..................................................................................1017 Crankshaft Position Sensor (OBD)..................................................................................1017 Tank Fuel Temperature Sensor......................................................................................1017 el........................................................................................................................1018 QUICK REFERENCE INDEX................................................................................................. 0 TABLE OF CONTENTS.....................................................................................................1018 PRECAUTIONS...........................................................................................................1021 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER".......................................1021 Wiring Diagrams and Trouble Diagnosis.............................................................................1021 HARNESS CONNECTOR.....................................................................................................1022 Description.......................................................................................................1022 STANDARDIZED RELAY....................................................................................................1024 Description.......................................................................................................1024 POWER SUPPLY ROUTING..................................................................................................1026 Schematic.........................................................................................................1026 Wiring Diagram - POWER -..........................................................................................1027 Inspection........................................................................................................1034 GROUND................................................................................................................1035 Ground Distribution...............................................................................................1035 COMBINATION SWITCH....................................................................................................1044 Check.............................................................................................................1044 Replacement.......................................................................................................1045 STEERING SWITCH.......................................................................................................1046 Check.............................................................................................................1046 HEADLAMP (FOR USA)....................................................................................................1047 System Description................................................................................................1047 Wiring Diagram - H/LAMP -.........................................................................................1048 Trouble Diagnoses.................................................................................................1049 Bulb Replacement..................................................................................................1050 Aiming Adjustment.................................................................................................1050 HEADLAMP (FOR CANADA) - DAYTIME LIGHT SYSTEM -........................................................................1052 System Description................................................................................................1052 Wiring Diagram - DTRL -...........................................................................................1054 Trouble Diagnoses.................................................................................................1056 Bulb Replacement..................................................................................................1057 Aiming Adjustment.................................................................................................1057 PARKING, LICENSE AND TAIL LAMPS.......................................................................................1058 Wiring Diagram - TAIL/L-..........................................................................................1058 STOP LAMP.............................................................................................................1060 Wiring Diagram - STOP/L...........................................................................................1060 BACK-UP LAMP..........................................................................................................1061 Wiring Diagram - BACK/L...........................................................................................1061 FRONT FOG LAMP........................................................................................................1062 System Description................................................................................................1062 Wiring Diagram - F/FOG -..........................................................................................1063 Aiming Adjustment.................................................................................................1064 TURN SIGNAL AND HAZARD WARNING LAMPS..................................................................................1065 System Descripton.................................................................................................1065 Wiring Diagram - TURN -...........................................................................................1067 Trouble Diagnoses.................................................................................................1069 Electrical Components Inspection..................................................................................1069 ILLUMINATION..........................................................................................................1070 System Description................................................................................................1070 Schematic.........................................................................................................1071 Wiring Diagram - ILL -............................................................................................1072 INTERIOR ROOM LAMP....................................................................................................1075 System Description................................................................................................1075 Wiring Diagram - ROOM/L -.........................................................................................1077 VANITY MIRROR AND TRUNK ROOM LAMPS....................................................................................1079 System Description................................................................................................1079 Wiring Diagram - INT/L -..........................................................................................1080 METERS AND GAUGES.....................................................................................................1081 Component Parts and Harness Connector Location....................................................................1081 System Description................................................................................................1081 Wiring DIagram - METER -..........................................................................................1084 Meter/Gauge Operation and Odo/Trip Meter Segment Check in Diagnosis Mode..........................................1085 Flexible Print Circuit (FPC)......................................................................................1086 Trouble Diagnoses.................................................................................................1087 Electrical Components Inspections.................................................................................1092 WARNING LAMPS.........................................................................................................1094 Schematic.........................................................................................................1094 Wiring Diagram - WARN -...........................................................................................1095 Electrical Components Inspection..................................................................................1099 A/T INDICATOR.........................................................................................................1100 Wiring Diagram - AT/IND -.........................................................................................1100 WARNING CHIME.........................................................................................................1101 Component Parts and Harness Connector Location....................................................................1101 System Description................................................................................................1101 Wiring Diagram - CHIME -..........................................................................................1103 Trouble Diagnoses.................................................................................................1104 FRONT WIPER AND WASHER................................................................................................1107 System Description................................................................................................1107 Wiring Diagram - WIPER -..........................................................................................1109 Removal and Installation..........................................................................................1110 Washer Nozzle Adjustment..........................................................................................1111 Washer Tube Layout................................................................................................1111 HORN..................................................................................................................1112 Wiring Diagram - HORN -...........................................................................................1112 CIGARETTE LIGHTER.....................................................................................................1113 Wiring Diagram - CIGAR -..........................................................................................1113 REAR WINDOW DEFOGGER..................................................................................................1114 Component Parts and Harness Connector Location....................................................................1114 System Description................................................................................................1114 Wiring Diagram - DEF -............................................................................................1116 Trouble Diagnoses.................................................................................................1117 Electrical Components Inspection..................................................................................1118 Filament Check....................................................................................................1119 Filament Repair...................................................................................................1119 AUDIO.................................................................................................................1121 System Description................................................................................................1121 Wiring Diagram - AUDIO -..........................................................................................1122 Trouble Diagnoses.................................................................................................1124 Inspection........................................................................................................1125 AUDIO ANTENNA.........................................................................................................1126 System Description................................................................................................1126 Wiring Diagram - P/ANT -..........................................................................................1127 Trouble Diagnoses.................................................................................................1128 Location of Antenna...............................................................................................1128 Antenna Rod Replacement...........................................................................................1128 POWER SUNROOF.........................................................................................................1130 Wiring Diagram -SROOF -...........................................................................................1130 DOOR MIRROR...........................................................................................................1131 Wiring Diagram - MIRROR -.........................................................................................1131 POWER SEAT ...........................................................................................................1132 Wiring Diagram -SEAT -............................................................................................1132 HEATED SEAT...........................................................................................................1133 Wiring Diagram - HSEAT -..........................................................................................1133 AUTOMATIC SPEED CONTROL DEVICE (ASCD).................................................................................1134 Component Parts and Harness Connector Location....................................................................1134 System Description................................................................................................1135 Schematic.........................................................................................................1137 Wiring Diagram - ASCD -...........................................................................................1138 Fail-safe System..................................................................................................1142 Trouble Diagnoses.................................................................................................1143 Electrical Component Inspection...................................................................................1152 ASCD Wire Adjustment..............................................................................................1153 POWER WINDOW..........................................................................................................1154 System Description................................................................................................1154 Schematic.........................................................................................................1156 Wiring Diagram - WINDOW -.........................................................................................1157 Trouble Diagnoses.................................................................................................1160 POWER DOOR LOCK.......................................................................................................1161 Component Parts and Harness Connector Location....................................................................1161 System Description................................................................................................1161 Schematic.........................................................................................................1162 Wiring Diagram - D/LOCK -.........................................................................................1163 Trouble Diagnoses.................................................................................................1166 MULTI-REMOTE CONTROL SYSTEM...........................................................................................1173 Component Parts and Harness Connector Location....................................................................1173 System Description................................................................................................1173 Wiring Diagram - MULTI -..........................................................................................1175 Trouble Diagnoses.................................................................................................1177 ID Code Entry Procedure...........................................................................................1185 Remote Controller Battery Replacement.............................................................................1186 THEFT WARNING SYSTEM..................................................................................................1187 Component Parts and Harness Connector Location....................................................................1187 System Description................................................................................................1188 Schematic.........................................................................................................1191 Wiring Diagram - THEFT -..........................................................................................1192 Trouble Diagnoses.................................................................................................1196 SMART ENTRANCE CONTROL UNIT...........................................................................................1209 Description.......................................................................................................1209 Schematic.........................................................................................................1211 Smart Entrance Control Unit Inspection Table......................................................................1213 INTEGRATED HOMELINK TRANSMITTER.......................................................................................1214 Wiring Diagram - TRNSMT -.........................................................................................1214 Trouble Diagnoses.................................................................................................1215 ELECTRICAL UNITS LOCATION.............................................................................................1216 Engine Compartment................................................................................................1216 Passenger Compartment.............................................................................................1217 HARNESS LAYOUT........................................................................................................1219 How to Read Harness Layout........................................................................................1219 Outline...........................................................................................................1220 Main Harness......................................................................................................1221 Engine Room Harness...............................................................................................1223 Engine Control Harness............................................................................................1226 Body Harness......................................................................................................1227 Body No. 2 Harness................................................................................................1228 Tail & Tail No. 2 Harness.........................................................................................1229 Engine Harness....................................................................................................1230 Room Lamp Harness.................................................................................................1231 Air Bag Harness...................................................................................................1232 Front Door Harness................................................................................................1233 Rear Door Harness.................................................................................................1234 BULB SPECIFICATIONS...................................................................................................1235 Headlamp..........................................................................................................1235 Exterior Lamp.....................................................................................................1235 Interior Lamp.....................................................................................................1235 WIRING DIAGRAM CODES (CELL CODES).....................................................................................1236 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 JOINT CONNECTOR (J/C)................................................................................................. 5 Terminal Arrangement.............................................................................................. 5 em........................................................................................................................1238 QUICK REFERENCE INDEX................................................................................................. 0 TABLE OF CONTENTS.....................................................................................................1238 PRECAUTIONS...........................................................................................................1240 Parts Requiring Angular Tightening................................................................................1240 Liquid Gasket Application Procedure...............................................................................1240 PREPARATION...........................................................................................................1241 Special Service Tools.............................................................................................1241 Commercial Service Tools..........................................................................................1243 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING..................................................................1245 NVH Troubleshooting - Engine Noise................................................................................1246 OUTER COMPONENT PARTS.................................................................................................1247 Removal and Installation..........................................................................................1247 MEASUREMENT OF COMPRESSION PRESSURE OIL PAN...........................................................................1250 OIL PAN...............................................................................................................1251 Components........................................................................................................1251 Removal...........................................................................................................1251 Installation......................................................................................................1253 TIMING CHAIN..........................................................................................................1256 Components .......................................................................................................1256 Removal...........................................................................................................1257 Inspection........................................................................................................1261 Installation......................................................................................................1261 OIL SEAL..............................................................................................................1271 Replacement.......................................................................................................1271 VALVE OIL SEAL................................................................................................1271 FRONT OIL SEAL................................................................................................1271 REAR OIL SEAL.................................................................................................1272 CYLINDER HEAD.........................................................................................................1273 Components........................................................................................................1273 Removal...........................................................................................................1274 Disassembly.......................................................................................................1274 Inspection........................................................................................................1276 CYLINDER HEAD DISTORTION......................................................................................1276 CAMSHAFT VISUAL CHECK.........................................................................................1277 CAMSHAFT RUNOUT...............................................................................................1277 CAMSHAFT JOURNAL CLEARANCE....................................................................................1277 CAMSHAFT END PLAY.............................................................................................1278 CAMSHAFT SPROCKET RUNOUT......................................................................................1278 CAMSHAFT GUIDE CLEARANCE......................................................................................1278 VALVE GUIDE REPLACEMENT.......................................................................................1279 VALVE SEATS...................................................................................................1280 REPLACING VALVE SEAT FOR SERVICE PARTS........................................................................1280 VALVE DIMENSIONS..............................................................................................1281 VALVE SPRING..................................................................................................1282 HYDRAULIC LASH ADJUSTER.......................................................................................1282 ROCKER ARM, SHIM AND ROCKER ARM GUIDE.........................................................................1283 Assembly..........................................................................................................1283 Installation......................................................................................................1287 ENGINE ASSEMBLY.......................................................................................................1288 Removal and Installation..........................................................................................1288 REMOVAL.......................................................................................................1289 INSTALLATION..................................................................................................1290 CYLINDER BLOCK........................................................................................................1291 Components........................................................................................................1291 Removal and Installation..........................................................................................1292 Disassembly.......................................................................................................1292 PISTON AND CRANKSHAFT.........................................................................................1292 Inspection........................................................................................................1292 PISTON AND PISTON PIN CLEARANCE...............................................................................1292 PISTON RING SIDE CLEARANCE....................................................................................1293 PISTON RING END GAP...........................................................................................1293 CONNECTING ROD BEND AND TORSION...............................................................................1293 CYLINDER BLOCK DISTORTION AND WEAR............................................................................1294 PISTON-TO-BORE CLEARANCE......................................................................................1294 CRANKSHAFT....................................................................................................1295 BEARING CLEARANCE.............................................................................................1296 CONNECTING ROD BUSHING CLEARANCE (SMALL END)..................................................................1298 REPLACEMENT OF CONNECTING ROD BUSHING (SMALL END).............................................................1299 REPLACEMENT OF PILOT BUSHING (M/T) OR PILOT CONVERTER (A/T)...................................................1299 FLYWHEEL/DRIVE PLATE RUNOUT...................................................................................1299 Assembly..........................................................................................................1300 PISTON........................................................................................................1300 CRANKSHAFT....................................................................................................1301 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................1304 General Specifications............................................................................................1304 Compression Pressure..............................................................................................1304 Cylinder Head.....................................................................................................1304 Valve.............................................................................................................1305 VALVE.........................................................................................................1305 VALVE SPRING..................................................................................................1305 HYDRAULIC LASH ADJUSTER (HLA).................................................................................1305 VALVE GUIDE...................................................................................................1306 VALVE SHIM CLEARANCE ADJUSTMENT...............................................................................1306 AVAILABLE SHIM................................................................................................1307 VALVE SEAT....................................................................................................1308 VALVE SEAT RESURFACE LIMIT....................................................................................1309 Camshaft and Camshaft Bearing.....................................................................................1309 Cylinder Block....................................................................................................1310 Piston, Piston Ring and Piston Pin................................................................................1311 PISTON........................................................................................................1311 PISTON RING...................................................................................................1311 PISTON PIN....................................................................................................1311 Connecting Rod....................................................................................................1312 Crankshaft........................................................................................................1313 Main Bearing......................................................................................................1314 STANDARD SIZE.................................................................................................1314 UNDERSIZE.....................................................................................................1314 Connecting Rod Bearing............................................................................................1314 STANDARD......................................................................................................1314 UNDERSIZE.....................................................................................................1314 Bearing Clearance.................................................................................................1315 Miscellaneous Components..........................................................................................1315 fe........................................................................................................................1316 QUICK REFERENCE INDEX................................................................................................. 0 TABLE OF CONTENTS.....................................................................................................1316 ACCELERATOR CONTROL SYSTEM............................................................................................1317 Removal and Installation..........................................................................................1317 Adjusting Accelerator Wire........................................................................................1317 FUEL SYSTEM...........................................................................................................1318 Removal and Installatioin.........................................................................................1318 FUEL PUMP AND GAUGE...........................................................................................1319 EXHAUST SYSTEM........................................................................................................1321 Removal and Installation..........................................................................................1321 foldout...................................................................................................................1323 QUICK REFERENCE INDEX................................................................................................. 0 SUPER MULTIPLE JUNCTION (SMJ).........................................................................................1323 Installation......................................................................................................1323 Terminal Arrangement..............................................................................................1324 FUSE BLOCK - JUNCTION BOX (J/B).......................................................................................1325 Terminal Arrangement..............................................................................................1325 FUSE AND FUSIBLE LINK BOX.............................................................................................1326 Terminal Arrangement..............................................................................................1326 ELECTRICAL UNITS......................................................................................................1327 Terminal Arrangement..............................................................................................1327 JOINT CONNECTOR (J/C).................................................................................................1328 Terminal Arrangement..............................................................................................1328 gi........................................................................................................................1329 QUICK REFERENCE INDEX................................................................................................. 0 TABLE OF CONTENTS.....................................................................................................1329 PRECAUTIONS...........................................................................................................1331 Precautions.......................................................................................................1331 PRECAUTIONS FOR SUPPLEMENTA RESTRAINT SYSTEM (SRS) "AIR BAG" AND "SEAT BELT PRE-TENSIONER"....................1331 GENERAL PRECAUTIONS...........................................................................................1332 PRECAUTIONS FOR MULTIPORT FUEL INJECTION SYSTEM OR ENGINE CONTROL SYSTEM......................................1333 PRECAUTIONS FOR THREE WAY CATALYST............................................................................1333 PRECAUTIONS FOR ENGINE OILS...................................................................................1334 PRECAUTIONS FOR FUEL..........................................................................................1334 PRECAUTIONS FOR AIR CONDITIONING..............................................................................1335 HOW TO USE THIS MANUAL................................................................................................1336 HOW TO READ WIRING DIAGRAMS...........................................................................................1338 Sample/Wiring Diagram - EXAMPL -..................................................................................1338 OPTIONAL SPLICE...............................................................................................1339 Description.......................................................................................................1340 CONNECTOR SYMBOLS.............................................................................................1342 HARNESS INDICATION............................................................................................1343 COMPONENT INDICATION..........................................................................................1343 SWITCH POSITIONS..............................................................................................1343 DETECTABLE LINES AND NON-DETECTABLE LINES.....................................................................1344 MULTIPLE SWITCH...............................................................................................1345 FOLDOUT PAGE..................................................................................................1346 HOW TO CHECK TERMINAL.................................................................................................1347 Connector and Terminal Pin Kit....................................................................................1347 How to Probe Connectors...........................................................................................1347 PROBING FROM HARNESS SIDE.....................................................................................1347 PROBING FROM TERMINAL SIDE....................................................................................1347 How to Check Enlarged Contact Spring of Terminal..................................................................1348 Waterproof Connector Inspection...................................................................................1349 RUBBER SEAL INSPECTION........................................................................................1349 WIRE SEAL INSPECTION..........................................................................................1349 Terminal Lock Inspection..........................................................................................1349 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT.........................................................1350 Work Flow.........................................................................................................1350 Incident Simulation Tests.........................................................................................1351 INTRODUCTION..................................................................................................1351 VEHICLE VIBRATION.............................................................................................1351 HEAT SENSITIVE................................................................................................1352 FREEZING......................................................................................................1352 WATER INTRUSION...............................................................................................1353 ELECTRICAL LOAD...............................................................................................1353 COLD OR HOT START UP..........................................................................................1353 Circuit Inspection................................................................................................1353 INTRODUCTION..................................................................................................1353 TESTING FOR "OPENS" IN THE CIRCUIT............................................................................1354 TESTING FOR "SHORTS" IN THE CIRCUIT...........................................................................1355 GROUND INSPECTION.............................................................................................1356 VOLTAGE DROP TESTS............................................................................................1357 CONTROL UNIT CIRCUIT TEST.....................................................................................1358 HOW TO FOLLOW TROUBLE DIAGNOSES.......................................................................................1360 How to Follow Test Groups in Trouble Diagnoses....................................................................1361 Key to Symbols Signifying Meaasurements or Procedures.............................................................1362 CONSULT CHECKING SYSTEM...............................................................................................1364 Function and System Application...................................................................................1364 Lithium Battery Replacement.......................................................................................1364 Checking Equipment................................................................................................1364 Loading Procedure.................................................................................................1365 CONSULT Data Link Connector (DLC) Circuit.........................................................................1365 INSPECTION PROCEDURE..........................................................................................1365 IDENTIFICATION INFORMATION............................................................................................1366 Model Variation...................................................................................................1366 Identification Number.............................................................................................1367 VEHICLE IDENTIFICATION NUMBER ARRANGEMENT.....................................................................1367 IDENTIFICATION PLATE..........................................................................................1368 ENGINE SERIAL NUMBER..........................................................................................1368 AUTOMATIC TRANSAXLE NUMBER....................................................................................1368 MANUAL TRANSAXLE NUMBER.......................................................................................1368 Dimensions........................................................................................................1369 Wheels & Tires....................................................................................................1369 LIFTING POINTS AND TOW TRUCK TOWING...................................................................................1370 Preparation.......................................................................................................1370 SPECIAL SERVICE TOOLS.........................................................................................1370 Board-on Lift.....................................................................................................1370 Garage Jack and Safety Stand......................................................................................1371 2-pole Lift.......................................................................................................1372 Tow Truck Towing..................................................................................................1372 VEHICLE RECOVERY (FREEING A STUCK VEHICLE)....................................................................1374 TIGHTENING TORQUE OF STANDARD BOLTS...................................................................................1375 SAE J1930 TERMINOLOGY LIST............................................................................................1376 SAE J1930 Terminology List........................................................................................1376 ha........................................................................................................................1380 QUICK REFERENCE INDEX................................................................................................. 0 TABLE OF CONTENTS.....................................................................................................1380 AUTO..................................................................................................................1382 PRECAUTIONS.......................................................................................................1383 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"...................................1383 Precautions for Working with HFC-134a (R-134a)................................................................1383 General Refrigerant Precautions...............................................................................1383 Precautions for Refrigerant Conection.........................................................................1383 Precautions for Servicing Compressor..........................................................................1386 Precautions for Service Equipment.............................................................................1386 Wiring Diagrams and Trouble Diagnosis.........................................................................1388 PREPARATION.......................................................................................................1389 Special Service Tools.........................................................................................1389 HFC-134a (R-134a) Service Tools and Equipment.................................................................1390 DESCRIPTION.......................................................................................................1393 Refrigeration System..........................................................................................1393 Component Layout..............................................................................................1394 Introduction..................................................................................................1395 Features......................................................................................................1395 Overview of Control System....................................................................................1398 Control Operation.............................................................................................1398 Discharge Air Flow............................................................................................1400 TROUBLE DIAGNOSES.................................................................................................1402 Component Location............................................................................................1402 Circuit Diagram...............................................................................................1404 Wiring Diagram - A/C, A -.....................................................................................1405 Auto Amp. Terminals and Reference Value.......................................................................1408 Self-diagnosis................................................................................................1409 How to Perform Trouble Diagnoses for Quick and Accurate Repair................................................1416 Operational Check.............................................................................................1417 A/C System....................................................................................................1420 Mode Door Motor...............................................................................................1422 Air Mix Door Motor............................................................................................1427 Intake Door Motor.............................................................................................1431 Blower Motor..................................................................................................1437 Magnet Clutch.................................................................................................1443 Insufficient Cooling..........................................................................................1449 Insufficient Heating..........................................................................................1457 Noise.........................................................................................................1458 Self-diagnosis................................................................................................1459 Memory Function...............................................................................................1460 ECON (ECONOMY) Mode...........................................................................................1461 Ambient Sensor Circuit........................................................................................1461 In-vehicle Sensor Circuit.....................................................................................1464 Sunload Sensor Circuit........................................................................................1466 Intake Sensor Circuit.........................................................................................1469 Air Mix Door Motor PBR Circuit................................................................................1471 SERVICE PROCEDURE.................................................................................................1472 HFC-134a (R-134a) Service Procedure...........................................................................1472 Maintenance of Lubricant Quantity in Compressor...............................................................1474 Compressor....................................................................................................1474 Compressor Clutch.............................................................................................1477 Thermal Protector.............................................................................................1480 Refrigerant Lines.............................................................................................1481 Belt..........................................................................................................1485 Fast Idle Control Device (FICD................................................................................1485 Ventilation Air Filter........................................................................................1485 MANUAL................................................................................................................1486 PRECAUTIONS.......................................................................................................1486 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"...................................1486 Precautions for Working with HFC-134a (R-134a)................................................................1486 General Refrigerant Precautions...............................................................................1487 Precautions for Service Compressor............................................................................1490 Precautions for Service Equipment.............................................................................1490 Wiring Diagrams and Trouble Diagnosis.........................................................................1492 PREPARATION.......................................................................................................1493 Special Service Tools.........................................................................................1493 HFC -134a (R-134a) Service Tools and Equipment................................................................1494 DESCRIPTION.......................................................................................................1497 Refrigeration System..........................................................................................1497 Component Layout..............................................................................................1498 Control Operation.............................................................................................1499 Discharge Air Flow............................................................................................1500 System Description............................................................................................1501 TROUBLE DIAGNOSES.................................................................................................1502 Component Location............................................................................................1502 Circuit Diagram - Air Conditioner.............................................................................1504 Wiring Diagram - A/C, M -.....................................................................................1505 How to Perform Trouble Diagnoses for Quick and Accurate Repair................................................1509 Operational Check.............................................................................................1510 A/C System....................................................................................................1512 Intake Door...................................................................................................1514 Mode Door Motor...............................................................................................1518 Air Mix Motor.................................................................................................1522 Blower Motor..................................................................................................1527 Magnet Clutch ................................................................................................1532 Insufficient Cooling..........................................................................................1538 Insufficient Heating..........................................................................................1545 Noise.........................................................................................................1546 SERVICE PROCEDURE.................................................................................................1547 HFC-134a (R-134a) Service Procedure...........................................................................1547 Maintenance of Lubricant Quantity in Compressor...............................................................1549 Compressor....................................................................................................1549 Compressor Clutch.............................................................................................1552 Thermal Protector.............................................................................................1555 Refrigerant Lines.............................................................................................1556 Belt..........................................................................................................1560 Fast Idle Control Device (FICD)...............................................................................1560 Ventilation Air Filter........................................................................................1560 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................1561 Auto..............................................................................................................1561 Manual............................................................................................................1561 idx.......................................................................................................................1563 QUICK REFERENCE INDEX................................................................................................. 0 lc........................................................................................................................1572 QUICK REFERENCE INDEX................................................................................................. 0 TABLE OF CONTENTS.....................................................................................................1572 ENGINE LUBRICATION SYSTEM.............................................................................................1573 Precautions.......................................................................................................1573 LIQUID GASKET APPLICATION PROCEDURE...........................................................................1573 Preparation.......................................................................................................1573 SPECIAL SERVICE TOOLS.........................................................................................1573 Lubrication Circuit...............................................................................................1574 Oil Pressure Check................................................................................................1575 Oil Pump..........................................................................................................1575 REMOVAL ......................................................................................................1575 DISASSEMBLY AND ASSEMBLY......................................................................................1576 INSPECTION....................................................................................................1576 REGULATOR VALVE INSPECTION....................................................................................1577 INSTALLATION..................................................................................................1578 Oil Filter........................................................................................................1578 ENGINE COOLING SYSTEM.................................................................................................1579 Precautions.......................................................................................................1579 LIQUID GASKET APPLICATION PROCEDURE...........................................................................1579 Preparation.......................................................................................................1579 SPECIAL SERVICE TOOLS.........................................................................................1579 Cooling Circuit...................................................................................................1580 System Check......................................................................................................1580 CHECKING COOLANT SYSTEM HOSES.................................................................................1580 CHECKING COOLING SYSTEM FOR LEAKS.............................................................................1580 CHECKING RADIATOR.............................................................................................1581 CHECKING RADIATOR CAP.........................................................................................1581 Water Pump........................................................................................................1581 REMOVAL.......................................................................................................1581 INSPECTION....................................................................................................1582 INSTALLATION..................................................................................................1582 Thermostat........................................................................................................1583 REMOVAL AND INSTALLATION......................................................................................1583 INSPECTION....................................................................................................1584 Water Outlet......................................................................................................1584 INSPECTION ...................................................................................................1584 INSTALLATION..................................................................................................1584 Radiator..........................................................................................................1585 COMPONENTS....................................................................................................1585 Cooling Fan Control System........................................................................................1585 Refilling Engine Coolant..........................................................................................1586 Overheating Cause Analysis........................................................................................1586 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................1588 Oil Pressure Check................................................................................................1588 Regulator Valve Inspection........................................................................................1588 Oil Pump Inspection...............................................................................................1588 Thermostat........................................................................................................1588 Radiator..........................................................................................................1588 ma........................................................................................................................1589 QUICK REFERENCE INDEX................................................................................................. 0 TABLE OF CONTENTS.....................................................................................................1589 PRECAUTIONS...........................................................................................................1590 Precautions for Supplemental Restraint System (SRS) "AIR BAG".....................................................1590 PREPARATION...........................................................................................................1591 Special Service Tool..............................................................................................1591 Commercial Service Tool...........................................................................................1591 GENERAL MAINTENANCE...................................................................................................1592 PERIODIC MAINTENANCE..................................................................................................1594 Schedule 1........................................................................................................1595 EMISSION CONTROL SYSTEM MAINTENANCE..........................................................................1595 CHASSIS AND BODY MAINTENANCE..................................................................................1596 Schedule 2........................................................................................................1597 EMISSION CONTROL SYSTEM MAINTENANCE .........................................................................1597 CHASSIS AND BODY MAINTENANCE..................................................................................1598 RECOMMENDED FLUIDS AND LUBRICANTS.....................................................................................1599 Fluids and Lubricants.............................................................................................1599 SAE Viscosity Number..............................................................................................1599 GASOLINE ENGINE OIL...........................................................................................1599 Anti-freeze Coolant Mixture Ratio.................................................................................1600 ENGINE MAINTENANCE....................................................................................................1601 Checking Drive Belts..............................................................................................1601 Changing Engine Coolant...........................................................................................1602 - DRAINING ENGINE COOLANT -...................................................................................1602 - REFILLING ENGINE COOLANT -..................................................................................1603 - FLUSHING COOLING SYSTEM -...................................................................................1604 Checking Fuel Lines...............................................................................................1604 Changing Fuel Filter..............................................................................................1604 WITH CONSULT..................................................................................................1604 WITHOUT CONSULT...............................................................................................1605 Changing Air Cleaner Filter.......................................................................................1605 VISCOUS PAPER TYPE............................................................................................1605 Changing Engine Oil...............................................................................................1605 Changing Oil Filter...............................................................................................1606 Changing Spark Plugs (Platinum-tipped type).......................................................................1607 Changing Spart Plugs (Conventional type)..........................................................................1608 Checking EVAP Vapor Lines.........................................................................................1609 CHASSIS AND BODY MAINTENANCE..........................................................................................1610 Checking Exhaust System...........................................................................................1610 Checking Clutch Fluid Level and Leaks.............................................................................1610 Checking M/T Oil..................................................................................................1610 Changing M/T Oil..................................................................................................1610 Checking A/T Fluid................................................................................................1611 Changing A/T Fluid................................................................................................1611 Balancing Wheels..................................................................................................1612 Tire Rotation.....................................................................................................1612 Checking Brake Fluid Level and Leaks..............................................................................1612 Checking Brake Lines and Cables...................................................................................1612 Checking Disc Brake...............................................................................................1612 ROTOR.........................................................................................................1612 CALIPER.......................................................................................................1613 PAD...........................................................................................................1613 Checking Steering Gear and Linkage................................................................................1613 STEERING GEAR.................................................................................................1613 STEERING LINKAGE..............................................................................................1613 Checking Power Steering Fluid and Lines...........................................................................1613 CHECKING FLUID LEVEL..........................................................................................1613 CHECKING LINES................................................................................................1613 Lubricating Locks, Hinges and Hood Latches........................................................................1614 Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters...................................................1614 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................1615 Engine Maintenance................................................................................................1615 DRIVE BELT DEFLECTION AND TENSION.............................................................................1615 SPARK PLUG TYPE...............................................................................................1615 Chassis and Body Maintenance......................................................................................1615 WHEEL BALANCE.................................................................................................1615 mt........................................................................................................................1616 QUICK REFERENCE INDEX................................................................................................. 0 TABLE OF CONTENTS.....................................................................................................1616 PREPARATION...........................................................................................................1617 Special ServiceTools..............................................................................................1617 Commercial Service Tools..........................................................................................1619 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING..................................................................1620 NVH Troubleshooting Chart.........................................................................................1620 DESCRIPTION...........................................................................................................1621 Cross-sectional View..............................................................................................1621 DOUBLE-CONE SYNCHRONIZER......................................................................................1622 REVERSE BRAKE MECHANISM.......................................................................................1622 ON-VEHICLE SERVICE....................................................................................................1623 Replacing Oil Seal................................................................................................1623 DIFFERENTIAL OIL SEAL.........................................................................................1623 STRIKING ROD OIL SEAL.........................................................................................1623 Position Switch Check.............................................................................................1624 BACK-UP LAMP SWITCH...........................................................................................1624 PARK/NEUTRAL POSITION SWITCH..................................................................................1624 Viscous Coupling Check............................................................................................1625 REMOVAL AND INSTALLATION..............................................................................................1626 Removal...........................................................................................................1626 Installation......................................................................................................1628 OVERHAUL..............................................................................................................1629 Transaxle Gear Control............................................................................................1629 Case Components...................................................................................................1630 Gear Components...................................................................................................1631 Shift Control Components..........................................................................................1632 DISASSEMBLY...........................................................................................................1633 REPAIR FOR COMPONENT PARTS............................................................................................1646 Input Shaft and Gears.............................................................................................1646 DISASSEMBLY...................................................................................................1646 INSPECTION....................................................................................................1637 ASSEMBLY......................................................................................................1637 Mainshaft and Gears...............................................................................................1639 DISASSEMBLY...................................................................................................1639 INSPECTION....................................................................................................1641 ASSEMBLY......................................................................................................1642 Final Drive.......................................................................................................1645 DISASSEMBLY...................................................................................................1617 INSPECTION....................................................................................................1646 ASSEMBLY......................................................................................................1647 Shift Control Comonents...........................................................................................1649 INSPECTION....................................................................................................1649 ADJUSTMENT OF INPUT SHAFT BRAKING MECHANISM...................................................................1650 Case Compnents....................................................................................................1651 REMOVAL AND INSTALLATION......................................................................................1651 ADJUSTMENT............................................................................................................1643 Differential Side Bearing Preload.................................................................................1643 ASSEMBLY..............................................................................................................1655 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................1659 General Specifications............................................................................................1659 TRANSAXLE.....................................................................................................1659 FINAL GEAR....................................................................................................1659 Gear End Play.....................................................................................................1660 Clearance Between Baulk Ring and Gear ............................................................................1660 1ST, 4TH, 5TH BAULK RING......................................................................................1660 2ND AND 3RD BAULK RING........................................................................................1660 Available Check Plugs.............................................................................................1660 REVERSE CHECK PLUG............................................................................................1660 Available Case Cover..............................................................................................1661 CASE COVER....................................................................................................1661 Available Snap Rings..............................................................................................1661 INPUT SHAFT FRONT BEARING.....................................................................................1661 INPUT SHAFT 5TH SYNCHRONIZED HUB..............................................................................1661 Available C-rings.................................................................................................1662 MAINSHAFT C-RING..............................................................................................1662 Available Spacers.................................................................................................1662 MAINSHAFT BEARING ADJUSTING SPACER............................................................................1662 Available Washers.................................................................................................1663 DIFFERENTIAL SIDE GEAR THRUST WASHER..........................................................................1663 Available Shims - Differential Side Bearing Preload and Adjusting Shim............................................1663 BEARING PRELOAD (REUSED BEARING) TURNING TORQUE (NE...........................................................1663 TURNING TORQUE (NEW BEARING)..................................................................................1663 DIFFERENTIAL SIDE BEARING ADJUSTING SHIIMS....................................................................1664 Input Shaft Braking Mechanism.....................................................................................1665 rs........................................................................................................................1666 QUICK REFERENCE INDEX.................................................................................................1666 TABLE OF CONTENTS.....................................................................................................1666 SEAT BELTS............................................................................................................1666 Precautions.......................................................................................................1666 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) "AIR BAG" AND "SEAT BELT PRE-TENSIONER"...................................1668 PRECAUTON FOR SEAT BELT SERVICE...............................................................................1668 Front Seat Belt...................................................................................................1669 REMOVAL AND INSTALLATION......................................................................................1669 Rear Seat Belt....................................................................................................1671 REMOVAL AND INSTALLATIOIN.....................................................................................1671 Seat Belt Inspection..............................................................................................1673 AFTER A COLLISION.............................................................................................1673 PRELIMINARY CHECKS............................................................................................1673 SEAT BELT RETRACTOR ON-VEHICLE CHECK..........................................................................1674 SEAT BELT RETRACTOR OFF-VEHICLE CHECK.........................................................................1674 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)...................................................................................1676 Precautions.......................................................................................................1676 SUPPLEMENTAL RESTRAIN SYSTEM (SRS) "AIR BAG" AND "SEAT BELT PRE-TENSIONER"....................................1676 PRECAUTIONS FOR SRS "AIR BAG" AND "SEAT BELT PRE-TENSIONER" SERVICE...........................................1676 WIRING DIAGRAMS AND TROUBLE DIAGNOSIS.........................................................................1676 Preparation.......................................................................................................1677 SPECIAL SERVICE TOLS..........................................................................................1677 SRS Configuration.................................................................................................1678 Seat Belt Pre-tensioner with Load Limiter.........................................................................1679 Built-in Type Side Air Bag........................................................................................1679 SRS Component Parts Location......................................................................................1680 Maintenance Items.................................................................................................1680 Diagnosis Sensor Unit.............................................................................................1681 REMOVAL AND INSTALLATIOIN.....................................................................................1681 Seat Belt Pre-tensioner...........................................................................................1682 REMOVAL AND INSTALLATION......................................................................................1682 Satellite Sensor..................................................................................................1683 REMOVAL AND INSTALLATION......................................................................................1683 Driver Air Bag Module and Spiral Cable............................................................................1683 REMOVAL AND INSTALLATION......................................................................................1683 REMOVAL.......................................................................................................1684 INSTALLATION..................................................................................................1685 Front Passenger Air Bag Module....................................................................................1686 REMOVAL ......................................................................................................1686 INSTALLATION..................................................................................................1686 Side Air Bag Module...............................................................................................1687 REMOVAL ......................................................................................................1687 INSTALLATION..................................................................................................1688 Disposal of Air Bag Module and Seat Belt Pre-tensioner............................................................1689 CHECKING DEPLOYMENT TOOL......................................................................................1689 DEPLOYMENT PROCEDURES FOR AIR BAG MODULE (OUTSIDE OF VEHICLE).................................................1690 DEPLOYMENT PROCEDURES FOR SEAT BELT PRE-TENSIONER (OUTSIDE OF VEHICLE)........................................1693 DEPLOYMENT OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER WHILE MOUNTED IN VEHICLE.............................1693 DISPOSING OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER.......................................................1694 Trouble Diagnoses Introduction....................................................................................1695 DIAGNOSIS FUNCTION............................................................................................1695 DIAGNOSIS MODE FOR CONSULT....................................................................................1695 HOW TO CHANGE SELF-DIAGNOSIS MODE WITH CONSULT................................................................1696 HOW TO CHANGE SELF-DIAGNOSIS MODE WITHOUT CONSULT.............................................................1696 HOW TO ERASE SELF-DIAGNOSIS RESULTS...........................................................................1696 How to Perform Trouble Diagnoses for Quick and Accurate Repair....................................................1698 INFORMATION FROM CUSTOMER.....................................................................................1698 PRELIMINARY CHECK.............................................................................................1698 WORK FLOW.....................................................................................................1699 Schematic.........................................................................................................1700 Wiring Diagram - SRS -............................................................................................1701 SRS Operation Check...............................................................................................1704 DIAGNOSTIC PROCEDURE 1........................................................................................1704 Trouble Diagnoses with CONSULT....................................................................................1706 DIAGNOSTIC PROCEDURE 2........................................................................................1706 DIAGNOSTIC PROCEDURE 3 .......................................................................................1709 DIAGNOSTIC PROCEDURE 4 (CONTINUED FROM DIAGNOSTIC PROCEDURE 2)................................................1711 DIAGNOSTIC PROCEDURE 5 .......................................................................................1711 Trouble Diagnoses without CONSULT.................................................................................1715 DIAGNOSTIC PROCEDURE 6........................................................................................1715 DIAGNOSTIC PROCEDURE 7........................................................................................1718 DIAGNOSTIC PROCEDURE 8 (CONTINUED FROM DIAGNOSTIC PROCEDURE 6)................................................1720 Trouble Diagnoses: "AIR BAG" Warning Lamp Does Not Turn Off.......................................................1721 DIAGNOSTIC PROCEDURE 9........................................................................................1721 Trouble Diagnoses: "AIR BAG" Warning Lamp Does Not Turn ON........................................................1722 DIAGNOSTIC PROCEDURE 10.......................................................................................1722 Trouble Diagnoses: SRS Does Not Enter Diagnosis Mode Using Door Switch............................................1723 DIAGNOSTIC PROCEDURE 11.......................................................................................1723 Trouble Diagnoses: "SEAT BELT" Warning Lamp Does Not Turn Off.....................................................1724 DIAGNOSTIC PROCEDURE 12.......................................................................................1724 Trouble Diagnoses: "SEAT BELT" Warning Lamp Does Not Turn On......................................................1725 DIAGNOSTIC PROCEDURE 13.......................................................................................1725 Collision Diagnosis...............................................................................................1725 FOR FRONTAL COLLISION.........................................................................................1725 FOR SIDE COLLISION............................................................................................1727 sc........................................................................................................................1729 QUICK REFERENCE INDEX................................................................................................. 0 TABLE OF CONTENTS.....................................................................................................1729 PRECAUTIONS...........................................................................................................1730 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER".......................................1730 Wiring Diagrams and Trouble Diagnosis.............................................................................1730 BATTERY...............................................................................................................1731 How to Handle Battery.............................................................................................1731 METHODS OF PREVENTING OVER-DISCHARGE..........................................................................1731 CHECKING ELECTROLYTE LEVEL....................................................................................1731 SPECIFIC GRAVITY CHECK........................................................................................1732 CHARGING THE BATTERY..........................................................................................1733 STARTING SYSTEM.......................................................................................................1734 System Description................................................................................................1734 M/T MODELS....................................................................................................1734 A/T MODELS....................................................................................................1734 Wiring Diagram -START -...........................................................................................1736 M/T MODELS....................................................................................................1736 A/T/ MODELS...................................................................................................1737 Construction......................................................................................................1738 Removal and Installation..........................................................................................1738 Pinion/Clutch Check...............................................................................................1738 CHARGING SYSTEM.......................................................................................................1739 System Description................................................................................................1739 Wiring Diagram - CHARGE -.........................................................................................1740 Trouble Diagnoses.................................................................................................1741 WITH IC REGULATOR.............................................................................................1741 MALFUNCTION INDICATOR.........................................................................................1741 Construction......................................................................................................1742 Removal and Installation..........................................................................................1742 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................1743 Battery...........................................................................................................1743 Starter...........................................................................................................1743 Alternator........................................................................................................1743 st........................................................................................................................1744 QUICK REFERENCE INDEX................................................................................................. 0 TABLE OF CONTENTS....................................................................................................1744 PRECAUTIONS...........................................................................................................1745 Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER".......................................1745 Precautions for Steering System...................................................................................1745 PREPARATION...........................................................................................................1746 Special Service Tools.............................................................................................1746 Commercial Service Tools..........................................................................................1747 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING..................................................................1748 NVH Troubleshooting Chart.........................................................................................1748 ON-VEHICLE SERVICE....................................................................................................1749 Checking Steering Wheel Play......................................................................................1749 Checking Neutral Position on Steering Wheel.......................................................................1749 PRE-CHECKING..................................................................................................1749 CHECKING......................................................................................................1749 Front Wheel Turning Angle.........................................................................................1749 Checking Gear Housing Movement....................................................................................1749 Checking and Adjustment Drive Belts...............................................................................1750 Checking Fluid level..............................................................................................1750 Checking Fluid Leakage............................................................................................1750 Bleeding Hydraulic System.........................................................................................1750 Checking Steering Wheel Turning Force.............................................................................1751 Checking Hydraulic System.........................................................................................1751 STEERING WHEEL AND STEERING COLUMN....................................................................................1753 Components........................................................................................................1753 Removal and Installation..........................................................................................1753 STEERING WHEEL................................................................................................1753 STEERING COLUMN...............................................................................................1754 Disassembly and Assembly..........................................................................................1756 Inspection........................................................................................................1757 TILT MECHANISM................................................................................................1757 POWER STEERING GEAR AND LINKAGE.......................................................................................1758 Components........................................................................................................1758 Removal and Installation..........................................................................................1759 Disassembly.......................................................................................................1761 Inspection........................................................................................................1761 BOOT..........................................................................................................1761 RACK..........................................................................................................1761 PINION ASSEMBLY...............................................................................................1762 GEAR HOUSING CYLINDER.........................................................................................1762 TIE-ROD OUTER AND INNER SOCKETS...............................................................................1762 Assembly..........................................................................................................1762 Adjustment........................................................................................................1767 POWER STEERING OIL PUMP...............................................................................................1769 Components........................................................................................................1769 Pre-disassembly Inspection........................................................................................1769 Disassembly.......................................................................................................1770 Inspection........................................................................................................1770 Assembly..........................................................................................................1771 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................1772 General Specifications............................................................................................1772 Steering Wheel....................................................................................................1772 Steering Column...................................................................................................1772 Steering Gear and Linkage.........................................................................................1773 Power Steering....................................................................................................1774 su........................................................................................................................1775 QUICK REFERENCE INDEX................................................................................................. 0 TABLE OF CONTENTS.....................................................................................................1775 FRONT SUSPENSION......................................................................................................1776 Precautions.......................................................................................................1776 PRECAUTIONS...................................................................................................1776 Preparation.......................................................................................................1776 SPECIAL SERVICE TOOLS.........................................................................................1776 COMMERCIAL SERVICE TOOLS......................................................................................1776 Noise, Vibration and Harsness (NVH) Troubleshooting...............................................................1777 NVH TROUBLESHOOTING CHART.....................................................................................1777 Components........................................................................................................1778 On-vehicle Service................................................................................................1779 FRONT SUSPENSION PARTS........................................................................................1779 FRONT WHEEL ALIGNMENT.........................................................................................1780 Coil Spring and Shock Absorber....................................................................................1783 COMPONENTS ...................................................................................................1783 REMOVAL.......................................................................................................1784 DISASSEMBLY...................................................................................................1784 INSPECTION....................................................................................................1784 ASSEMBLY......................................................................................................1785 Third Link and Upper Link.........................................................................................1785 REMOVAL.......................................................................................................1785 INSTALLATION..................................................................................................1785 DISASSEMBLY...................................................................................................1786 ASSEMBLY......................................................................................................1786 Stabilizer Bar....................................................................................................1787 REMOVAL AND INSTALLATION......................................................................................1787 Transverse Link and Lower Ball Joint..............................................................................1788 REMOVAL AND INSTALLATION......................................................................................1788 INSPECTION....................................................................................................1788 REAR SUSPENSION.......................................................................................................1789 Precautions.......................................................................................................1789 PRECAUTIONS...................................................................................................1789 Preparation.......................................................................................................1789 COMMERCIAL SERVICE TOOLS......................................................................................1789 Noise, Vibration and Harshness (NVH) Troubleshooting..............................................................1789 Components........................................................................................................1790 On-vehicle Service................................................................................................1791 REAR SUSPENSION PARTS.........................................................................................1791 REAR WHEEL ALIGNMENT..........................................................................................1791 Removal and Installation..........................................................................................1793 REMOVAL.......................................................................................................1794 INSTALLATION..................................................................................................1794 Coil Spring and Shock Absorber....................................................................................1794 REMOVAL.......................................................................................................1794 DISASSEMBLY...................................................................................................1795 INSPECTION....................................................................................................1795 ASSEMBLY......................................................................................................1795 Torsion Beam, Lateral Link and Control Rod........................................................................1796 DISASSEMBLY...................................................................................................1796 INSPECTION....................................................................................................1796 ASSEMBLY......................................................................................................1796 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................1798 General Specifications (Front)....................................................................................1798 Front Wheel Alignment (Unladen*1).................................................................................1798 Lower Ball Joint..................................................................................................1798 Wheelarch Height (Unladen*).......................................................................................1799 Wheel Runout......................................................................................................1799 General Specifications (Rear).....................................................................................1799 Rear Wheel Alignment (Unladen*)...................................................................................1799
DESCRIPTION:
1999 INFINITI G20 P10 Series Service Manual PDF DOWNLOAD
FOREWORD
- This manual contains maintenance and repair procedures for the 1999 INFINITI G20.
- In order to assure your safety and the efficient functioning of the vehicle, this manual should be read thoroughly.
- It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task.
- All information in this manual is based on the latest product infor• mation at the time of publication. The right is reserved to make changes in specifications and methods at any time without notice.
Important Safety Notice:
- The proper performance of service Is essential for both the safety of the technician and the efficient functioning of the vehicle.
- The service methods in this Service Manual are described In such a manner that the service may be performed safely and accurately.
- Service varies with the procedures used, the skills of the technician and the tools and parts available.
- Accordingly, anyone using service procedures, tools or parts which are not specifically recommended by INFINITI must first completely satisfy himself that neither his safety nor the vehicle’s safety will be jeopardized by the service method selected.
Customer Support: [email protected]
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PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
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