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1999 NISSAN FRONTIER D22 Series(2.4L KA Engine) Service Manual PDF DOWNLOAD
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1999 NISSAN FRONTIER D22 Series(2.4L KA Engine) Service Manual PDF DOWNLOAD
NISSAN FRONTIER D22 SERIES FOR THE VEHICLES EQIPPED WITH THE 2.4L, KA ENGINE
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Description
1999 NISSAN FRONTIER D22 Series(2.4L KA Engine) Service Manual PDF DOWNLOAD
FILE DETAILS:
1999 NISSAN FRONTIER D22 Series(2.4L KA Engine) Service Manual PDF DOWNLOAD
Language : English
Pages : 1489
Downloadable : Yes
File Type : PDF
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DESCRIPTION:
1999 NISSAN FRONTIER D22 Series(2.4L KA Engine) Service Manual PDF DOWNLOAD
FOREWORD
- This manual contains maintenance and repair procedure for the 1999 NISSAN FRONTIER FOR THE VEHICLES EQIPPED WITH THE 2.4L, KA ENGINE
- In order to assure your safety and the efficient functioning of the vehicle, this manual should be read thoroughly.
- It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task.
- All information in this manual is based on the latest product information at the time of publication. The right is reserved to make changes in specifications and methods at any time without notice.
IMPORTANT SAFETY NOTICE
- The proper performance of service is essential for both the safety of the technician and the efficient functioning of the vehicle.
- The service methods in this Service Manual are described in such a manner that the service may be performed safely and accurately.
- Service varies with the procedures used, the skills of the technician and the tools and parts available.
- Accordingly, anyone using service procedures, tools or parts which are not specifically recommended by NISSAN must first be completely satisfied that neither personal safety nor the vehicle’s safety will be jeopardized by the service method selected.
TABLE OF CONTENTS:
1999 NISSAN FRONTIER D22 Series(2.4L KA Engine) Service Manual PDF DOWNLOAD
NISSAN FRONTIER D22 SERIES FOR THE VEHICLES EQIPPED WITH THE 2.4L, KA ENGINE
fwd....................................................................................................... 1 QUICK REFERENCE INDEX................................................................................. 1 FOREWORD.............................................................................................. 2 GI - General Information.............................................................................. 0 MA - Maintenance...................................................................................... 0 EM - Engine Mechanical................................................................................ 0 LC - Engine Lubrication & Cooling System.............................................................. 0 EC - Engine Control System............................................................................ 0 FE - Accelerator Control, Fuel & Exhaust System....................................................... 0 CL - Clutch........................................................................................... 0 MT - Manual Transmission.............................................................................. 0 AT - Automatic Transmission........................................................................... 0 TF - Transfer......................................................................................... 0 PD - Propeller Shaft & Differential Carrier........................................................... 0 FA - Front Axle & Front Suspension.................................................................... 0 RA - Rear Axle & Rear Suspension...................................................................... 0 BR - Brake System..................................................................................... 0 ST - Steering System.................................................................................. 0 RS - Restraint System................................................................................. 0 BT - Body & Trim...................................................................................... 0 HA - Heating & Air Conditioner....................................................................... 0 EL - Electrical System................................................................................ 0 IDX - Alphabetical Index.............................................................................. 1 Foldout............................................................................................... 0 GST Mode 6 - Test Value & Test Limit ................................................................. 3 at........................................................................................................ 4 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents..................................................................................... 4 PRECAUTIONS AND PREPARATION........................................................................... 5 Supplemental Restraint System (SRS) "AIR BAG"..................................................... 5 Precautions....................................................................................... 5 Service Notice or Precautions..................................................................... 6 Special Service Tools............................................................................. 7 OVERALL SYSTEM........................................................................................ 9 Circuit Diagram................................................................................... 9 Wiring DIagram.................................................................................... 10 Cross-Sectional View.............................................................................. 12 Hydraulic COntrol Circuits........................................................................ 13 Shift Mechanism................................................................................... 15 TROUBLE DIAGNOSIS - Basic Inspection.................................................................. 26 Symptom Chart..................................................................................... 33 TROUBLE DIAGNOSIS FOR DTC P1550....................................................................... 37 Torque Converter Clutch Solenoid Valve............................................................ 37 TROUBLE DIAGNOSES..................................................................................... 39 Component Inspection.............................................................................. 39 TROUBLE DIAGNOSES - A/T Shilft Lock System............................................................ 42 Description....................................................................................... 42 Shift Lock System Electrical Parts Location....................................................... 42 Wiring DIagram.................................................................................... 43 Diagnostic Procedure.............................................................................. 44 Shift Lock Rod.................................................................................... 46 Component Check................................................................................... 47 ON-VEHICLE SERVICE.................................................................................... 48 Control Valve Assembly and Accumulators Removal................................................... 48 Rear Oil Seal Replacement......................................................................... 48 Parking Components Inspection..................................................................... 49 Governor Valve.................................................................................... 49 Throttle Wire Adjustment.......................................................................... 49 Park/Neutral Postions (PNP) Switch Adjustment..................................................... 50 Control Cable Adjustment.......................................................................... 50 REMOVAL AND INSTALLATION.............................................................................. 51 Removal........................................................................................... 52 Installation...................................................................................... 53 MAJOR OVERHAUL........................................................................................ 54 Oil Channel....................................................................................... 56 Locations of Needle Bearings, Thrust Washers and Snap of Rings.................................... 57 DISASSEMBLY........................................................................................... 58 REPAIR FOR COMPONENT PARTS............................................................................ 69 Oil Pump.......................................................................................... 69 Control Valve Assembly............................................................................ 73 Control Valve Upper Body.......................................................................... 78 Control Valve Lower Body.......................................................................... 82 Governor Valve Assembly........................................................................... 84 Parking Gear...................................................................................... 84 Reverse Clutch.................................................................................... 85 High Clutch....................................................................................... 89 Forward and Overrun Clutches...................................................................... 91 Low & Reverse Brake............................................................................... 95 Forward Clutch Drum Assembly...................................................................... 98 Rear Internal Gear and Forward Clutch Hub......................................................... 100 Band Servo Piston Assembly........................................................................ 102 Parking Pawl Components........................................................................... 106 ASSEMBLY.............................................................................................. 108 Assembly (1)...................................................................................... 108 Adjustment........................................................................................ 116 Assembly (2)...................................................................................... 118 SERVICE DATA AND SPECIFICATIONS (SDS)................................................................. 125 br........................................................................................................ 129 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents..................................................................................... 129 PRECAUTIONS AND PREPARATION........................................................................... 131 Supplemental Restraint System (SRS) "AIR BAG"..................................................... 131 Precautions for Brake System...................................................................... 132 Commercial Service Tools.......................................................................... 132 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING.................................................. 133 NVH Troubleshooting Chart......................................................................... 133 ON-VEHICLE SERVICE.................................................................................... 134 Checking Brake Fluid Level........................................................................ 134 Checking Brake Line............................................................................... 134 Changing Brake Fluid.............................................................................. 134 Brake Burnishing Procedure........................................................................ 134 Bleeding Brake System............................................................................. 135 BRAKE HYDRAULIC LINE.................................................................................. 136 CONTROL VALVE......................................................................................... 138 Load Sensing Valve (2WD).......................................................................... 138 BRAKE HYDRAULIC LINE/CONTROL VALVE.................................................................... 140 Proportioning Valve (4WD)......................................................................... 140 BRAKE PEDAL AND BRACKET............................................................................... 141 Removal and Installation.......................................................................... 141 Inspection........................................................................................ 142 Adjustment........................................................................................ 142 MASTER CYLINDER....................................................................................... 143 Removal........................................................................................... 143 Disassembly....................................................................................... 143 Inspection........................................................................................ 144 Assembly.......................................................................................... 144 Installation...................................................................................... 145 BRAKE BOOSTER......................................................................................... 146 On-vehicle Service................................................................................ 146 Removal........................................................................................... 146 Inspection........................................................................................ 146 Installation...................................................................................... 147 VACUUM HOSE........................................................................................... 148 Removal and Installation.......................................................................... 148 Inspection........................................................................................ 148 FRONT DISC BRAKE...................................................................................... 149 Pad Replacement................................................................................... 149 Removal........................................................................................... 150 Disassembly....................................................................................... 151 Inspection – Caliper.............................................................................. 151 Inspection – Rotor................................................................................ 151 Assembly.......................................................................................... 152 Installation...................................................................................... 152 REAR DRUM BRAKE....................................................................................... 153 Removal........................................................................................... 154 Inspection – Wheel Cylinder....................................................................... 155 Wheel Cylinder Overhaul........................................................................... 155 Inspection – Drum................................................................................. 155 Inspection – Lining............................................................................... 155 Installation...................................................................................... 155 PARKING BRAKE CONTROL................................................................................. 157 Removal and installation.......................................................................... 158 Inspection........................................................................................ 158 Adjustment........................................................................................ 158 ABS - 2WD............................................................................................. 159 REAR WHEEL ANTI-LOCK BRAKE SYSTEM................................................................. 159 Purpose....................................................................................... 159 Operation..................................................................................... 159 ABS Hydraulic Circuit......................................................................... 159 System Components............................................................................. 160 System Description............................................................................ 160 Removal and Installation...................................................................... 161 TROUBLE DIAGNOSES................................................................................. 163 How to Perform Trouble diagnoses for Quick and Accurate Repair................................ 163 Preliminary Check............................................................................. 165 Component Parts and Harness Connector Location................................................ 166 Schematic..................................................................................... 168 Wiring Diagram - ABS - ....................................................................... 169 Self-diagnosis................................................................................ 171 Main Power Supply and Ground Circuit Check.................................................... 174 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS....................................................... 175 Diagnostic Procedure 1........................................................................ 175 Diagnostic Proceudre 2........................................................................ 175 Diagnostic Procedure 3........................................................................ 176 Diagnostic Procedure 4........................................................................ 177 Diagnostic Procedure 5........................................................................ 177 Diagnostic Procedure 6........................................................................ 177 Diagnostic Procedure 7 (Warning lamp flashing 5).............................................. 178 TROUBLE DIAGNOSES FOR SYMPTOMS.................................................................... 179 Diagnostic Procedure 8 (ABS works frequently)................................................. 179 Diagnostic Procedure 9 (Brake pedal stroke is large).......................................... 180 Diagnostic Procedure 10 (Long stopping distance).............................................. 180 Diagnostic Procedure 11 (ABS does not work.).................................................. 181 Diagnostic Procedure 12 (Pedal vibration or noise)............................................ 181 Electrical Components Inspection.............................................................. 182 ABS - 4WD............................................................................................. 183 ANTI-LOCK BRAKE SYSTEM............................................................................ 183 Purpose....................................................................................... 183 Operation..................................................................................... 183 ABS Hydraulic Circuit......................................................................... 183 System Components............................................................................. 184 System Description............................................................................ 184 Removal and Installation...................................................................... 186 TROUBLE DIAGNOSES................................................................................. 189 How to Perform Trouble Diagnoses for Quick and Accurate Repair................................ 189 Preliminary Check............................................................................. 191 Component Parts and Harness Connector Location................................................ 192 Schematic..................................................................................... 193 Wiring Diagram - ABS -........................................................................ 194 Self-diagnosis................................................................................ 197 CONSULT....................................................................................... 200 CONSULT Inspection Procedure.................................................................. 201 Ground Circuit Check.......................................................................... 206 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS....................................................... 207 Diagnostic Procedure 1 (Wheel sensor or rotor)................................................ 207 Diagnostic Procedure 2 (ABS actuator solenoid valve and solenoid valve relay)................. 209 Diagnostic Procedure 3 (Motor relay or motor)................................................. 211 Diagnostic Procedure 4 (Low voltage).......................................................... 213 Diagnostic Procedure 5 (G sensor)............................................................. 214 Diagnostic Procedure 6 (Control unit)......................................................... 215 TROUBLE DIAGNOSES FOR SYMPTOMS.................................................................... 216 Diagnostic Procedure 7 (ABS works frequently.)................................................ 216 Diagnostic Procedure 8 (Unexpected pedal action).............................................. 217 Diagnostic Procedure 9 (Long stopping distance)............................................... 217 Diagnostic Procedure 10 (ABS does not work.).................................................. 218 Diagnostic Procedure 11 (Pedal vibration and noise)........................................... 218 Diagnostic Procedure 12 (Warning lamp does not come on when ignition switch is turned ON.).... 219 Diagnostic Procedure 13 (Warning lamp stays on when ignition switch is turned ON.)............ 221 Electrical Components Inspection.............................................................. 223 SERVICE DATA AND SPECIFICATIONS (SDS)................................................................. 224 General Specifications............................................................................ 224 Inspection and Adjustment......................................................................... 225 bt........................................................................................................ 226 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents..................................................................................... 226 PRECAUTIONS AND PREPARATION........................................................................... 227 Service Notice.................................................................................... 227 Supplemental Restraint System (SRS) "AIR BAG"..................................................... 227 GENERAL SERVICING..................................................................................... 228 Clip and Fastener................................................................................. 238 BODY END.............................................................................................. 230 Body Front End.................................................................................... 230 Removal - Front bumper assembly................................................................... 230 Body Rear End..................................................................................... 233 Removal - Rear bumper assembly.................................................................... 233 DOOR.................................................................................................. 235 Front Door........................................................................................ 235 INSTRUMENT PANEL...................................................................................... 236 Removal - Instrument panel assembly............................................................... 236 INTERIOR TRIM......................................................................................... 239 Side and Floor Trim............................................................................... 239 Removal - Body side trim.......................................................................... 239 King cab model.................................................................................... 239 Standard cab model............................................................................... 239 Door trim......................................................................................... 242 Removal........................................................................................... 242 Door trim (Formed type)........................................................................... 242 Roof Trim......................................................................................... 245 Removal - Headlining.............................................................................. 245 EXTERIOR.............................................................................................. 247 1 Hood front sealing rubber....................................................................... 248 2 Cowl top seal and cowl top grille............................................................... 248 3 Windshield side molding......................................................................... 248 4 Windshield upper molding....................................................................... 248 5 Sunroof weatherstrip and lid protector.......................................................... 248 6 Drip weatherstrip............................................................................... 249 7 Body side welt.................................................................................. 249 8 Door weatherstrip............................................................................... 249 9 Door outside molding............................................................................ 249 10 Drafter duct................................................................................... 250 11 Over fender.................................................................................... 250 12 Rear combination lamp.......................................................................... 250 SEAT.................................................................................................. 251 Front Seat........................................................................................ 251 Jump Seat- King Cab Model......................................................................... 254 SUNROOF............................................................................................... 255 WINDSHIELD AND WINDOWS................................................................................ 256 Windshield........................................................................................ 257 Side Window....................................................................................... 257 Back Window....................................................................................... 258 Rearview Mirror................................................................................... 259 MIRROR................................................................................................ 260 Door Mirror....................................................................................... 260 Removal - Door mirror............................................................................. 260 CAB AND REAR BODY..................................................................................... 261 Body Mounting..................................................................................... 261 BODY ALIGNMENT........................................................................................ 262 Engine Compartmennt............................................................................... 263 Measurement....................................................................................... 263 Measurement Points................................................................................ 264 Underbody......................................................................................... 265 Measurement....................................................................................... 265 2WD-4WD (Short wheelbase) models.................................................................. 265 Measurement Points................................................................................ 266 2WD-4WD (Short wheelbase) models.................................................................. 266 Measurement....................................................................................... 267 2WD-4WD (long wheelbase) models................................................................... 267 Measurement Points................................................................................ 268 2WD-4WD (Long wheelbase) models................................................................... 268 cl........................................................................................................ 269 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents..................................................................................... 269 PRECAUTIONS AND PREPARATION........................................................................... 270 Precautions....................................................................................... 270 Special Service Tools............................................................................. 270 Commercial Service Tools.......................................................................... 270 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING.................................................. 271 NVH Troubleshooting Chart......................................................................... 271 CLUTCH SYSTEM......................................................................................... 272 Clutch Pedal...................................................................................... 273 INSPECTION AND ADJUSTMENT............................................................................. 274 Adjusting Clutch Pedal............................................................................ 274 Air Bleeding Procedure............................................................................ 275 HYDRAULIC CLUCTCH CONTROL............................................................................. 276 Clutch Master Cylinder (With clutch damper)....................................................... 276 Operating Cylinder................................................................................ 277 CLUTCH RELEASE MECHANISM.............................................................................. 278 CLUTCH DISC AND CLUTCH COVER.......................................................................... 281 Clutch Disc....................................................................................... 281 Clutch Cover and Flywheel......................................................................... 282 SERVICE DATA AND SPECIFICATIONS (SDS)................................................................. 283 General Specifications............................................................................ 283 Clutch Control System......................................................................... 283 Inspection and Adjustment......................................................................... 283 ec........................................................................................................ 284 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents..................................................................................... 284 DIAGNOSTIC TROUBLE CODE INDEX......................................................................... 287 Alphabetical & P No. Index for DTC................................................................ 287 PRECAUTIONS AND PREPARATION........................................................................... 289 Special Service Tools............................................................................. 289 Commercial Service Tools.......................................................................... 289 Supplemental Restraint System (SRS) "AIR BAG"..................................................... 290 Precautions for On Board Diagnostics (OBD) System of Engine....................................... 290 Engine Fuel & Emission Control System............................................................. 291 Precautions....................................................................................... 292 ENGINE AND EMISSION CONTROL OVERALL SYSTEM............................................................ 294 Circuit Diagram................................................................................... 294 Engine Control Component Parts Location........................................................... 295 System Diagram.................................................................................... 297 Vacuum Hose Drawing............................................................................... 298 System Chart...................................................................................... 297 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION.................................................. 300 Multiport Fuel Injection (MFI) System............................................................. 300 Distributor Ignition (DI) System.................................................................. 302 Air Conditioning Cut Control...................................................................... 303 Fuel Cut Control.................................................................................. 304 EVAPORATIVE EMISSION SYSTEM........................................................................... 305 Description....................................................................................... 305 Inspection........................................................................................ 305 Evaporative Emission Line Drawing................................................................. 308 POSITIVE CRANKCASE VENTILATION........................................................................ 310 Description....................................................................................... 310 Inspection........................................................................................ 310 BASIC SERVICE PROCEDURE............................................................................... 311 Fuel Pressure Release............................................................................. 311 Fuel Pressure Check............................................................................... 311 Fuel Pressure Regulator Check..................................................................... 311 Injector Removal and Installation................................................................. 312 Fast Idle Cam (FIC)............................................................................... 313 Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment.......................................... 314 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION................................................................ 320 Introduction...................................................................................... 320 Two Trip Detection Logic.......................................................................... 320 Emission-related Diagnostic Information........................................................... 321 Malfunction Indicator Lamp (MIL).................................................................. 331 OBD System Operation Chart........................................................................ 334 CONSULT........................................................................................... 339 Generic Scan Tool (GST)........................................................................... 350 TROUBLE DIAGNOSIS - Introduction...................................................................... 352 Introduction...................................................................................... 352 Diagnostic Worksheet.............................................................................. 352 TROUBLE DIAGNOSIS - Work Flow......................................................................... 354 Work Flow......................................................................................... 354 Description of Work Flow.......................................................................... 355 TROUBLE DIAGNOSIS - Basic Inspection.................................................................. 356 Basic Inspection.................................................................................. 356 TROUBLE DIAGNOSIS - General Description............................................................... 362 Diagnostic trouble Code (DTC) Inspection Priority Chart........................................... 362 Fail-Safe Chart................................................................................... 363 Symptom Matrix Chart.............................................................................. 364 CONSULT Reference Value in Data Monitor Mode...................................................... 367 Major Sensor Reference Graph in Data Monitor Mode................................................. 369 ECM Terminals and Reference Value................................................................. 371 TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT........................................................... 380 Description....................................................................................... 380 Common I/I Report Situations...................................................................... 380 Diagnostic Procedure.............................................................................. 380 TROUBLE DIAGNOSIS FOR POWER SUPPLY.................................................................... 381 Main Power Supply and Ground Circuit.............................................................. 381 DTC P0100, Mass Air Flow Sensor (MAFS)................................................................ 386 DTC P0105, Absolute Pressure Sensor................................................................... 397 DTC P0110, Intake Air Temperature Sensor.............................................................. 402 DTC P0115, Engine Coolant Temperature Sensor (ECTS) (Circuit)......................................... 408 DTC P0120, Throttle Position Sensor................................................................... 413 DTC P0125, Engine Coolant Temperature (ECT) Sensor.................................................... 427 DTC P0130, Front Heated Oxygen Sensor (Circuit) (Front HO2S).......................................... 432 DTC P0131, Front Heated Oxygen Sensor (Lean Shift Monitoring) (Front HO2S)............................ 438 DTC P0132, Front Heated Oxygen Sensor (Rich Shift Monitoring) (Front HO2S)............................ 444 DTC P0133, Front Heated Oxygen Sensor (Response Monitoring) (Front HO2S).............................. 450 DTC P0134, Front Heated Oxygen Sensor (High Voltage) (Front HO2S)..................................... 458 DTC P0135, Front Heated Oxygen Sensor Heater.......................................................... 464 DTC P0137, Rear Heated Oxygen Sensor (Min. Voltage Monitoring) (Rear HO2S)........................... 468 DTC P0138, Rear Heated Oxygen Sensor (Max. Voltage Monitoring) (Rear HO2S)........................... 475 DTC P0139, Rear Heated Oxygen Sensor (Response Monitoring) (Rear HO2S)................................ 482 DTC P0140, Rear Heated Oxygen Sensor (High Voltage) (Rear HO2S)....................................... 489 DTC P0141, Rear Heated Oxygen Sensor Heater........................................................... 494 DTC P0171, Fuel Injection System Function (Lean side)................................................. 498 DTC P0172, Fuel Injection System Function (Rich side)................................................. 503 DTC P0180, Tank Fuel Temperature Sensor............................................................... 508 DTC P0300 - P0304, No. 4 - 1 Cylinder Misfire, Multiple Cylinder Misfire.............................. 512 DTC P0325, Knock Sensor (KS).......................................................................... 517 DTC P0335, Crankshaft Position Sensor (CKPS) (OBD).................................................... 521 DTC P0340, Camshaft Position Sensor (CMPS)............................................................ 526 DTC P0400, EGR Function (Close)....................................................................... 532 DTC P0402, EGRC-BPT Valve Function.................................................................... 540 DTC P0420, Three Way Catalyst Function................................................................ 545 DTC P0440, Evaporative Emission (EVAP) Control System (Small Leak) (Negative Pressure)................ 550 DTC P0443, Evaporative Emission (EVAP) Canister Purge Volume Control Solenoid Valve (Circuit)......... 560 DTC P0446, Evaporative Emission (EVAP) Canister Vent Control Valve (Circuit).......................... 566 DTC P0450, Evaporative Emission (EVAP) Control System Pressure Sensor................................. 571 DTC P0500, Vehicle Speed Sensor (VSS)................................................................. 577 DTC P0505, Idle Air Control Valve (IACV) - Auxiliary Air Control (AAC) Valve.......................... 582 DTC P0510, Closed Throttle Position Switch............................................................ 588 DTC P0605, Engine Control Module (ECM)................................................................ 594 DTC P1105, Manifold Absolute Pressure (MAP)/Barometric Pressure (BARO) Switch Solenoid Valve.......... 596 DTC P1148, Closed Loop Control........................................................................ 605 DTC P1320, Ignition SIgnal............................................................................ 607 DTC P1336, Crankshaft Position Sensor (CRPS) (OBD) (COG).............................................. 614 DTC P1400, EGRC-Solenoid Valve........................................................................ 617 DTC P1401, EGR Temperature Sensor..................................................................... 624 DTC P1402, EGR Function (Open)........................................................................ 630 DTC P1440, Evaporative Emission (EVAP) Control System (Small Leak) (Positive Pressure)................ 637 DTC P1444, Evaporative Emission (EVAP) Canister Purge Volume Control Solenoid Valve................... 647 DTC P1446, Evaporative Emission Emission (EVAP) Canister Vent Control Valve (Close)................... 655 DTC P1447, Evaporative Emission (EVAP) Control System Purge Flow Monitoring........................... 660 DTC P1448, Evaporative Emission (EVAP) Canister Vent Control Valve (Open)............................. 666 DTC P1490, Vacuum Cut Valve Bypass Valve (Circuit).................................................... 671 DTC P1491, Vacuum Cut Valve Bypass Valve.............................................................. 676 DTC P1706, Park/Neutral Position (PNP) Switch......................................................... 681 DTC P1775 Torque Converter Clutch Solenoid Valve (Circuit)............................................ 686 DTC P1776 Torque Converter Clutch Solenoid Valve...................................................... 690 TROUBLE DIAGNOSIS FOR OVERHEAT........................................................................ 694 Overheat.......................................................................................... 694 TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS............................................................ 697 Injector.......................................................................................... 697 Start Signal...................................................................................... 700 Fuel Pump......................................................................................... 703 Power Steering Oil Pressure Switch................................................................ 708 IACV-FICD Solenoid Valve.......................................................................... 713 MIL & Data Link Connectors........................................................................ 715 SERVICE DATA AND SPECIFICATIONS (SDS)................................................................. 716 General Specifications............................................................................ 716 Inspection and Adjustment......................................................................... 716 el........................................................................................................ 718 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents..................................................................................... 718 PRECAUTIONS AND PREPARATION........................................................................... 721 Supplemental Restraint System (SRS) "AIR BAG"..................................................... 721 HARNESS CONNECTOR..................................................................................... 722 Description....................................................................................... 722 STANDARDIZED RELAY.................................................................................... 724 Description....................................................................................... 724 POWER SUPPLY ROUTING.................................................................................. 727 Schematic......................................................................................... 727 Wiring Diagram-POWER-............................................................................. 729 Fuse.............................................................................................. 734 Fusible Link...................................................................................... 734 Circuit Breaker Inspection........................................................................ 734 GROUND DISTRIBUTION................................................................................... 735 Main Harness...................................................................................... 735 Engine Room Harness............................................................................... 738 Engine Control Harness............................................................................ 740 Engine No. 2 Harness.............................................................................. 741 BATTERY............................................................................................... 742 How to Handle Battery............................................................................. 742 Service Data and Specifiactions (SDS)............................................................. 745 STARTING SYSTEM....................................................................................... 746 System Description................................................................................ 746 Wiring Diagram –START–............................................................................ 748 Construction...................................................................................... 750 Removal and Installation.......................................................................... 752 Pinion/Clutch Check.............................................................................. 752 Service Data and Specifications (SDS)............................................................. 752 CHARGING SYSTEM....................................................................................... 753 System Description................................................................................ 753 Wiring Diagram -CHARGE-........................................................................... 754 Trouble Diagnoses................................................................................. 755 Constuction....................................................................................... 756 Removal and Installation.......................................................................... 757 Service Data and Specifications (SDS)............................................................. 757 COMBINATION SWITCH.................................................................................... 758 Check............................................................................................. 758 Replacement....................................................................................... 759 STEERING SWITCH....................................................................................... 760 Check............................................................................................. 760 HEADLAMP.............................................................................................. 761 System Description (For USA)..................................................................... 761 Wiring Diagram (For USA) -H/LAMP-................................................................. 762 Trouble Diagnoses................................................................................. 763 Bulb Replacment................................................................................... 764 Aiming Adjustment................................................................................. 764 HEADLAMP-Daytime Light System-........................................................................ 767 System Description (For Canada)................................................................... 767 Operation (For Canada)............................................................................ 768 Schematic (For Canada)............................................................................ 769 Wiring Diagram (For Canada) -DTRL-................................................................ 770 Trouble Diagnoses (For Canada).................................................................... 773 Bulb Replacement.................................................................................. 774 Aiming Adjustment................................................................................. 774 PARKING, LICENSE AND TAIL LAMPS....................................................................... 775 Wiring Diagram -TAIL/L-........................................................................... 775 STOP LAMP............................................................................................. 777 Wiring Diagram -STOP/L-........................................................................... 777 BACK-UP LAMP.......................................................................................... 778 Wiring Diagram -BACK/L-........................................................................... 778 FRONT FOG LAMP........................................................................................ 779 System Description................................................................................ 779 Wiring Diagram -F/FOG-............................................................................ 780 Aiming Adjustment................................................................................. 781 Removal and Installation.......................................................................... 782 Bulb and Lens Replacement......................................................................... 782 TURN SIGNAL AND HAZARD WARNING LAMPS.................................................................. 783 System Description................................................................................ 783 Wiring Diagram -TURN-............................................................................. 785 Trouble Diagnoses................................................................................. 787 Electrical Components Inspection.................................................................. 787 ILLUMINATION.......................................................................................... 788 System Description................................................................................ 788 Wiring Diagram -ILL-.............................................................................. 789 INTERIOR ROOM LAMP.................................................................................... 790 Component Parts and Harness Connector Location.................................................... 790 System Description................................................................................ 791 Wiring Diagram-ROOM/L-............................................................................ 793 Trouble Diagnoses (For model with power door locks).............................................. 795 SPOT LAMP............................................................................................. 797 Wiring Diagram-INT/L-............................................................................. 797 METER AND GAUGES...................................................................................... 798 Component Parts and Harness Connector Location.................................................... 798 System Description................................................................................ 799 Unified Control Meter............................................................................. 799 How To Change The Display For Odo/Trip Meter...................................................... 799 Combination Meter................................................................................. 801 With Tachometer................................................................................... 801 Without Tachometer................................................................................ 802 Wiring Diagram-METER-............................................................................. 803 Meter/gauge Operation and Odo/Trip Meter.......................................................... 804 Segment Check in Diagnoses Mode................................................................... 804 Diagnosis Fuction................................................................................. 804 How To Alternate Diagnosis Mode................................................................... 804 Flexible Print Circuit (FPC)...................................................................... 805 Disconnect........................................................................................ 805 Connect........................................................................................... 805 Trouble Diagnoses................................................................................. 806 Preliminary Check................................................................................. 806 Symptom Chart 1 (Malfunction is indicated in diagnosis mode)...................................... 807 Symptom Chart 2 ( No malfunction is indicated in diagnosis mode).................................. 807 Power Supply And Ground Circuit Check............................................................. 808 Inspection/Vehicle Speed Sensor................................................................... 809 Inspection/Engine Revolution Signal (Models with tachometer)...................................... 809 Inspection/Fuel Tank Gauge........................................................................ 810 Inspection/Thermal Transmitter.................................................................... 810 Electrical Components Inspection.................................................................. 811 Meter/Gauge Resistance Check...................................................................... 811 Fuel tank Gauge Unit Check........................................................................ 811 Thermal Transmitter Check......................................................................... 812 Vehicle Speed Sensor Signal Check................................................................. 812 WARNING LAMPS......................................................................................... 813 System Description................................................................................ 813 Schematic......................................................................................... 815 Wiring Diagram -WARN-............................................................................. 816 Electrical Components Inspection.................................................................. 819 A/T INDICATOR......................................................................................... 820 Wiring Diagram-AT/IND-............................................................................ 820 WARNING CHIME......................................................................................... 821 Component Parts and Harness Connector Location.................................................... 821 System Description................................................................................ 822 Wiring diagram-CHIME-............................................................................. 824 Trouble Diagnoses................................................................................. 826 Electrical Components Inspection.................................................................. 832 FRONT WIPER AND WASHER................................................................................ 833 System Description................................................................................ 833 Wiring Diagram-WIPER-............................................................................. 835 Trouble Diagnoses (With intermittent wipers)...................................................... 837 Removal and Installation.......................................................................... 839 Washer Nozzle Adjustment.......................................................................... 840 Washer Tube Layout................................................................................ 840 HORN.................................................................................................. 841 Wiring diagram-HORN-.............................................................................. 841 CIGARETTE LIGHTER..................................................................................... 842 Wiring Diagram -CIGAR-............................................................................ 842 AUDIO................................................................................................. 843 System Description................................................................................ 843 Base Audio System................................................................................. 843 Premium Audio System.............................................................................. 843 Wiring Diagram-AUDIO-............................................................................. 844 Trouble Diagnoses................................................................................. 847 Inspection........................................................................................ 848 AUDIO ANTENNA......................................................................................... 849 Fixed Antenna Rod Replacement..................................................................... 849 Removal........................................................................................... 849 Installation...................................................................................... 849 POWER DOOR MIRROR..................................................................................... 850 Wiring Diagram-MIRROR-............................................................................ 850 AUTOMATIC SPEED CONTRL DEVICE (ASCD).................................................................. 851 Component Parts and Harness Connector Location.................................................... 851 System Description................................................................................ 852 Schematic......................................................................................... 854 Wiring Diagram-ASCD-.............................................................................. 855 Fail-Safe System Description...................................................................... 859 Fail-Safe System Check............................................................................ 860 Trouble Diagnoses................................................................................. 861 ASCD Wire Adjustment.............................................................................. 869 Electrical Components Inspection.................................................................. 870 POWER WINDOW.......................................................................................... 871 System Description................................................................................ 871 Wiring diagram-WINDOW-............................................................................ 873 Trouble Diagnoses................................................................................. 875 POWER DOOR LOCKS...................................................................................... 876 Component Parts and Harness Connector Location.................................................... 876 System Description................................................................................ 877 Schematic......................................................................................... 879 Wiring Diagram-D/LOCK-............................................................................ 880 Trouble Diagnoses................................................................................. 883 MULTI-REMOTE CONTROL SYSTEM........................................................................... 891 Component Parts and Harness Connector Location.................................................... 891 System Description................................................................................ 892 Schematic......................................................................................... 894 Wiring Diagram-MULTI-............................................................................. 895 Trouble Diagnoses................................................................................. 898 Electrical Components Inspection.................................................................. 904 ID Code Entry Procedure........................................................................... 905 THEFT WARNING SYSTEM.................................................................................. 906 Component Parts and Harness Connector Location.................................................... 906 System Description................................................................................ 908 Schematic......................................................................................... 911 Wiring Diagram-THEFT-............................................................................. 912 Trouble Diagnoses................................................................................. 915 SMART ENTRANCE CONTROL UNIT........................................................................... 926 Description....................................................................................... 926 Input/Output Operation Signal..................................................................... 927 Schematic......................................................................................... 929 LOCATION OF ELECTRICAL UNITS.......................................................................... 931 Engine Compartment................................................................................ 931 Passenger Compartment............................................................................. 932 HARNESS LAYOUT........................................................................................ 934 Outline........................................................................................... 934 How to Read Harness Layout........................................................................ 935 Main Harness...................................................................................... 937 Engine Room Harness............................................................................... 939 Engine Control Harness............................................................................ 943 Engine No. 2 Harness.............................................................................. 945 Chassis and Tail Harness.......................................................................... 947 Room Lamp Harness................................................................................. 948 Door Harness...................................................................................... 949 Air Bag Harness................................................................................... 950 BULB SPECIFICATIONS................................................................................... 951 Headlamp.......................................................................................... 951 Exterior Lamp..................................................................................... 951 Interior Lamp..................................................................................... 951 WIRING DIAGRAM CODES (CELL CODES)..................................................................... 952 em........................................................................................................ 953 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents..................................................................................... 953 PRECAUTIONS AND PREPARATION........................................................................... 954 Supplemental Restraint System (SRS) "AIR BAG"..................................................... 954 Parts Requiring Angular Tightening............................................................... 954 Liquid Gasket Application Procedure............................................................... 954 Special Service Tools............................................................................. 956 Commercial Service Tools.......................................................................... 959 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING.................................................. 960 NVH Troubleshooting Chart - Engine Noise.......................................................... 961 OUTER COMPONENTS PARTS................................................................................ 962 COMPRESSION PRESSURE.................................................................................. 965 Measurement of Compression Pressure............................................................... 965 OIL PAN............................................................................................... 966 Removal........................................................................................... 966 Installation...................................................................................... 967 TIMING CHAIN.......................................................................................... 968 Removal........................................................................................... 970 Upper Timing Chain............................................................................ 970 Lower Timing Chain............................................................................ 972 Inspection........................................................................................ 973 Installation...................................................................................... 973 Lower Timing Chain............................................................................ 973 Upper Timing Chain............................................................................ 974 OIL SEAL REPLACEMENT.................................................................................. 977 Valve Oil Seal.................................................................................... 977 Oil Seal Installing Direction..................................................................... 977 Front Oil Seal.................................................................................... 977 Rear Oil Seal..................................................................................... 978 CYLINDER HEAD......................................................................................... 980 Removal and Installation.......................................................................... 981 Disassembly....................................................................................... 981 Inspection........................................................................................ 982 Assembly.......................................................................................... 987 Valve Clearance................................................................................... 987 Checking...................................................................................... 987 Adjusting..................................................................................... 988 ENGINE REMOVAL........................................................................................ 990 Removal........................................................................................... 991 Installation...................................................................................... 992 CYLINDER BLOCK........................................................................................ 993 Disassembly....................................................................................... 994 Inspection........................................................................................ 994 Assembly..........................................................................................1000 SERVICE DATA AND SPECIFICATION (SDS)..................................................................1004 General Specifications............................................................................1004 Compression Pressure..........................................................................1004 Inspection and Adjustment.........................................................................1004 Cylinder Head.................................................................................1004 Valve.........................................................................................1004 Camshaft and Camshaft Bearing.................................................................1008 Piston, Piston Ring and Piston Pin............................................................1009 Connecting Rod................................................................................1009 fa........................................................................................................1012 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents.....................................................................................1012 PRECAUTIONS AND PREPARATION...........................................................................1013 Precautions.......................................................................................1013 Special Service Tools.............................................................................1013 Commercial Service Tools..........................................................................1014 NOISE, VIBRATION AND NOISE (NVH) TROUBLESHOOTING......................................................1015 NVH Troubleshooting...............................................................................1015 FRONT SUSPENSION SYSTEM...............................................................................1016 2WD...............................................................................................1016 4WD...............................................................................................1017 ON-VEHICLE SERVICE....................................................................................1018 Front Axle and Front Suspension...................................................................1018 Front Wheel Bearing...............................................................................1018 Front Wheel Alignment.............................................................................1020 Drive Shaft.......................................................................................1024 FRONT AXLE............................................................................................1025 Manual-lock Free-running Hub -- 4WD --............................................................1027 Auto-lock Free-running Hub -- 4WD --..............................................................1028 Wheel Hub and Rotor Disc..........................................................................1028 Knuckle Spindle...................................................................................1030 Drive Shaft -- 4WD --.............................................................................1033 FRONT SUSPENSION......................................................................................1038 Shock Absorber....................................................................................1040 Torsion Bar Spring................................................................................1040 Stabilizer Bar....................................................................................1042 Upper Link........................................................................................1043 Tension Rod.......................................................................................1044 Lower Link........................................................................................1045 Upper Ball Joint and Lower Ball Joint.............................................................1046 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................1047 General Specifications............................................................................1047 Inspection and Adjustment.........................................................................1047 fe........................................................................................................1051 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents.....................................................................................1051 PREPARATION...........................................................................................1052 Special Service Tool..............................................................................1052 ACCELERATOR CONTROL SYSTEM............................................................................1053 Adjusting Accelerator Wire........................................................................1053 FUEL SYSTEM...........................................................................................1054 Fuel Tank.........................................................................................1054 Fuel Pump and Gauge...............................................................................1057 EXHAUST SYSTEM........................................................................................1058 foldout...................................................................................................1061 QUICK REFERENCE INDEX................................................................................. 0 gi........................................................................................................1067 QUICK REFERENCE GUIDE................................................................................. 0 Table of Contents.....................................................................................1067 PRECAUTIONS AND PREPARATION...........................................................................1068 Supplemental Restraint System (SRS) "AIR BAG".....................................................1068 General Precautions...............................................................................1069 Precautions for Multiport Fuel Injection System or Engine Control System..........................1071 Precautions for Three Way Catalyst................................................................1071 Precautions for Engine Oils.......................................................................1071 Precautions for Fuel..............................................................................1072 Precautions for Air Conditioning..................................................................1072 HOW TO USE THIS MANUAL................................................................................1073 HOW TO READ WIRING DIAGRAM............................................................................1075 Sample/Wiring Diagram - EXAMPL -..................................................................1075 Description.......................................................................................1077 HOW TO CHECK TERMINAL.................................................................................1083 Connector and Terminal Pin Kit....................................................................1083 How to Probe Connectors...........................................................................1083 How to Check Enlarged Contact Spring of Terminal..................................................1084 Waterproof Connector Inspection...................................................................1085 Terminal Lock Inspection..........................................................................1085 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT.........................................1086 Work Flow.........................................................................................1086 Incident Simulation Tests.........................................................................1087 Circuit Inspection................................................................................1089 Control Unit Circuit Test.........................................................................1095 HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES.........................................................1096 How to Follow This Flow Chart.....................................................................1097 CONSULT CHECKING SYSTEM...............................................................................1099 Function and System Application...................................................................1099 Lithium Battery Replacement.......................................................................1099 Checking Equipment................................................................................1099 Loading Procedures................................................................................1100 CONSULT Data Link Connector (DLC) Circuit.........................................................1100 IDENTIFICATION INFORMATION............................................................................1101 Model Variation...................................................................................1101 Identification Number.............................................................................1103 Dimensions........................................................................................1105 Wheels and Tires..................................................................................1105 LIFTING POINTS AND TOW TRUCK TOWING...................................................................1106 Pantograph Jack...................................................................................1106 Garage Jack and Safety Stand......................................................................1107 2-pole Lift.......................................................................................1108 Tow Truck Towing..................................................................................1109 2-WHEEL DRIVE MODELS..........................................................................1109 4-WHEEL DRIVE MODELS..........................................................................1110 Towing Point......................................................................................1111 Vehicle Recovery (Freeing a stuck vehicle)....................................................1111 TIGHTENING TORQUE OF STANDARD BOLTS...................................................................1112 SAE J1930 TERMINOLOGY LIST............................................................................1113 ha........................................................................................................1117 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents.....................................................................................1117 PRECAUTIONS AND PREPARATION...........................................................................1118 Supplemental Restraint System (SRS) "AIR BAG".....................................................1118 Precuations for Working with R-134a...............................................................1118 Contaminated Refrigerant......................................................................1119 General Refrigerant Precautions...................................................................1119 Precautions for Refrigerant Connection............................................................1120 Precautions for Servicing Compressor..............................................................1123 R-134a Service Tools and Equipment................................................................1124 Special Service Tools.............................................................................1126 Commercial Service Tools..........................................................................1126 Precautions for Service Equipment.................................................................1127 DESCRIPTION...........................................................................................1129 Refrigeration Cycle...............................................................................1129 Control Operation.................................................................................1130 Component Layout..................................................................................1131 Discharge Air Flow................................................................................1132 Component Location................................................................................1133 Circuit Diagram...................................................................................1135 Wiring Diagram - HEATER-..........................................................................1136 Wiring Diagram - A/C-.............................................................................1137 Operational Check.................................................................................1139 TROUBLE DIAGNOSES.....................................................................................1141 How to Perform Trouble Diagnoses for Quick and Accurate Repair....................................1141 Blower Motor Circuit..............................................................................1142 Air Outlet........................................................................................1146 Intake Door.......................................................................................1148 Magnet Clutch Circuit.............................................................................1149 Trouble Diagnosis Procedure For Insufficient Cooling..............................................1155 Performance Test Diagnoses........................................................................1157 Performance Chart.................................................................................1159 Trouble Diagnoses for Abnormal Pressure...........................................................1160 Trouble Diagnosis for Insufficient Heating .......................................................1163 Troulble Diagnosis for Noise......................................................................1165 SERVICE PROCEDURES....................................................................................1166 Refrigerant Lines.................................................................................1166 Checking Refrigerant Leaks........................................................................1167 R-134a Service Procedure..........................................................................1170 Compressor Lubricant Quantity.....................................................................1172 Compressor Mounting...............................................................................1174 Belt Tension......................................................................................1174 Fast Idle Control Device (FICD)...................................................................1174 Condenser.........................................................................................1174 Compressor........................................................................................1175 Compressor Clutch.................................................................................1175 Thermal Protector.................................................................................1178 Heater Unit (Heater Core).........................................................................1179 Cooling Unit (A/C Evaporator).....................................................................1180 Blower Case and Motor.............................................................................1181 Fan Lever and Illumination Bulbs..................................................................1182 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................1183 General Specifications............................................................................1183 Inspection and Adjustment.........................................................................1183 idx.......................................................................................................1184 QUICK REFERENCE INDEX................................................................................. 0 lc........................................................................................................1193 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents.....................................................................................1193 PRECAUTIONS AND PREPARATION...........................................................................1194 Supplemental Restraint System (SRS) "AIR BAG".....................................................1194 Liquid Gasket Application Procedure...............................................................1194 Special Service Tools.............................................................................1195 ENGINE LUBRICATION SYSTEM.............................................................................1196 Lubrication Circuit...............................................................................1196 Oil Pressure Check................................................................................1197 Oil Pump..........................................................................................1197 ENGINE COOLING SYSTEM.................................................................................1196 Cooling Circuit...................................................................................1199 System Check......................................................................................1199 Water Pump........................................................................................1201 Removal.......................................................................................1201 Thermostat........................................................................................1202 Radiator..........................................................................................1203 Cooling Fan (Crankshaft driven)...................................................................1204 Inspection....................................................................................1204 Refilling engine coolant..................................................................1204 Radiator (Aluminum type)..........................................................................1205 Inspection....................................................................................1205 Overheating Cause Analysis........................................................................1206 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................1207 Engine Lubrication System.........................................................................1207 Engine Cooling System.............................................................................1207 ma........................................................................................................1208 QUICK REFERENCE INDEX................................................................................ 0 Table of Contents.....................................................................................1208 PRECAUTIONS AND PREPARATION...........................................................................1209 Supplemental Restraint System (SRS) "AIR BAG".....................................................1209 Special Service Tool..............................................................................1209 Commercial Service Tool...........................................................................1209 GENERAL MAINTENANCE...................................................................................1210 PERIODIC MAINTENANCE..................................................................................1212 Schedule 1........................................................................................1213 Schedule 2........................................................................................1214 RECOMMENDED FLUIDS AND LUBRICANTS.....................................................................1215 Fluids and Lubricants.............................................................................1215 SAE Viscosity Number..............................................................................1216 Antifreeze Coolant Mixture Ratio..................................................................1216 ENGINE MAINTENANCE....................................................................................1217 Checking Drive Belts..............................................................................1217 Changing Engine Coolant...........................................................................1219 -DRAINING ENGINE COOLANT-.....................................................................1219 -REFILLING ENGINE COOLANT-....................................................................1219 -FLUSHING COOLING SYSTEM-.....................................................................1220 Checking Fuel Lines...............................................................................1221 Changing Fuel Filter..............................................................................1221 Changing Air Cleaner Filter.......................................................................1221 Changing Engine Oil...............................................................................1222 Changing Oil Filter...............................................................................1222 Changing Spark Plugs..............................................................................1223 Checking EVAP Vapor Lines.........................................................................1224 CHASSIS AND BODY MAINTENANCE..........................................................................1225 Checking Exhaust System...........................................................................1225 Checking Clutch Fluid Level and Leaks.............................................................1225 Checking M/T Oil..................................................................................1225 Changing M/T Oil..................................................................................1225 Checking Water Entry - For 4WD models.............................................................1225 Checking A/T Fluid................................................................................1225 Changing A/T Fluid................................................................................1226 Checking Transfer Fluid...........................................................................1226 Changing Transfer Fluid...........................................................................1227 Checking Propeller Shaft..........................................................................1227 Checking Differential Gear Oil....................................................................1227 Changing Differential Gear Oil....................................................................1228 Balancing Wheels..................................................................................1228 Tire Rotation.....................................................................................1228 Checking Brake Fluid Level and Leaks..............................................................1229 Checking Brake System.............................................................................1229 Checking Disc Brake...............................................................................1229 Checkiing Drum Brake..............................................................................1229 Checking Steering Gear Oil Level and Leaks........................................................1230 Lubricating Hood Latches, Locks and Hinges........................................................1231 Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters...................................1232 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................1233 Engine Maintenance................................................................................1233 Chassis and Body Maintenance......................................................................1233 mt........................................................................................................1234 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents.....................................................................................1234 PREPARATION...........................................................................................1235 Special Service Tools.............................................................................1235 Commercial Service Tools..........................................................................1236 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING..................................................1237 NVH Troubleshooting Chart.........................................................................1237 DESCRIPTION...........................................................................................1238 Cross-sectional View -- 2WD Model --..............................................................1238 Cross-sectional View -- 4WD Model --..............................................................1239 ON-VEHICLE SERVICE....................................................................................1240 Replacing Rear Oil Seal -- 2WD Model --...........................................................1240 Position Switch Check.............................................................................1240 REMOVAL AND INSTALLATION..............................................................................1241 MAJOR OVERHAUL........................................................................................1244 Case Components...................................................................................1244 Gear Components -- 2WD Model --...................................................................1245 Gear Components -- 4WD Model --...................................................................1246 Shift Control Components..........................................................................1247 DISASSEMBLY...........................................................................................1248 Case Components...................................................................................1248 Shift Control Components..........................................................................1248 Gear Components...................................................................................1249 INSPECTION............................................................................................1252 Shift Control Components..........................................................................1252 Gear Components...................................................................................1252 Gears And Shafts..............................................................................1252 Synchronizers.................................................................................1252 Bearings......................................................................................1253 ASSEMBLY..............................................................................................1254 Gear Components...................................................................................1254 Shift Control Components..........................................................................1260 Case Components...................................................................................1261 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................1264 General Specifications............................................................................1264 Inspection and Adjustment.........................................................................1265 pd........................................................................................................1267 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents.....................................................................................1267 PREPARATION...........................................................................................1269 Special Service Tools.............................................................................1269 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING..................................................1273 NVH Troubleshooting Chart.........................................................................1273 PROPELLER SHAFT.......................................................................................1274 PROPELLER SHAFT...................................................................................1274 On-vehicle Service............................................................................1276 Removal and Installation......................................................................1276 Inspection....................................................................................1276 Disassembly...................................................................................1277 Assembly......................................................................................1278 FINAL DRIVE...........................................................................................1280 ON-VEHICLE SERVICE................................................................................1280 Front Oil Seal Replacement (Front final drive: Model R180A)...................................1280 Rear Cover Gasket Replacement (Rear final drive: Model C200)..................................1280 REMOVAL AND INSTALLATION (Front final drive)......................................................1281 Removal.......................................................................................1281 Installation..................................................................................1281 REMOVAL AND INSTALLATION (Rear final drive).......................................................1282 Removal.......................................................................................1282 Installation..................................................................................1282 FRONT FINAL DRIVE, R180A..............................................................................1283 FRONT FINAL DRIVE.................................................................................1283 DISASSEMBLY.......................................................................................1284 Pre-inspection................................................................................1284 Final Drive Housing...........................................................................1284 Differential Case.............................................................................1286 Extension Tube and Differential Side Shaft....................................................1287 INSPECTION........................................................................................1289 Ring Gear and Drive Pinion....................................................................1289 Differential Case Assembly....................................................................1289 Bearing.......................................................................................1289 ADJUSTMENT........................................................................................1290 Side Bearing Preload..........................................................................1290 Pinion Gear Height and Pinion Bearing Preload.................................................1291 Tooth Contact.................................................................................1295 ASSEMBLY..........................................................................................1296 Extension Tube and Differential Side Shaft....................................................1296 Differential Case.............................................................................1296 Final Drive Housing...........................................................................1297 REAR FINAL DRIVE, H190A...............................................................................1301 REAR FINAL DRIVE..................................................................................1301 DISASSEMBLY.......................................................................................1302 Pre-inspection................................................................................1302 Differential Carrier..........................................................................1302 Differential Case.............................................................................1304 INSPECTION........................................................................................1306 Ring Gear and Drive Pinion....................................................................1306 Differential Case Assembly....................................................................1306 Bearing.......................................................................................1306 ADJUSTMENT........................................................................................1307 Side Bearing Preload..........................................................................1307 Pinion Gear Height............................................................................1308 Tooth Contact.................................................................................1312 ASSEMBLY..........................................................................................1313 Differential Case.............................................................................1313 Differential Carrier..........................................................................1314 REAR FINAL DRIVE, 2WD MODELS, C200....................................................................1318 REAR FINAL DRIVE..................................................................................1318 2WD models....................................................................................1318 4WD models....................................................................................1319 DISASSEMBLY.......................................................................................1320 Pre-inspection................................................................................1320 Differential Carrier..........................................................................1320 Differential Case.............................................................................1322 INSPECTION........................................................................................1324 Ring Gear and Drive Pinion....................................................................1324 Differential Case Assembly....................................................................1324 Bearing.......................................................................................1324 ADJUSTMENT........................................................................................1325 Side Bearing Preload..........................................................................1325 Pinion Gear Height............................................................................1326 Tooth Contact.................................................................................1330 ASSEMBLY..........................................................................................1331 Differential Case.............................................................................1331 Differential Carrier..........................................................................1332 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................1336 Propeller Shaft...................................................................................1336 Final Drive.......................................................................................1337 General Specifications........................................................................1337 Inspection And Adjustment (R180A).............................................................1338 Inspection And Adjustment (H190A).............................................................1339 Inspection And Adjustment (C200)..............................................................1340 ra........................................................................................................1341 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents.....................................................................................1341 PRECAUTIONS AND PREPARATION...........................................................................1342 Precautions.......................................................................................1342 Special Service Tools.............................................................................1342 Commercial Service Tools..........................................................................1343 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING..................................................1344 NVH Troubleshooting Chart.........................................................................1344 REAR SUSPENSION SYSTEM................................................................................1345 2WD models........................................................................................1345 4WD models........................................................................................1345 ON-VEHICLE SERVICE....................................................................................1346 Rear Axle and Rear Suspension Parts...............................................................1346 Rear Wheel Bearing................................................................................1346 REAR AXLE.............................................................................................1347 Components........................................................................................1347 Removal...........................................................................................1348 Inspection........................................................................................1350 Axle Shaft....................................................................................1350 Wheel Bearing.................................................................................1350 Axle Case.....................................................................................1350 Installation -- 2WD models........................................................................1350 Installation -- 4WD models........................................................................1352 REAR SUSPENSION.......................................................................................1354 2WD models........................................................................................1354 4WD models........................................................................................1354 Shock Absorber....................................................................................1355 Removal And Installation......................................................................1355 Inspection....................................................................................1355 Leaf Spring.......................................................................................1355 Removal And Installation......................................................................1355 Inspection....................................................................................1356 Installation..................................................................................1356 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................1357 General Specifications............................................................................1357 Inspection and Adjustment.........................................................................1357 rs........................................................................................................1358 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents.....................................................................................1358 PRECAUTIONS AND PREPARATION...........................................................................1359 Supplemental Restraint System (SRS) "AIR BAG".....................................................1359 SEAT BELTS............................................................................................1360 Front Seat Belt...................................................................................1361 Rear Seat Belt....................................................................................1362 Seat Belt Inspection..............................................................................1363 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)...................................................................1366 Precautions for SRS "AIR BAG" Service.............................................................1366 Special Service Tools.............................................................................1367 Description.......................................................................................1368 Passenger air bag deactivation switch.............................................................1368 SRS Component Parts Location......................................................................1369 Maintenance Items.................................................................................1370 Diagnosis Sensor Unit and Crash Zone Sensor.......................................................1371 Removal And Installation......................................................................1371 Air bag diagnosis sensor unit.............................................................1371 Crash zone sensor (4WD models)............................................................1371 Driver Air Bag Module and Spiral Cable............................................................1372 Passenger Air Bag Module..........................................................................1376 Passenger Air Bag Deactivation Switch.............................................................1378 Passenger Air Bag Deactivation Switch Lock Cylinder...............................................1378 Passenger Air Bag Deactivation Switch Indicator...................................................1379 Disposal of Air Bag Module........................................................................1380 TROUBLE DIAGNOSES – Supplemental Restraint System (SRS)...............................................1384 Trouble Diagnosis Introduction....................................................................1384 How to Perform Trouble diagnoses for Quick and Accurate Repair....................................1387 Schematic.........................................................................................1388 Wiring Diagram –SRS–..............................................................................1389 Passenger Air Bag Deactivation Switch Indicator Operation Check...................................1391 SRS Operation Check...............................................................................1392 Trouble Diagnoses with CONSULT....................................................................1393 Trouble Diagnoses without CONSULT.................................................................1402 Trouble Diagnoses: "AIR BAG" Warning Lamp Does Not Turn Off.......................................1406 Trouble Diagnoses: "AIR BAG" Warning Lamp Does Not Turn On........................................1407 Trouble Diagnoses: SRS Does Not Enter Diagnosis Mode Using Door Switch............................1408 COLLISION DIAGNOSIS...................................................................................1409 st........................................................................................................1412 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents.....................................................................................1412 PRECAUTIONS AND PREPARATION...........................................................................1414 Supplemental Restraint System (SRS) "AIR BAG".....................................................1414 Precautions for Steering System...................................................................1414 Special Service Tools.............................................................................1415 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING..................................................1417 NVH Troubleshooting...............................................................................1417 ON-VEHICLE SERVICE....................................................................................1418 Steering System...................................................................................1418 Checking and Adjusting Drive Belts (For power steering)...........................................1418 Checking Fluid Level (For power steering).........................................................1418 Checking Fluid Leakage (For power steering).......................................................1419 Bleeding Hydraulic System (For power steering)....................................................1419 Checking Steering Wheel Turning Force (For power steering)........................................1420 Checking Steering Wheel Play......................................................................1420 Checking Neutral Position on Steering Wheel ......................................................1421 Checking......................................................................................1421 Checking Front Wheel Turning Angle................................................................1421 Checking Hydraulic System (For power steering)....................................................1422 STEERING WHEEL AND STEERING COLUMN....................................................................1423 Steering Wheel....................................................................................1423 Removal And Installation......................................................................1423 Steering Column...................................................................................1424 Removal.......................................................................................1424 Installation..................................................................................1424 Disassembly and Assembly..........................................................................1425 Tilt mechanism................................................................................1426 Inspection........................................................................................1426 MANUAL STEERING GEAR (Model: VB66K)...................................................................1427 Removal and Installation..........................................................................1427 Disassembly.......................................................................................1428 Assembly and Adjustment...........................................................................1428 Worm Gear Bearing Preload.....................................................................1428 Sector Shaft End Play.........................................................................1430 Steering Gear Preload and Backlash............................................................1430 Inspection........................................................................................1431 Sector Shaft..................................................................................1431 Steering Worm Assembly........................................................................1432 Bearing.......................................................................................1432 Oil Seals.....................................................................................1432 POWER STEERING SYSTEM (Model: PB48S)..................................................................1433 Description.......................................................................................1433 POWER STEERING GEAR (Model: PB48S)....................................................................1433 Removal and Installation..........................................................................1434 Steering Gear.................................................................................1434 Power Steering Gear Component.....................................................................1434 Pre-disassembly Inspection and Adjustment.........................................................1435 Turning Torque Measurement....................................................................1435 Disassembly.......................................................................................1435 Adjusting Screw Lock Nut O-Ring...............................................................1436 Sector Shaft Oil Seal.........................................................................1436 Rear Housing O-Ring...........................................................................1437 Rear Cover O-Ring and Oil Seal................................................................1437 Assembly..........................................................................................1438 Adjusting Screw Lock Nut O-Ring...............................................................1438 Sector Shaft Oil Seal.........................................................................1438 Sector Shaft End Play.........................................................................1439 Rear Cover O-Ring and Oil Seal................................................................1439 Rear Housing O-Ring...........................................................................1439 Sector Shaft..................................................................................1440 POWER STEERING SYSTEM (Model: PB59K)..................................................................1441 Removal and Installation..........................................................................1442 Steering Gear.................................................................................1442 Power Steering Gear Component.....................................................................1442 Pre-disassembly Inspection and Adjustment.........................................................1443 Turning Torque Measurement....................................................................1443 Disassembly.......................................................................................1444 Assembly..........................................................................................1445 POWER STEERING OIL PUMP...............................................................................1448 Disassembly and Assembly..........................................................................1448 Pre-disassembly Inspection........................................................................1448 Inspection........................................................................................1449 Pulley and Pulley Shaft.......................................................................1449 Disassembly.......................................................................................1449 Assembly..........................................................................................1450 STEERING LINKAGE......................................................................................1451 Removal and Installation..........................................................................1451 Disassembly.......................................................................................1452 Idler Arm Assembly............................................................................1452 Cross Rod and Tie-Rod.........................................................................1452 Inspection........................................................................................1453 Ball Joint and Swivel Joint...................................................................1453 Idler Arm Assembly............................................................................1453 Cross Rod and Tie-Rod.........................................................................1453 Fixing Location...............................................................................1453 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................1454 General Specifications............................................................................1454 Inspection and Adjustment.........................................................................1454 Steering Column Length........................................................................1454 Manual Steering Gear (Model: VB66K)...........................................................1455 Steering Linkage .............................................................................1455 Power Steering System (Model: PB48S)..........................................................1455 Power Steering System (Model: PB59K)..........................................................1456 tf........................................................................................................1457 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents.....................................................................................1457 PREPARATION...........................................................................................1458 Special Service Tools.............................................................................1458 Commercial Service Tools..........................................................................1459 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING..................................................1460 NVH Troubleshooting Chart.........................................................................1460 Transfer......................................................................................1460 DESCRIPTION...........................................................................................1461 Cross-sectional View..............................................................................1461 ON-VEHICLE SERVICE....................................................................................1462 Replacing Oil Seal................................................................................1462 Center Case Oil Seal..........................................................................1462 Shift Shaft Oil Seal..........................................................................1462 Rear Oil Seal.................................................................................1463 REMOVAL AND INSTALLATION..............................................................................1464 TRANSFER GEAR CONTROL.................................................................................1465 MAJOR OVERHAUL........................................................................................1466 Case Components...................................................................................1466 Gear Components...................................................................................1467 Shift Control Components..........................................................................1468 DISASSEMBLY...........................................................................................1469 REPAIR FOR COMPONENTS PARTS...........................................................................1474 Mainshaft.........................................................................................1474 Front Drive Shaft.................................................................................1476 Counter Gear......................................................................................1477 Main Gear.........................................................................................1477 Front Case........................................................................................1479 Shift Shaft Oil Seal..........................................................................1479 Front Case Cover..................................................................................1479 Cover Oil Seal................................................................................1479 Bearing Retainer..................................................................................1480 Oil Catcher...................................................................................1480 Rear Case.........................................................................................1480 Rear Oil Seal.................................................................................1480 Air Breather..................................................................................1480 Shift Control Components..........................................................................1481 ASSEMBLY..............................................................................................1482 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................1489 General Specifications............................................................................1489 Inspection and Adjustment.........................................................................1489
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