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1999 NISSAN FRONTIER D22 Series(3.3L VG Engine) Service Manual PDF DOWNLOAD
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1999 NISSAN FRONTIER D22 Series(3.3L VG Engine) Service Manual PDF DOWNLOAD
NISSAN FRONTIER D22 SERIES FOR VEHICLES EQIPPED WITH THE 3.3L, VG ENGINE
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Description
1999 NISSAN FRONTIER D22 Series(3.3L VG Engine) Service Manual PDF DOWNLOAD
FILE DETAILS:
1999 NISSAN FRONTIER D22 Series(3.3L VG Engine) Service Manual PDF DOWNLOAD
Language : English
Pages : 1673
Downloadable : Yes
File Type : PDF
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DESCRIPTION:
1999 NISSAN FRONTIER D22 Series(3.3L VG Engine) Service Manual PDF DOWNLOAD
FOREWORD
- This manual contains maintenance and repair procedure for the 1999 NISSAN FRONTIER FOR THE VEHICLES EQIPPED WITH THE 3.3L, VG 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(3.3L VG Engine) Service Manual PDF DOWNLOAD
NISSAN FRONTIER D22 SERIES FOR VEHICLES EQIPPED WITH THE 3.3L, VG ENGINE
fwd........................................................................................................................ 1 QUICK REFERENCE INDEX.................................................................................................. 1 FOREWORD............................................................................................................... 2 GI - General Information............................................................................................... 0 MA - Maintenance....................................................................................................... 0 EM - Engine Mechanical................................................................................................. 0 LC - Engine Lubrication & Cooling Systems.............................................................................. 0 EC - Engine Control System............................................................................................. 0 FE - Accelerator Control, Fuel & Exhaust Systems....................................................................... 0 CL - Clutch............................................................................................................ 0 MT - Manual Transmission............................................................................................... 0 AT - Automatic Transmission............................................................................................ 0 TF - Transfer.......................................................................................................... 0 PD - Propeller Shaft & Differential Carrier............................................................................ 0 FA - Front Axle & Front Suspension..................................................................................... 0 RA - Rear Axle & Rear Suspension....................................................................................... 0 BR - Brake System...................................................................................................... 0 ST - Steering System................................................................................................... 0 RS - Restraint System.................................................................................................. 0 BT - Body & Trim....................................................................................................... 0 HA - Heater & Air Conditioner.......................................................................................... 0 EL - Electrical System................................................................................................. 0 IDX - Alphabetical Index............................................................................................... 1 Foldout................................................................................................................ 0 GST Mode 6 - Test Value & Test Limit .................................................................................. 3 at......................................................................................................................... 4 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS...................................................................................................... 4 Alphabetical & P No. Index for DTC..................................................................................... 7 PRECAUTIONS............................................................................................................ 9 Precautions for Supplemental Restraint System (SRS) "AIR BAG"...................................................... 9 Precautions for On Board Diagnostic (OBD) System of A/T and Engine................................................. 9 Precautions........................................................................................................ 10 Service Notice or Precautions...................................................................................... 11 Wiring Diagrams and Trouble Diagnosis.............................................................................. 12 PREPARATION............................................................................................................ 13 Special Service Tools.............................................................................................. 13 OVERALL SYSTEM ........................................................................................................ 15 A/T Electrical Parts Location...................................................................................... 15 Circuit Diagram.................................................................................................... 16 Cross-sectional View............................................................................................... 17 Hydraulic Control Circuit.......................................................................................... 18 Shift Mechanism.................................................................................................... 19 Control System..................................................................................................... 28 Control Mechanism.................................................................................................. 29 Control Valve...................................................................................................... 34 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION................................................................................. 36 Introduction....................................................................................................... 36 OBD-II Function for A/T System..................................................................................... 36 One or Two Trip Detection Logic of OBD-II.......................................................................... 36 OBD-II Diagnostic Trouble Code (DTC)............................................................................... 36 Malfunction Indicator Lamp (MIL)................................................................................... 40 CONSULT............................................................................................................ 40 Diagnostic Procedure Without CONSULT............................................................................... 49 TROUBLE DIAGNOSIS - INTRODUCTION....................................................................................... 54 Introduction....................................................................................................... 54 Work Flow.......................................................................................................... 58 TROUBLE DIAGNOSIS - BASIC INSPECTION................................................................................... 60 A/T Fluid Check.................................................................................................... 60 Stall Test......................................................................................................... 60 Line Pressure Test................................................................................................. 63 Road Test.......................................................................................................... 64 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION................................................................................ 75 Sympton Chart...................................................................................................... 75 TCM Terminals and Reference Value.................................................................................. 86 TROUBLE DIAGNOSIS FOR POWER SUPPLY..................................................................................... 90 Wiring Diagram -AT-MAIN............................................................................................ 90 DTC P0705 PARK/NEUTRAL POSITION SWITCH................................................................................. 92 Description........................................................................................................ 92 Wiring Diagram -AT-PNP/SW.......................................................................................... 94 Diagnostic Procedure............................................................................................... 95 Component Inspection............................................................................................... 96 DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT......................................................................... 97 Description........................................................................................................ 97 Wiring Diagram -AT-FTS............................................................................................. 99 Diagnostic Procedure............................................................................................... 100 Component Inspection............................................................................................... 101 DTC P0720 VEHICLE SPEED SENSOR-A/T (REVOLUTION SENSOR)................................................................. 102 Description........................................................................................................ 102 Wiring Diagram -AT-VSSA/T.......................................................................................... 104 Diagnostic Procedure............................................................................................... 105 Component Inspection............................................................................................... 106 DTC P0725 ENGINE SPEED SIGNAL.......................................................................................... 107 Description........................................................................................................ 107 Wiring Diagram -AT-ENGSS........................................................................................... 109 Diagnostic Procedure............................................................................................... 110 DTC P0731 IMPROPER SHIFTING TO 1ST GEAR POSITION....................................................................... 111 Description........................................................................................................ 111 Wiring Diagram -AT-1ST............................................................................................. 114 Diagnostic Procedure............................................................................................... 115 Component Inspection............................................................................................... 116 DTC P0732 IMPROPER SHIFTING TO 2ND GEAR POSITION....................................................................... 117 Description........................................................................................................ 117 Wiring Diagram -AT-2ND............................................................................................. 120 Diagnostic Procedure............................................................................................... 121 Component Inspection............................................................................................... 121 DTC P0733 IMPROPER SHIFTING TO 3RD GEAR POSITION....................................................................... 123 Description........................................................................................................ 123 Wiring Diagram -AT-3RD............................................................................................. 126 Diagnostic Procedure............................................................................................... 127 Component Inspection............................................................................................... 127 DTC P0734 IMPROPER SHIFTING TO 4TH GEAR POSITION....................................................................... 129 Description........................................................................................................ 129 Wiring Diagram -AT-4TH............................................................................................. 133 Diagnostic Procedure............................................................................................... 134 Component Inspection............................................................................................... 136 DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE....................................................................... 138 Description........................................................................................................ 138 Wiring Diagram -AT-TCV............................................................................................. 140 Diagnostic Procedure............................................................................................... 141 Component Inspection............................................................................................... 141 DTC P0744 IMPROPER LOCK-UP OPERATION................................................................................... 143 Description........................................................................................................ 143 Wiring Diagram -AT-TCCSIG.......................................................................................... 146 Diagnostic Procedure............................................................................................... 147 Component Inspection............................................................................................... 149 DTC P0745 LINE PRESSURE SOLENOID VALVE................................................................................. 151 Description........................................................................................................ 151 Wiring Diagram -AT-LPSV............................................................................................ 153 Diagnostic Procedure............................................................................................... 154 Component Inspection............................................................................................... 155 DTC P0750 SHIFT SOLENOID VALVE A....................................................................................... 156 Description........................................................................................................ 156 Wiring Diagram -AT-SSV/A........................................................................................... 158 Diagnostic Procedure............................................................................................... 159 Component Inspection............................................................................................... 159 DTC P0755 SHIFT SOLENOID VALVE B....................................................................................... 161 Description........................................................................................................ 161 Wiring Diagram -AT-SSV/B........................................................................................... 163 Diagnostic Procedure............................................................................................... 164 Component Inspection............................................................................................... 164 DTC P1705 THROTTLE POSITION SENSOR..................................................................................... 166 Description........................................................................................................ 166 Wiring Diagram -AT-TPS............................................................................................. 169 Diagnostic Procedure............................................................................................... 170 Component Inspection............................................................................................... 172 DTC P1760 OVERRUN CLUTCH SOLENOID VALVE................................................................................ 173 Description........................................................................................................ 173 Wiring Diagram -AT-OVRCSV.......................................................................................... 175 Diagnostic Procedure .............................................................................................. 176 Component Inspection............................................................................................... 176 DTC BATT/FLUID TEM SEN A/T FLUID TEMPERATURE SENSOR CIRCUIT AND TCM POWER SOURCE....................................... 178 Description........................................................................................................ 178 Wiring Diagram -AT-BA/FTS.......................................................................................... 180 Diagnostic Procedure............................................................................................... 181 Component Inspection............................................................................................... 182 VEHICLE SPEED SENSOR-MTR............................................................................................... 183 Description........................................................................................................ 183 Wiring Diagram -AT-VSSMTR.......................................................................................... 185 Diagnostic Procedure............................................................................................... 186 DTC CONTROL UNIT (RAM), CONTROL UNIT (ROM)............................................................................. 187 Description........................................................................................................ 187 Diagnostic Procedure............................................................................................... 188 TROUBLE DIAGNOSES FOR SYMPTOMS......................................................................................... 189 Wiring Diagram -AT-NNDTC........................................................................................... 189 1. O/D OFF Indicator Lamp Does Not Come On......................................................................... 192 2. Engine Cannot Be Started In P and N Position.................................................................... 194 3. In "P" Position, Vehicle Moves Forward Or Backward When Pushed.................................................. 195 4. In N Position, Vehicle Moves.................................................................................... 196 5. Large Shock, N-R Position....................................................................................... 197 6. Vehicle Does Not Creep Backward In $ Position................................................................... 198 7. Vehicle Does Not Creep Forward in D1, 2 Or 1 Position........................................................... 200 8. Vehicle Cannot Be Started From D1............................................................................... 202 9. A/T Does Not Shift: D1-D2 Or Does Not Kickdown: D4-D2........................................................... 204 10. A/T Does Not Shift: D2-D3...................................................................................... 206 11. A/T Does Not Shift: D3-D4...................................................................................... 208 12. A/T Does Not Perform Lock-up................................................................................... 210 13. A/T Does Not Hold Lock-up Condition............................................................................ 211 14. Lock-up Is Not Released........................................................................................ 212 15. Engine Speed Does Not Return To Idle (Light Braking D4-D3)..................................................... 213 16. Vehicle Does Not Start From D1................................................................................. 214 17. A/T Does Not Shift: D4-D3, When Overdrive Control Switch ON-OFF................................................ 215 18. A/T Does Not Shift: D3-22, When Selector Lever D-2 Position.................................................... 216 19. A/T Does Not Shift: 22-11, When Selector Lever 2-1 Position.................................................... 217 20. Vehicle Does Not Decelerate By Engine Brake.................................................................... 217 21. TCM Self-diagnosis Does Not Activate (PNP, Overdrive Control and Throttle Position Switches Circuit Checks).... 218 A/T SHIFT LOCK SYSTEM.................................................................................................. 224 Description........................................................................................................ 224 Wiring Diagram -SHIFT-............................................................................................. 225 Diagnostic Procedure............................................................................................... 226 Component Check.................................................................................................... 227 KEY INTERLOCK CABLE.................................................................................................... 229 Components......................................................................................................... 229 Removal............................................................................................................ 229 Installation....................................................................................................... 230 ON-VEHICLE SERVICE..................................................................................................... 231 Control Valve Assembly and Accumulators............................................................................ 231 Revolution Sensor Replacement...................................................................................... 232 Rear Oil Seal Replacement.......................................................................................... 232 Parking Components Inspection...................................................................................... 232 Park/Neutral Position (PNP) Switch Adjustment...................................................................... 232 Manual Control Linkage Adjustment.................................................................................. 233 REMOVAL AND INSTALLATION............................................................................................... 234 Removal............................................................................................................ 234 Installation....................................................................................................... 235 OVERHAUL............................................................................................................... 237 Components......................................................................................................... 237 Oil Channel........................................................................................................ 239 Locations of Needle Bearings, Thrust Washers and Snap Rings........................................................ 240 DISASSEMBLY............................................................................................................ 241 REPAIR FOR COMPONENT PARTS............................................................................................. 252 Oil Pump........................................................................................................... 252 Control Valve Assembly............................................................................................. 256 Control Valve Upper Body........................................................................................... 262 Control Valve Lower Body........................................................................................... 267 Reverse Clutch..................................................................................................... 269 High Clutch........................................................................................................ 273 Forward and Overrun Clutches....................................................................................... 275 Low & Reverse Brake................................................................................................ 279 Forward Clutch Drum Assembly....................................................................................... 283 Rear Internal Gear and Forward Clutch Hub.......................................................................... 285 Band Servo Piston Assembly......................................................................................... 288 Parking Pawl Components............................................................................................ 292 ASSEMBLY............................................................................................................... 294 Assembly (1)....................................................................................................... 294 Adjustment......................................................................................................... 301 Assembly (2)....................................................................................................... 304 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................. 311 General Specifications............................................................................................. 311 Shift Schedule..................................................................................................... 311 Stall Revolution................................................................................................... 311 Line Pressure...................................................................................................... 311 Return Springs..................................................................................................... 312 Accumulator O-ring................................................................................................. 313 Clutches and Brakes................................................................................................ 313 Oil Pump and Low One-way Clutch.................................................................................... 315 Total End Play..................................................................................................... 315 Reverse Clutch Drum End Play....................................................................................... 316 Removal and Installation........................................................................................... 316 br......................................................................................................................... 317 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS...................................................................................................... 317 PRECAUTIONS AND PREPARATION............................................................................................ 319 Supplemental Restraint System (SRS) "AIR BAG"...................................................................... 319 Precautions for Brake System....................................................................................... 320 Commercial Service Tools........................................................................................... 320 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING................................................................... 321 NVH Troubleshooting Chart.......................................................................................... 321 ON-VEHICLE SERVICE..................................................................................................... 322 Checking Brake Fluid Level......................................................................................... 322 Checking Brake Line................................................................................................ 322 Changing Brake Fluid............................................................................................... 322 Brake Burnishing Procedure......................................................................................... 322 Bleeding Brake System.............................................................................................. 323 BRAKE HYDRAULIC LINE................................................................................................... 324 BRAKE HYDRAULIC LINE/CONTROL VALVE..................................................................................... 326 Proportioning Valve................................................................................................ 326 BRAKE PEDAL AND BRACKET................................................................................................ 327 Removal and Installation........................................................................................... 327 Inspection......................................................................................................... 328 Adjustment......................................................................................................... 328 MASTER CYLINDER........................................................................................................ 329 Removal............................................................................................................ 329 Disassembly........................................................................................................ 330 Inspection......................................................................................................... 330 Assembly........................................................................................................... 330 Installation....................................................................................................... 331 BRAKE BOOSTER.......................................................................................................... 332 On-vehicle Service................................................................................................. 332 Removal............................................................................................................ 332 Inspection......................................................................................................... 332 Installation....................................................................................................... 333 VACUUM HOSE............................................................................................................ 334 Removal and Installation........................................................................................... 334 Inspection......................................................................................................... 334 FRONT DISC BRAKE....................................................................................................... 335 Pad Replacement.................................................................................................... 335 Removal............................................................................................................ 336 Disassembly........................................................................................................ 337 Inspection -Caliper................................................................................................ 337 Inspection-Rotor................................................................................................... 337 Assembly........................................................................................................... 338 Installation....................................................................................................... 338 REAR DRUM BRAKE........................................................................................................ 339 Removal ........................................................................................................... 340 Inspection -Wheel Cylinder......................................................................................... 341 Wheel Cylinder Overhaul............................................................................................ 341 Inspection-Drum.................................................................................................... 341 Inspection-Lining.................................................................................................. 341 Installation....................................................................................................... 341 PARKING BRAKE CONTROL.................................................................................................. 343 Removal and Installation........................................................................................... 344 Inspection......................................................................................................... 344 Adjustment......................................................................................................... 344 ANTI-LOCK BRAKE SYSTEM................................................................................................. 345 Purpose............................................................................................................ 345 Operation.......................................................................................................... 345 ABS Hydraulic Circuit.............................................................................................. 345 System Components.................................................................................................. 346 System Description................................................................................................. 346 Removal and Installation........................................................................................... 348 TROUBLE DIAGNOSES...................................................................................................... 351 How to Perform Trouble Diagnoses for Quick and Accurate Repair..................................................... 351 Preliminary Check.................................................................................................. 353 Component Parts and Harness Connector Location..................................................................... 354 Schematic.......................................................................................................... 355 Wiring Diagram-ABS-................................................................................................ 356 Self-diagnosis .................................................................................................... 359 CONSULT............................................................................................................ 362 CONSULT Inspection Procedure....................................................................................... 363 Ground Circuit Check............................................................................................... 368 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS............................................................................ 369 Diagnostic Procedure 1 (Wheel sensor or rotor)..................................................................... 369 Diagnostic Procedure 2 (ABS actuator solenoid valve and solenoid valve relay)...................................... 371 Diagnostic Procedure 3 (Motor relay or motor)...................................................................... 373 Diagnostic Procedure 4 (Low voltage)............................................................................... 375 Diagnostic Procedure 5 (G sensor).................................................................................. 376 Diagnostic Procedure 6 (Control unit).............................................................................. 377 TROUBLE DIAGNOSES FOR SYMPTOMS......................................................................................... 378 Diagnostic Procedure 7 (ABS works frequently)...................................................................... 378 Diagnostic Procedure 8 (Unexpected pedal action)................................................................... 379 Diagnostic Procedure 9 (Long stopping distance).................................................................... 379 Diagnostic Procedure (ABS does not work)........................................................................... 380 Diagnostic Procedure 11 (Pedal vibration and noise)................................................................ 380 Diagnostic Procedure 12 (Warning lamp does not come on when ignition switch is turned ON).......................... 381 Diagnostic Procedure 13 (Warning lamp stays on when ignition switch is turned ON).................................. 383 Electrical Components Inspection................................................................................... 385 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................. 386 General Specifications............................................................................................. 386 Inspection and Adjustment.......................................................................................... 387 bt......................................................................................................................... 388 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS...................................................................................................... 388 PRECAUTIONS AND PREPARATION............................................................................................ 389 Service Notice..................................................................................................... 389 Supplemental Restraint System (SRS) "AIR BAG"...................................................................... 389 GENERAL SERVICING...................................................................................................... 390 Clip and Fastener.................................................................................................. 390 BODY END............................................................................................................... 392 Body Front End..................................................................................................... 392 Removal-Front bumper assembly.................................................................................. 392 Body Rear End...................................................................................................... 395 Removal-Rear bumper assembly................................................................................... 395 DOOR................................................................................................................... 397 Front Door......................................................................................................... 397 INSTRUMENT PANEL....................................................................................................... 398 Removal-Instrument panel assembly.................................................................................. 398 INTERIOR TRIM.......................................................................................................... 401 Side and Floor Trim................................................................................................ 401 Removal-Body side trim............................................................................................. 401 King cab model................................................................................................. 401 Standard cab model............................................................................................. 401 Door Trim.......................................................................................................... 404 Removal............................................................................................................ 404 Door trim (Formed type)........................................................................................ 404 Roof Trim.......................................................................................................... 407 Removal-Headlining............................................................................................. 407 EXTERIOR............................................................................................................... 409 Hood front sealing rubber.......................................................................................... 410 Cowl top seal and cowl top grille.................................................................................. 410 Windshield side molding............................................................................................ 410 Windshield upper molding........................................................................................... 410 Sunroof weatherstrip and lid protector............................................................................. 410 Drip weatherstrip.................................................................................................. 411 Body side welt..................................................................................................... 411 Door weatherstrip.................................................................................................. 411 Door outside molding............................................................................................... 411 Drafter duct....................................................................................................... 412 Over fender........................................................................................................ 412 Rear combination lamp.............................................................................................. 412 SEAT................................................................................................................... 413 Front Seat......................................................................................................... 413 Jump Seat-King Cab Model........................................................................................... 416 SUNROOF................................................................................................................ 417 WINDSHIELD AND WINDOWS................................................................................................. 418 Windshield......................................................................................................... 419 Side Window........................................................................................................ 419 Back Window........................................................................................................ 420 Rearview Mirror.................................................................................................... 421 MIRROR................................................................................................................. 422 Door Mirror........................................................................................................ 422 Removal-Door mirror............................................................................................ 422 CAB AND REAR BODY...................................................................................................... 423 Body Mounting...................................................................................................... 423 BODY ALIGNMENT......................................................................................................... 424 Engine Compartment................................................................................................. 425 Measurement.................................................................................................... 425 Measurement Points............................................................................................. 426 Underbody.......................................................................................................... 427 Measurements................................................................................................... 427 2WD-4WD (Short wheelbase) models........................................................................... 427 Measurement Points............................................................................................. 428 2WD-4WD (Short wheelbase) models).......................................................................... 428 Measurement.................................................................................................... 429 2WD-4WD (Long wheelbase) models............................................................................ 429 Measurement Points............................................................................................. 430 2WD-4WD (Long wheelbase) models............................................................................ 430 cl......................................................................................................................... 431 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS...................................................................................................... 431 PRECAUTIONS AND PREPARATION............................................................................................ 432 Precautions........................................................................................................ 432 Special Service Tools.............................................................................................. 432 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLEWHOOTING................................................................... 433 NVH Troubleshooting Chart.......................................................................................... 433 CLUTCH SYSTEM.......................................................................................................... 434 Clutch Pedal....................................................................................................... 435 INSPECTION AND ADJUSTMENT.............................................................................................. 436 Adjusting Clutch Pedal............................................................................................. 436 Air Bleeding Procedure............................................................................................. 437 HYDRAULIC CLUTCH CONTROL............................................................................................... 438 Clutch Master Cylinder (With clutch damper)........................................................................ 438 Operating Cylinder................................................................................................. 439 CLUTCH RELEASE MECHANISM............................................................................................... 440 CLUTCH DISC AND CLUTCH COVER........................................................................................... 442 Clutch Disc........................................................................................................ 442 Clutch Cover and Flywheel.......................................................................................... 443 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................. 444 General Specifications............................................................................................. 444 Clutch Control System.............................................................................................. 444 Inspection and Adjustment.......................................................................................... 444 ec......................................................................................................................... 445 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS...................................................................................................... 445 TROUBLE DIAGNOSIS - INDEX.............................................................................................. 452 Alphabetical & P No. Index for DTC................................................................................. 452 PRECAUTIONS ........................................................................................................... 458 Supplemental Restraint System (SRS) "AIR BAG"...................................................................... 458 Precautions for On Board Diagnostic (OBD) SYSTEM OF ENGINE AND A/T................................................. 458 Engine Fuel & Emission Control System ............................................................................. 459 Precautions ....................................................................................................... 460 Wiring Diagrams and Trouble Diagnosis .......................................................................... 461 PREPARATION ........................................................................................................... 462 Special Service Tools.............................................................................................. 462 Commercial Service Tools .......................................................................................... 462 ENGINE AND EMISSION CONTROL OVERALL SYSTEM............................................................................. 464 Engine Control Component Parts Location ........................................................................... 464 Circuit Diagram ................................................................................................... 466 System Diagram..................................................................................................... 467 Vacuum Hose Drawing ............................................................................................... 468 System Chart....................................................................................................... 469 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION .................................................................. 470 Multiport Fuel Injection (MFI) System.............................................................................. 470 Distributor Ignition (DI) System .................................................................................. 472 Air Conditioning Cut Control ...................................................................................... 473 Fuel Cut Control (at no load & high engine speed).................................................................. 474 Evaporative Emission System........................................................................................ 474 Positive Crankcase Ventilation..................................................................................... 480 BASIC SERVICE PROCEDURE ............................................................................................... 481 Fuel Pressure Release ............................................................................................. 481 Fuel Pressure Check ............................................................................................... 481 Fuel Pressure Regulator Check...................................................................................... 482 Injector........................................................................................................... 482 Fast Idle Cam (FIC)................................................................................................ 483 Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment........................................................... 485 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION................................................................................. 494 Introduction ...................................................................................................... 494 Two Trip Detection Logic .......................................................................................... 494 Emission-related Diagnostic Information............................................................................ 495 Malfunction Indicator Lamp (MIL)................................................................................... 507 OBD System Operation Chart ........................................................................................ 511 CONSULT ........................................................................................................... 516 Generic Scan Tool (GST)............................................................................................ 530 TROUBLE DIAGNOSIS - INTRODUCTION ...................................................................................... 532 Introduction ...................................................................................................... 532 Work Flow ......................................................................................................... 534 TROUBLE DIAGNOSIS - BASIC INSPECTION................................................................................... 536 Basic Inspection................................................................................................... 536 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION ............................................................................... 545 DTC Inspection Priority Chart ..................................................................................... 545 Fail-safe Chart ................................................................................................... 546 Symptom Matrix Chart .............................................................................................. 547 CONSULT Reference Value in Data Monitor Mode ..................................................................... 551 Major Sensor Reference Graph in Data Monitor Mode.................................................................. 553 ECM Terminals and Reference Value ................................................................................. 556 TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT ........................................................................... 565 Description ....................................................................................................... 565 Diagnostic Procedure .............................................................................................. 565 TROUBLE DIAGNOSIS FOR POWER SUPPLY .................................................................................... 566 Main Power Supply and Ground Circuit .............................................................................. 566 DTC P0100 MASS AIR FLOW SENSOR (MAFS).................................................................................. 571 Component Description ............................................................................................. 571 CONSULT Reference Value in Data Monitor Mode ...................................................................... 571 ECM Terminals and Reference Value ................................................................................. 571 On Board Diagnosis Logic .......................................................................................... 571 DTC Confirmation Procedure ........................................................................................ 572 Overall Function Check ............................................................................................ 575 Wiring Diagram .................................................................................................... 576 Diagnostic Procedure .............................................................................................. 577 Component Inspection............................................................................................... 579 DTC P0105 ABSOLUTE PRESSURE SENSOR .................................................................................... 580 Component Description.............................................................................................. 580 On Board Diagnosis Logic .......................................................................................... 580 DTC Confirmation Procedure ........................................................................................ 580 Overall Function Check ............................................................................................ 582 Wiring Diagram .................................................................................................... 583 Diagnostic Procedure .............................................................................................. 584 Component inspection .............................................................................................. 588 DTC P0110 INTAKE AIR TEMPERATURE SENSOR ............................................................................... 589 Component Description ............................................................................................. 589 On Board Diagnosis Logic .......................................................................................... 589 DTC confirmation Procedure ........................................................................................ 589 Wiring Diagram .................................................................................................... 592 Diagnostic Procedure .............................................................................................. 593 Component Inspection .............................................................................................. 594 DTC P0115 ENGINE COOLANT TEMPERATURE SENSOR (ECTS) (CIRCUIT ) ......................................................... 595 Component Description.............................................................................................. 595 On Board Diagram Logic ............................................................................................ 595 DTC Confirmation Procedure ........................................................................................ 596 Wiring Diagram .................................................................................................... 597 Diagnostic Procedure .............................................................................................. 598 Component Inspection............................................................................................... 599 DTC P0120 THROTTLE POSITION SENSOR .................................................................................... 600 Description ....................................................................................................... 600 CONSULT Reference Value in Data Monitor Mode ...................................................................... 600 ECM Terminals and Reference Value ................................................................................. 600 On Board Diagnosis Logic .......................................................................................... 601 DTC Confirmation Procedure......................................................................................... 601 Wiring Diagram .................................................................................................... 606 Diagnostic Procedure .............................................................................................. 607 Component Inspection............................................................................................... 609 DTC P0125 ENGINE COOLANT TEMPERATURE (ECT) SENSOR ..................................................................... 611 Description ....................................................................................................... 611 On Board Diagnosis Logic .......................................................................................... 611 DTC Comfirmation Procedure ....................................................................................... 611 Wiring Diagram .................................................................................................... 613 Diagnostic Procedure .............................................................................................. 614 Component Inspection .............................................................................................. 615 DTC P0130 (RIGHT BANK, -B1), P0150 (LEFT BANK, -B2) FRONT HEATED OXYGEM SENSOR (Front H02S) Circuit ............... 616 Component Description.............................................................................................. 616 CONSULT Reference Value in Data Monitor Mode ...................................................................... 616 ECM Terminals and Reference Value.................................................................................. 616 On Board Diagnosis Logic .......................................................................................... 617 DTC Confirmation Procedure......................................................................................... 617 Overall Function Check ............................................................................................ 618 Wiring Diagram..................................................................................................... 619 Diagnostic Procedure .............................................................................................. 621 Component Inspection .............................................................................................. 622 DTC P0131 (RIGHT BANK, -B1), P0151 (LEFT BANK, -B2) FRONT HEATED OXYGEN SENSOR (FRONT H02S) (LEAN SHIFT MONITORING).... 624 Component Description.............................................................................................. 624 CONSULT Reference Value in Data Monitor Mode....................................................................... 624 ECM Terminals and Reference Value ................................................................................. 624 On Board Diagnosis Logic .......................................................................................... 625 DTC Confirmation Procedure ........................................................................................ 625 Overall Function Check............................................................................................. 626 Diagnostic Procedure .............................................................................................. 627 Component Inspection .............................................................................................. 628 DTC P0132 (RIGHT BANK, -B1), P0152 (LEFT BANK, -B2) FRONT HEATED OXYGEN SENSOR (FRONT H02S) (RICH SHIFT MONITORING).... 630 Component Description ............................................................................................. 630 CONSULT Reference Value in Data Monitor Mode....................................................................... 630 ECM Terminals and Reference Value.................................................................................. 630 On Board Diagnosis Logic .......................................................................................... 631 DTC Confirmation Procedure ........................................................................................ 631 Overall Function Check ............................................................................................ 632 Diagnostic Procedure .............................................................................................. 633 Component Inspection............................................................................................... 634 DTC P0133 (RIGHT BANK, -B1), P0153 (LEFT BANK, -B2) FRONT HEATED OXYGEN SENSOR (FRONT H02S) (RESPONSE MONITORING)...... 636 Component Description.............................................................................................. 636 CONSULT Reference Value in Data Monitor Mode....................................................................... 636 ECM Terminals and Reference Value.................................................................................. 636 On Board Diagnosis Logic........................................................................................... 637 DTC Confirmation Procedure......................................................................................... 637 Overall Function Check............................................................................................. 638 Wiring Diagram..................................................................................................... 639 Diagnostic Procedure............................................................................................... 641 Component Inspection............................................................................................... 643 DTC P0134 (RIGHT BANK, -B1), P0154 (LEFT BANK, -B2) FRONT HEATED OXYGEN SENSOR (FRONT H02S) (HIGH VOLTAGE)............. 644 Component Description.............................................................................................. 644 CONSULT Reference Value in Data Monitor Mode....................................................................... 644 ECM Terminals and Reference Value.................................................................................. 644 On Board Diagnosis Logic .......................................................................................... 645 DTC Confirmation Procedure ........................................................................................ 645 Wiring Diagram..................................................................................................... 647 Diagnostic Procedure .............................................................................................. 649 Component Inspection............................................................................................... 650 DTC P0135 (RIGHT BANK, -B1), P0155 (LEFT BANK, -B2) FRONT HEATED OXYGEN SENSOR HEATER................................. 652 Description........................................................................................................ 652 CONSULT Reference Value in Data Monitor Mode....................................................................... 652 ECM Terminals and Reference Value ................................................................................. 652 On Board Diagnosis Logic .......................................................................................... 652 DTC Confirmation Procedure ........................................................................................ 653 Wiring Diagram..................................................................................................... 654 Diagnostic Procedure .............................................................................................. 656 Component Inspection .............................................................................................. 657 DTC P0137 (RIGHT BANK, -B1), P0157 (LEFT BANK, -B2) REAR HEATED OXYGEN SENSOR (REAR H02S) (MIN. VOLTAGE MONITORING).... 658 Component Description ............................................................................................. 658 CONSULT Reference Value in Data Monitor Mode ...................................................................... 658 ECM Terminals and Reference Value ................................................................................. 658 On Board Diagnosis Logic........................................................................................... 658 DTC Confirmation Procedure ........................................................................................ 659 Overall Function Check ............................................................................................ 660 Wiring Diagram .................................................................................................... 661 Diagnostic Procedure............................................................................................... 663 Component Inspection............................................................................................... 665 DTC P0138 (RIGHT BANK, -B1), P0158 (LIFT BANK, -B2) REAR HEATED OXYGEN SENSOR (REAR H02S) (MAX. VOLTAGE mONITORING).... 667 Component Description ............................................................................................. 667 CONSULT Reference Value in Data Monitor Mode....................................................................... 667 ECM Terminals and Reference Value.................................................................................. 667 On Board Diagnosis Logic .......................................................................................... 667 DTC Confirmation Procedure ........................................................................................ 668 Overall Function Check ............................................................................................ 669 Wiring Diagram .................................................................................................... 670 Diagnostic Procedure .............................................................................................. 672 Component Inspection .............................................................................................. 674 DTC P0139 (RIGHT BANK, -B1), P0159 (LEFT BANK, -B2) REAR HEATED OXYGEN SENSOR (REAR H02S) (RESPONSE MONITORING)........ 675 Component Description ............................................................................................. 675 CONSULT Reference Value in Data Monitor Mode ...................................................................... 675 ECM Terminals and Reference Value ................................................................................. 675 On Board Diagnosis Logic .......................................................................................... 675 DTC Confirmation Procedure ........................................................................................ 676 Overall Function Check ............................................................................................ 677 Wiring Diagram .................................................................................................... 678 Diagnostic Procedure .............................................................................................. 680 Component Inspection............................................................................................... 682 DTC P0140 (RIGHT BANK , -B1), P0160 (LEFT BANK, -B2) REAR HEATED OXYGEN SENSOR (REAR H02S) (HIGH VOLTAGE).............. 684 Component Description ............................................................................................. 684 CONSULT Reference Value in Data Monitor Mode ...................................................................... 684 ECM Terminals and Reference Value ................................................................................. 684 On Board Diagnosis Logic .......................................................................................... 684 DTC Confirmation Procedure......................................................................................... 685 Overall Function Check ............................................................................................ 685 Wiring Diagram .................................................................................................... 686 Diagnostic Procedure .............................................................................................. 688 Component Inspection .............................................................................................. 689 DTC P0141 (RIGHT BANK, -B1), P0161 (LEFT BANK, -B2) REAR HEATED OXYGEN SENSOR HEATER .................................. 691 Description........................................................................................................ 691 CONSULT Reference Value in Data Monitor Mode ...................................................................... 691 ECM Terminals and Reference Value.................................................................................. 691 On Board Diagnosis Logic........................................................................................... 691 DTC Confirmation Procedure ........................................................................................ 692 Wiring Diagram .................................................................................................... 693 Diagnostic Procedure .............................................................................................. 695 Component Inspection .............................................................................................. 696 DTC P0171 (RIGHT BANK, -B1), P0174 (LEFT BANK, -B2) FUEL INJECTION SYSTEM FUNCTION (LEAN SIDE)......................... 697 On Board Diagnosis Logic .......................................................................................... 697 DTC Confirmation Procedure ........................................................................................ 697 Wiring Diagram..................................................................................................... 699 Diagnostic Procedure .............................................................................................. 701 DTC P0172 (RIGHT BANK, -B1), P0175 (LEFT BANK, -B2) FUEL INJECTION SYSREM FUNCTION (RICH SIDE)......................... 704 On Board Diagnosis Logic .......................................................................................... 704 DTC Confirmation Procedure ........................................................................................ 704 Wiring Diagram .................................................................................................... 706 Diagnostic Procedure .............................................................................................. 708 DTC P0180 TANK FUEL TEMPERATURE SENSOR ................................................................................ 711 Component Description ............................................................................................. 711 On board Diagnosis Logic .......................................................................................... 711 DTC Confirmation Procedure ........................................................................................ 711 Wiring Diagram .................................................................................................... 713 Diagnostic Procedure .............................................................................................. 714 Component Inspection .............................................................................................. 715 DTCP0300 - P0306 NO. 6 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE ............................................... 716 On Board Diagnosis Logic .......................................................................................... 716 DTC Confirmation Procedure ........................................................................................ 716 Diagnostic Procedure .............................................................................................. 717 Component Inspection............................................................................................... 720 DTC P0325 KNOCK SENSOR (KS)............................................................................................ 721 Component Description.............................................................................................. 721 ECM Terminals and Reference Value.................................................................................. 721 On Board Diagnosis Logic........................................................................................... 721 DTC Confirmation Procedure......................................................................................... 721 Wiring Diagram..................................................................................................... 723 Diagnostic Procedure............................................................................................... 724 Component Inspection............................................................................................... 725 DTC P0335 CRANKSHAFT POSITION SENSOR (CKPS) (OBD)...................................................................... 726 Component Description.............................................................................................. 726 ECM Terminals and Reference Value.................................................................................. 726 On Board Diagnosis Logic........................................................................................... 726 DTC Confirmation Procedure......................................................................................... 727 Wiring Diagram..................................................................................................... 728 Diagnostic Procedure............................................................................................... 729 Component Inspection............................................................................................... 730 DTC P0340 CAMSHAFT POSITION SENSOR (CMPS).............................................................................. 731 Component Description.............................................................................................. 731 ECM Terminals and Reference Value.................................................................................. 731 On Board Diagnosis Logic........................................................................................... 732 DTC Confirmation Procedure......................................................................................... 732 Wiring Diagram..................................................................................................... 734 Diagnostic Procedure............................................................................................... 735 Component Inspection............................................................................................... 736 DTC P0400 EGR FUNCTION (CLOSE)..................................................................................... 738 Description........................................................................................................ 738 On Board Diagnosis Logic........................................................................................... 739 DTC Confirmation Procedure......................................................................................... 740 Overall Function Check............................................................................................. 741 Wiring Diagram..................................................................................................... 742 Diagnostic Procedure............................................................................................... 743 Component Inspection............................................................................................... 745 DTC P0400 EGR FUNCTION (CLOSE)......................................................................................... 738 System Description................................................................................................. 738 On Board Diagnosis Logic........................................................................................... 739 DTC Confirmation Procedure......................................................................................... 740 Overall Function Check............................................................................................. 741 Diagnostic Procedure............................................................................................... 748 Component Inspection............................................................................................... 745 DTC P0402 EGRC-BPT VALVE FUNCTION...................................................................................... 746 Description........................................................................................................ 746 On Board Diagnosis Logic........................................................................................... 746 DTC Confirmation Procedure......................................................................................... 747 Overall Function Check............................................................................................. 748 Diagnostic Procedure............................................................................................... 748 Component Inspection............................................................................................... 749 DTC P0420 (RIGHT BANK, -B1), P0430 (LEFT BANK, -B2) THREE WAY CATALYST FUNCTION........................................ 750 On Board Diagnosis Logic........................................................................................... 750 DTC Confirmation Procedure......................................................................................... 750 Overall Function Check............................................................................................. 751 Diagnostic Procedure............................................................................................... 751 DTC P0440 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM (SMALL LEAK) (NEGATIVE PRESSURE).................................. 753 On Board Diagnosis Logic........................................................................................... 753 DTC Confirmation Procedure......................................................................................... 754 Diagnostic Procedure............................................................................................... 755 DTC P0443 EVAPORATIVE EMISSION (EVAP) CANISTER PURGE VOLUME CONTROL SOLENOID VALVE (CIRCUIT)........................... 760 Description........................................................................................................ 760 CONSULT Reference Value in Data Monitor Mode....................................................................... 760 ECM Terminals and Reference Value.................................................................................. 761 On Board Diagnosis Logic........................................................................................... 761 DTC Confirmation Procedure......................................................................................... 761 Wiring Diagram..................................................................................................... 763 Diagnostic Procedure............................................................................................... 764 Component Inspection............................................................................................... 765 DTC P0446 EVAPORATIVE EMISSION (EVAP) CANISTER VENT CONTROL VALVE (CIRCUIT)............................................ 766 Component Description.............................................................................................. 766 CONSULT Reference Value in Data Monitor Mode....................................................................... 766 ECM Terminals and Reference Value.................................................................................. 766 On Board Diagnosis Logic........................................................................................... 766 DTC Confirmation Procedure......................................................................................... 766 Wiring Diagram..................................................................................................... 768 Diagnostic Procedure............................................................................................... 769 Component Inspection............................................................................................... 770 DTC P0450 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM PRESSURE SENSOR................................................... 772 Component Description.............................................................................................. 772 CONSULT Reference Value in Data Monitor Mode...................................................................... 772 ECM Terminals and Reference Value.................................................................................. 772 On Board Diagnosis Logic........................................................................................... 773 DTC Confirmation Procedure......................................................................................... 773 Wiring Diagram..................................................................................................... 775 Diagnostic Procedure............................................................................................... 776 Component Inspection............................................................................................... 778 DTC P0500 VEHICLE SPEED SENSOR (VSS)................................................................................... 780 Component Description.............................................................................................. 780 ECM Terminals and Reference Value.................................................................................. 780 On Board Diagnosis Logic........................................................................................... 780 DTC Confirmation Procedure......................................................................................... 780 Overall Function Check............................................................................................. 781 Wiring Diagram..................................................................................................... 783 Diagnostic Procedure............................................................................................... 784 DTC P0505 IDLE AIR CONTROL VALVE (IACV)- AUXILIARY AIR CONTROL (AAC) VALVE............................................. 785 Description........................................................................................................ 785 CONSULT Reference Value in Data Monitor Mode....................................................................... 786 ECM Terminals and Reference Value.................................................................................. 786 On Board Diagnosis Logic........................................................................................... 786 DTC Confirmation Procedure......................................................................................... 786 Wiring Diagram..................................................................................................... 789 Diagnostic Procedure............................................................................................... 790 Component Inspection............................................................................................... 791 DTC P0510 CLOSED THROTTLE POSITION SWITCH.............................................................................. 792 Component Description.............................................................................................. 792 CONSULT Reference Value in Data Monitor Mode....................................................................... 792 ECM Terminals and Reference Value.................................................................................. 792 On Board Diagnosis Logic........................................................................................... 792 DTC Confirmation Procedure......................................................................................... 793 Overall Function Check............................................................................................. 793 Wiring Diagram..................................................................................................... 794 Diagnostic Procedure............................................................................................... 795 Component Inspection............................................................................................... 796 DTC P0600 A/T CONTROL.................................................................................................. 798 System Description................................................................................................. 798 ECM Terminals and Reference Value.................................................................................. 798 On Board Diagnosis Logic........................................................................................... 798 DTC Confirmation Procedure......................................................................................... 798 Overall Function Check............................................................................................. 799 Wiring Diagram..................................................................................................... 800 Diagnostic Procedure............................................................................................... 801 DTC P0605 ECM.......................................................................................................... 802 Component Description.............................................................................................. 802 On Board Diagnosis Logic........................................................................................... 802 DTC Confirmation Procedure......................................................................................... 802 Diagnostic Procedure............................................................................................... 803 DTC P1105 MANIFOLD ABSOLUTE PRESSURE (MAP)/BAROMETRIC PRESSURE (BARO) SWITCH SOLENOID VALVE............................ 804 Description........................................................................................................ 804 CONSULT Reference Value in Data Monitor Mode....................................................................... 804 ECM Terminals and Reference Value.................................................................................. 805 On Board Diagnosis Logic........................................................................................... 805 DTC Confirmation Procedure......................................................................................... 805 Wiring Diagram..................................................................................................... 808 Diagnostic Procedure............................................................................................... 809 Component Inspection............................................................................................... 813 DTC P1148 (RIGHT BANK, -B1), P1168 (LEFT BANK, -B2) CLOSED LOOP CONTROL................................................ 814 On Board Diagnosis Logic........................................................................................... 814 DTC Confirmation Procedure......................................................................................... 814 Overall Function Check............................................................................................. 815 Diagnostic Procedure............................................................................................... 815 DTC P1320 IGNITION SIGNAL.............................................................................................. 816 Component Description.............................................................................................. 816 ECM Terminals and Reference Value.................................................................................. 816 On Board Diagnosis Logic........................................................................................... 817 DTC Confirmation Procedure......................................................................................... 817 Wiring Diagram..................................................................................................... 818 Diagnostic Procedure............................................................................................... 819 Component Inspection............................................................................................... 821 DTC P1336 CRANKSHAFT POSITION SENSOR (CKPS) (OBD) (COG)................................................................ 822 Component Description.............................................................................................. 822 ECM Terminals and Reference Value.................................................................................. 822 On Board Diagnosis Logic........................................................................................... 822 DTC Confirmation Procedure......................................................................................... 823 Wiring Diagram..................................................................................................... 824 Diagnostic Procedure............................................................................................... 825 Component Inspection............................................................................................... 826 DTC P1400 EGRC-SOLENOID VALVE.......................................................................................... 827 Component Description.............................................................................................. 827 CONSULT Reference Value in Data Monitor Mode....................................................................... 827 ECM Terminals and Reference Value.................................................................................. 827 On Board Diagnosis Logic........................................................................................... 827 DTC Confirmation Procedure......................................................................................... 827 Wiring Diagram..................................................................................................... 829 Diagnostic Procedure............................................................................................... 830 Component Inspection............................................................................................... 830 DTC P1401 EGR TEMPERATURE SENSOR....................................................................................... 832 Component Description.............................................................................................. 832 On Board Diagnosis Logic........................................................................................... 832 DTC Confirmation Procedure......................................................................................... 833 Overall Function Check............................................................................................. 835 Wiring Diagram .................................................................................................... 836 Diagnostic Procedure............................................................................................... 837 Component Inspection............................................................................................... 838 DTC P1402 EGR FUNCTION (OPEN).......................................................................................... 839 Description........................................................................................................ 839 On Board Diagnosis Logic........................................................................................... 840 DTC Confirmation Procedure......................................................................................... 840 Wiring Diagram..................................................................................................... 842 Diagnostic Procedure............................................................................................... 843 Component Inspection............................................................................................... 844 DTC P1440 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM (SMALL LEAK) (POSITIVE PRESSURE).................................. 845 On Board Diagnosis Logic........................................................................................... 845 DTC Confirmation Procedure......................................................................................... 846 Diagnostic Procedure............................................................................................... 847 DTC P1444 EVAPORATIVE EMISSION (EVAP) CANISTER PURGE VOLUME CONTROL SOLENOID VALVE..................................... 852 Description........................................................................................................ 852 CONSULT Reference Value in Data Monitor Mode....................................................................... 852 ECM Terminals and Reference Value.................................................................................. 853 On Board Diagnosis Logic........................................................................................... 853 DTC Confirmation Procedure......................................................................................... 854 Wiring Diagram..................................................................................................... 855 Diagnostic Procedure............................................................................................... 856 Component Inspection............................................................................................... 856 DTC P1446 EVAPORATIVE EMISSION (EVAP) CANISTER VENT CONTROL VALVE (CLOSE).............................................. 859 Component Description.............................................................................................. 859 CONSULT Reference Value in Data Monitor Mode....................................................................... 859 ECM Terminals and Reference Value.................................................................................. 859 On Board Diagnosis Logic........................................................................................... 859 DTC Confirmation Procedure......................................................................................... 860 Wiring Diagram..................................................................................................... 861 Diagnostic Procedure............................................................................................... 862 Component Inspection............................................................................................... 863 DTC P1447 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM PURGE FLOW MONITORING............................................. 864 System Description................................................................................................. 864 On Board Diagnosis Logic........................................................................................... 864 DTC Confirmation Procedure......................................................................................... 865 Overall Function Check............................................................................................. 865 Diagnostic Procedure............................................................................................... 867 DTC P1448 EVAPORATIVE EMISSION (EVAP) CANISTER VENT CONTROL VALVE (OPEN)............................................... 870 Component Description.............................................................................................. 870 CONSULT Reference Value in Data Monitor Mode....................................................................... 870 ECM Terminals and Reference Value.................................................................................. 870 On Board Diagnosis Logic........................................................................................... 870 DTC Confirmation Procedure......................................................................................... 871 Overall Function Check............................................................................................. 872 Wiring Diagram..................................................................................................... 873 Diagnostic Procedure............................................................................................... 874 Component Inspection............................................................................................... 875 DTC P1490 VACUUM CUT VALVE BYPASS VALVE (CIRCUIT)...................................................................... 877 Description........................................................................................................ 877 CONSULT Reference Value in Data Monitor Mode....................................................................... 877 ECM Terminals and Reference Value.................................................................................. 877 On Board Diagnosis Logic........................................................................................... 878 DTC Confirmation Procedure......................................................................................... 878 Wiring Diagram..................................................................................................... 879 Diagnostic Procedure .............................................................................................. 880 Component Inspection............................................................................................... 881 DTC P1491 VACUUM CUT VALVE BYPASS VALVE................................................................................ 882 Description........................................................................................................ 882 CONSULT Reference Value in Data Monitor Mode....................................................................... 882 ECM Terminals and Reference Value.................................................................................. 882 On Board Diagnosis Logic........................................................................................... 883 DTC Confirmation Procedure......................................................................................... 883 Overall Function Check............................................................................................. 884 Wiring Diagram..................................................................................................... 885 Diagnostic Procedure............................................................................................... 886 Component Inspection............................................................................................... 888 DTC P1605 A/T DIAGNOSIS COMMUNICATION LINE............................................................................. 889 Component Description.............................................................................................. 889 ECM Terminals and Reference Value.................................................................................. 889 On Board Diagnosis Logic........................................................................................... 889 DTC Confirmation Procedure......................................................................................... 889 Wiring Diagram..................................................................................................... 890 Diagnostic Procedure............................................................................................... 891 DTC P1706 PARK/NEUTRAL POSITION (PNP) SWITCH........................................................................... 892 Component Description.............................................................................................. 892 CONSULT Reference Value in Data Monitor Mode....................................................................... 892 ECM Terminals and Reference Value.................................................................................. 892 On Board Diagnosis Logic........................................................................................... 892 DTC Confirmation Procedure......................................................................................... 892 Overall Function Check............................................................................................. 894 Wiring Diagram..................................................................................................... 895 Diagnostic Procedure............................................................................................... 896 TROUBLE DIAGNOSIS OFR OVERHEAT (COOLING SYSTEM)........................................................................ 900 System Description................................................................................................. 900 CONSULT Reference Value in Data Monitor Mode....................................................................... 900 ECM Terminals and Reference Value.................................................................................. 900 On Board Diagnosis Logic........................................................................................... 900 Overall Function Check............................................................................................. 901 Wiring Diagram..................................................................................................... 903 Diagnostic Procedure............................................................................................... 904 Main 12 Causes of Overheating...................................................................................... 907 Component Inspection............................................................................................... 908 INJECTOR............................................................................................................... 909 Component Description.............................................................................................. 909 CONSULT Reference Value in Data Monitor Mode....................................................................... 909 ECM Terminals and Reference Value.................................................................................. 909 Wiring Diagram..................................................................................................... 910 Diagnostic Procedure............................................................................................... 911 Component Inspection............................................................................................... 912 START SIGNAL........................................................................................................... 913 CONSULT Reference Value in Data Monitor Mode....................................................................... 913 ECM Terminals and Reference Value.................................................................................. 913 Wiring Diagram..................................................................................................... 914 Diagnostic Procedure............................................................................................... 915 FUEL PUMP.............................................................................................................. 917 System Description................................................................................................. 917 Component Description.............................................................................................. 917 CONSULT Reference Value in Data Monitor Mode....................................................................... 917 ECM Terminals and Reference Value.................................................................................. 917 Wiring Diagram..................................................................................................... 918 Diagnostic Procedure............................................................................................... 919 Component Inspection............................................................................................... 920 POWER STEERING OIL PRESSURE SWITCH..................................................................................... 922 Component Description.............................................................................................. 922 CONSULT Reference Value in Data Monitor Mode....................................................................... 922 ECM Terminals and Reference Value.................................................................................. 922 Wiring Diagram..................................................................................................... 923 Diagnostic Procedure............................................................................................... 924 Component Inspection............................................................................................... 926 IACV-FICD SOLENOID VALVE............................................................................................... 927 Component Description.............................................................................................. 927 ECM Terminals and Reference Value.................................................................................. 927 Wiring Diagram..................................................................................................... 928 Diagnostic Procedure............................................................................................... 928 Component Inspection............................................................................................... 930 MIL & DATA LINK CONNECTORS............................................................................................. 932 Wiring Diagram..................................................................................................... 932 SERVICE DATA AND SPECIFICATION (SDS)................................................................................... 933 Fuel Pressure Regulator............................................................................................ 933 Idle Speed and Ignition Timing..................................................................................... 933 Ignition Coil...................................................................................................... 933 Mass Air Flow Sensor............................................................................................... 933 Engine Coolant Temperature Sensor.................................................................................. 933 EGR Temperature Sensor............................................................................................. 933 Front Heated Oxygen Sensor Heater.................................................................................. 933 Fuel Pump.......................................................................................................... 934 IACV-AAC Valve..................................................................................................... 934 Injector........................................................................................................... 934 Resister........................................................................................................... 934 Throttle Position Sensor........................................................................................... 934 Calculated Load Value.............................................................................................. 934 Intake Air Temperature Sensor...................................................................................... 934 Rear Heated Oxygen Sensor Heater................................................................................... 934 Crankshaft Position Sensor (OBD)................................................................................... 934 Tank Fuel Temperature Sensor....................................................................................... 934 el......................................................................................................................... 935 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents...................................................................................................... 935 PRECAUTIONS AND PREPARATION............................................................................................ 938 Supplemental Restraint System (SRS) "AIR BAG"...................................................................... 938 HARNESS CONNECTOR...................................................................................................... 939 Description........................................................................................................ 939 STANDARDIZED RELAY..................................................................................................... 941 Description........................................................................................................ 941 POWER SUPPLY ROUTING................................................................................................... 944 Schematic.......................................................................................................... 944 Wiring Diagram - POWER-............................................................................................ 946 Fuse............................................................................................................... 951 Fusible Link....................................................................................................... 951 Circuit Breaker Inspection......................................................................................... 951 GROUND DISTRIBUTION.................................................................................................... 952 Main Harness....................................................................................................... 952 Engine Room Harness................................................................................................ 954 Engine Control Harness............................................................................................. 956 Generator Harness.................................................................................................. 958 BATTERY................................................................................................................ 959 How to Handle Battery.............................................................................................. 959 Service Data and Specifications (SDS).............................................................................. 962 STARTING SYSTEM........................................................................................................ 963 System Description................................................................................................. 963 Wiring Diagram - START-............................................................................................ 965 Construction....................................................................................................... 967 Removal and Installation........................................................................................... 968 Pinion/Clutch Check................................................................................................ 968 Service Data and Specifications (SDS).............................................................................. 968 CHARGING SYSTEM........................................................................................................ 969 System Description................................................................................................. 969 Wiring Diagram - CHARGE-........................................................................................... 970 Trouble Diagnoses.................................................................................................. 971 Construction....................................................................................................... 972 Removal and Installation........................................................................................... 973 Service Data and Specifications (SDS).............................................................................. 973 COMBINATION SWITCH..................................................................................................... 974 Check.............................................................................................................. 974 Replacement........................................................................................................ 975 STEERING SWITCH........................................................................................................ 976 Check.............................................................................................................. 976 HEADLAMP............................................................................................................... 976 System Description (For USA)....................................................................................... 976 Wiring DIagram (For USA) - H/LAMP -................................................................................ 978 Trouble Diagnoses.................................................................................................. 979 Bulb Replacement................................................................................................... 980 Aiming Adjustment.................................................................................................. 980 HEADLAMP - Daytime Light System........................................................................................ 982 System Description (For Canada).................................................................................... 982 Operation (For Canada)............................................................................................. 983 Schematic (For Canada)............................................................................................. 984 Wiring Diagram (For Canada) - DTRL -............................................................................... 985 Trouble Diagnoses (For Canada)..................................................................................... 988 Bulb Replacement................................................................................................... 989 Aiming Adjustment.................................................................................................. 989 PARKING, LICENSE AND TAIL LAMPS........................................................................................ 990 Wiring Diagram - TAIL/L............................................................................................ 990 STOP LAMP.............................................................................................................. 992 Wiring Diagram - STOP/L............................................................................................ 992 BACK-UP LAMP........................................................................................................... 993 Wiring Diagram - BACK/L............................................................................................ 993 FRONT FOG LAMP......................................................................................................... 994 System Description................................................................................................. 994 Wiring DIagram - F/FOG............................................................................................. 995 Aiming Adjustment.................................................................................................. 996 Removal and Installation........................................................................................... 997 Bulb and Lens Replacement.......................................................................................... 997 TURN SIGNAL AND HAZARD WARNING LAMPS................................................................................... 998 System Description................................................................................................. 998 Wiring Diagram - TURN -............................................................................................1000 Trouble Diagnoses..................................................................................................1002 Electrical Components Inspection...................................................................................1002 ILLUMINATION...........................................................................................................1003 System Description.................................................................................................1003 Wiring Diagram - ILL...............................................................................................1004 INTERIOR ROOM LAMP.....................................................................................................1005 Component Parts and Harness Connector Location.....................................................................1005 System Description.................................................................................................1006 Wiring DIagram - ROOM/L............................................................................................1008 Trouble DIagnoses (For models with power door locks)...............................................................1011 SPOT LAMP..............................................................................................................1012 Wiring Diagram - INT/L.............................................................................................1012 METER AND GAUGES.......................................................................................................1013 Component Parts and Harness Connector Location.....................................................................1013 System Description.................................................................................................1014 Unified Control Meter..........................................................................................1014 How to Change The Display for Odo/Trip Meter...................................................................1014 Combination Meter..................................................................................................1016 With Tachometer................................................................................................1016 Without Tachometer.............................................................................................1017 Wiring Diagram - METER -...........................................................................................1018 Meter/gauge Operation and Odo/Trip Meter...........................................................................1019 Segment Check in Diagnosis Mode....................................................................................1019 Diagnosis Function.............................................................................................1019 How to Alternate Diagnosis Mode................................................................................1019 Flexible Print CIrcuit (FPC).......................................................................................1020 Disconnect.....................................................................................................1020 Connect........................................................................................................1020 Trouble Diagnoses..................................................................................................1021 Preliminary Check..............................................................................................1021 Symptom Chart 1 (Malfunction is indicated in diagnosis mode)...................................................1022 Symptom Chart 2 (No malfunction is indicated in diagnosis mode)................................................1022 Power Supply And Ground Circuit Check..........................................................................1023 Inspection/Vehicle Speed Sensor................................................................................1024 Inspection/Engine Revolution Signal (Models with tachometer)...................................................1024 Inspection/Fuel Tank Gauge.....................................................................................1025 Inspection/Thermal Transmitter.................................................................................1025 Electrical Components Inspection...................................................................................1026 Meter/Gauge Resistance Check...................................................................................1026 Fuel Tank Gauge Unit Check.....................................................................................1026 Thermal Transmitter Check......................................................................................1027 Vehicle Speed Sensor Signal Check..............................................................................1027 WARNING LAMPS..........................................................................................................1028 System Description.................................................................................................1028 Schematic..........................................................................................................1030 Wiring Diagram - WARN -............................................................................................1031 Electrical Components Inspection...................................................................................1036 A/T INDICATOR..........................................................................................................1037 Wiring Diagram - AT/IND -..........................................................................................1037 WARNING CHIME..........................................................................................................1038 Component Parts and Harness Connector..............................................................................1038 Location...........................................................................................................1038 System Description.................................................................................................1039 Wiring Diagram - CHIME -...........................................................................................1040 Trouble Diagnoses..................................................................................................1043 Electrical Components Inspection...................................................................................1047 FRONT WIPER AND WASHER.................................................................................................1050 System Description.................................................................................................1050 Wiring Diagram - WIPER -...........................................................................................1052 Trouble DIagnoses (With intermittent wipers).......................................................................1054 Removal and Installation...........................................................................................1056 Washer Nozzle Adjustment...........................................................................................1057 Washer Tube Layout.................................................................................................1057 HORN...................................................................................................................1058 Wiring Diagram - HORN -............................................................................................1058 CIGARETTE LIGHTER......................................................................................................1059 Wiring Diagram - CIGAR -...........................................................................................1059 AUDIO..................................................................................................................1060 System Description.................................................................................................1060 Base Audio System..............................................................................................1060 Premium Audio System...........................................................................................1060 Wiring Diagram - AUDIO -...........................................................................................1061 Trouble Diagnoses..................................................................................................1064 Inspection.........................................................................................................1065 AUDIO ANTENNA..........................................................................................................1067 Fixed Antenna Rod Replacement......................................................................................1067 Removal............................................................................................................1067 Installation.......................................................................................................1067 POWER DOOR MIRROR......................................................................................................1068 Wiring Diagram - MIRROR -..........................................................................................1068 AUTOMATIC SPEED CONTROL DEVICE (ASCD)..................................................................................1069 Component Parts and Harness Connector Location.....................................................................1069 System Description.................................................................................................1070 Schematic..........................................................................................................1072 Wiring Diagram - ASCD -............................................................................................1074 Fail-Safe System Description.......................................................................................1078 Fail-Safe System Check.............................................................................................1079 Trouble Diagnoses..................................................................................................1080 ASCD Wire Adjustment...............................................................................................1088 Electrical Components Inspection...................................................................................1089 POWER WINDOW...........................................................................................................1090 System Description.................................................................................................1090 Wiring Diagram - WINDOW -..........................................................................................1092 Trouble Diagnoses..................................................................................................1094 POWER DOOR LOCK........................................................................................................1095 Component Parts and Harness Connector Location.....................................................................1095 System Description.................................................................................................1096 Schematic..........................................................................................................1098 Wiring Diagram - D/LOCK -..........................................................................................1099 Trouble Diagnoses..................................................................................................1102 MULTI-REMOTE CONTROL SYSTEM............................................................................................1110 Component Parts and Harness Connector Location.....................................................................1110 System Description.................................................................................................1111 Schematic..........................................................................................................1113 Wiring Diagram - MULTI -...........................................................................................1114 Trouble Diagnoses..................................................................................................1117 Electrical Components Inspection...................................................................................1123 ID Code Entry Procedure............................................................................................1124 THEFT WARNING SYSTEM...................................................................................................1125 Component Parts and Harness Connector Location.....................................................................1125 System Description.................................................................................................1127 Schematic..........................................................................................................1130 Wiring Diagram - THEFT -...........................................................................................1131 Trouble Diagnoses..................................................................................................1134 SMART ENTRANCE CONTROL UNIT............................................................................................1145 Description........................................................................................................1145 Input/Output Operation Signal......................................................................................1146 Schematic..........................................................................................................1148 LOCATION OF ELECTRICAL UNITS...........................................................................................1150 Engine Compartment.................................................................................................1150 Passenger Compartment..............................................................................................1151 HARNESS LAYOUT.........................................................................................................1153 Outline............................................................................................................1153 How to Read Harness Layout.........................................................................................1154 Main Harness.......................................................................................................1156 Engine Room Harness................................................................................................1158 Engine Control Harness.............................................................................................1162 Engine No. 2 Harness...............................................................................................1164 Chassis and Tail Harness...........................................................................................1166 Room Lamp Harness..................................................................................................1167 Door Harness.......................................................................................................1168 Air Bag Harness....................................................................................................1169 BULB SPECIFICATIONS....................................................................................................1170 Headlamps..........................................................................................................1170 Exterior Lamps.....................................................................................................1170 Interior Lamps.....................................................................................................1170 WIRING DIAGRAM CODES (CELL CODES)......................................................................................1171 em.........................................................................................................................1173 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS......................................................................................................1173 PRECAUTIONS............................................................................................................1175 Parts Requiring Angular Tightening.................................................................................1175 Liquid Gasket Application Procedure................................................................................1175 PREPARATION............................................................................................................1176 Special Service Tools..............................................................................................1176 Commercial Service Tools...........................................................................................1178 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING...................................................................1179 NVH Troubleshooting Chart - Engine Noise...........................................................................1180 OUTER COMPONENT PARTS .................................................................................................1181 COMPRESSION PRESSURE...................................................................................................1183 Measurement of Compression Pressure....................................................................................1183 OIL PAN................................................................................................................1184 Removal ...........................................................................................................1184 Installation.......................................................................................................1185 TIMING BELT............................................................................................................1187 Removal ...........................................................................................................1188 Inspection.........................................................................................................1189 Belt Tensioner And Tensioner Spring ...........................................................................1190 Installation ......................................................................................................1190 Tension Adjustment.................................................................................................1191 After Belt Replacement ........................................................................................1191 After Engine Overhaul Or Engine Reassembly (With Rocker Covers Removed)........................................1191 OIL SEAL REPLACEMENT...................................................................................................1194 Valve Oil Seal ....................................................................................................1194 Oil Seal Installing Direction......................................................................................1194 Camshaft Oil Seal..................................................................................................1194 Front Oil Seal.....................................................................................................1195 Rear Oil Seal......................................................................................................1195 CYLINDER HEAD..........................................................................................................1196 Removal ...........................................................................................................1197 Disassembly .......................................................................................................1199 Inspection.........................................................................................................1200 Cylinder Head Distortion.......................................................................................1200 Camshaft Visual Check .........................................................................................1200 Camshaft Runout ...............................................................................................1200 Camshaft Cam Height............................................................................................1200 Camshaft Journal Clearance ....................................................................................1201 Camshaft End Play..............................................................................................1201 Camshaft Sprocket Runout.......................................................................................1202 Valve Guide Clearance .........................................................................................1202 Valve Guide Replacement........................................................................................1202 Valve Seats ...................................................................................................1203 Replacing Valve Seat For Service Parts.........................................................................1203 Valve Dimensions ..............................................................................................1204 Valve Spring ..................................................................................................1204 Squareness.................................................................................................1204 Pressure ..................................................................................................1204 Rocker Shaft And Rocker Arm....................................................................................1205 Hydraulic Valve Litter ........................................................................................1205 Assembly ..........................................................................................................1205 Installation ......................................................................................................1206 ENGINE REMOVAL.........................................................................................................1210 Front Engine Mounting .............................................................................................1210 Rear Engine Mounting ..............................................................................................1211 Removal ...........................................................................................................1212 CYLINDER BLOCK ........................................................................................................1213 Disassembly .......................................................................................................1214 Piston And Crankshaft .........................................................................................1214 Inspection.........................................................................................................1214 Piston And Piston Pin Clearance ...............................................................................1214 Piston Ring Side Clearance ....................................................................................1215 Piston Ring End Gap............................................................................................1215 Connecting Rod Bend And Torsion................................................................................1215 Cylinder Block Distortion And Wear ............................................................................1216 Piston-To-Bore Clearance ......................................................................................1216 Crankshaft ....................................................................................................1218 Bearing Clearance..............................................................................................1218 Method A (Using bore gauge & micrometer)...................................................................1218 Connecting rod bearing (Big end)...............................................................................1219 Method B (Using plastigage)................................................................................1220 Connecting Rod Bushing Clearance (Small end) ..................................................................1220 Replacement of Connecting Rod Bushing (Small end)..............................................................1220 Flywheel/Drive Plate Runout ...................................................................................1220 Assembly...........................................................................................................1221 Piston ........................................................................................................1221 Crankshaft.....................................................................................................1221 Replacing Pilot Bushing (M/T) Or Pilot Converter (A/T).........................................................1223 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1224 General Specifications.............................................................................................1224 Inspection and Adjustment..........................................................................................1224 Cylinder Head..................................................................................................1224 Valve..........................................................................................................1225 Valve spring...............................................................................................1225 Hydraulic valve lifter.....................................................................................1225 Valve guide................................................................................................1225 Rocker shaft and rocker arm................................................................................1225 Intake valve seat..........................................................................................1226 Exhaust valve seat.........................................................................................1226 Camshaft And Camshaft Bearing..................................................................................1226 Cylinder Block.................................................................................................1227 Connecting Rod.................................................................................................1227 Piston, Piston Ring And Piston Pin.............................................................................1227 Available piston...........................................................................................1227 Piston Ring................................................................................................1227 Piston pin.................................................................................................1228 Crankshaft.....................................................................................................1228 Available Main Bearing.........................................................................................1228 No. 1 main bearing.........................................................................................1228 No. 2 and 3 main bearing...................................................................................1228 No. 4 main bearing.........................................................................................1229 Main bearing 0.25 mm (0.0098 In) undersize.................................................................1229 Available Connecting Rod Bearing...............................................................................1229 Connecting rod bearing undersize...........................................................................1229 Miscellaneous Components.......................................................................................1229 Bearing clearance..........................................................................................1229 fa.........................................................................................................................1230 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS......................................................................................................1230 PRECAUTIONS AND PREPARATION............................................................................................1231 Precautions........................................................................................................1231 Special Service Tools..............................................................................................1231 Commercial Service Tools...........................................................................................1232 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING...................................................................1233 NVH Troubleshooting Chart..........................................................................................1233 FRONT SUSPENSION SYSTEM................................................................................................1234 ON-VEHICLE SERVICE.....................................................................................................1235 Front Axle and Front Suspension Parts..............................................................................1235 Front Wheel Bearing................................................................................................1235 Front Wheel Alignment..............................................................................................1236 Drive Shaft........................................................................................................1240 FRONT AXLE.............................................................................................................1241 Manual-lock Free-running Hub.......................................................................................1242 Auto-lock Free-running Hub.........................................................................................1243 Wheel Hub and Rotor Disc...........................................................................................1243 Knuckle Spindle....................................................................................................1245 Drive Shaft........................................................................................................1248 Shock Absorber.....................................................................................................1254 Torsion Bar Spring.................................................................................................1254 Stabilizer Bar.....................................................................................................1256 Upper Link.........................................................................................................1257 Tension Rod........................................................................................................1258 Upper Ball Joint and Lower Ball Joint..............................................................................1260 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1261 General Specifications.............................................................................................1261 Inspection and Adjustment..........................................................................................1261 fe.........................................................................................................................1264 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS......................................................................................................1264 PREPARATION............................................................................................................1265 Special Service Tools.............................................................................................1265 ACCELERATOR CONTROL SYSTEM.............................................................................................1266 Accelerator Control System.........................................................................................1266 Adjusting Accelerator Wire.........................................................................................1266 FUEL SYSTEM............................................................................................................1267 Fuel Tank..........................................................................................................1268 Removal........................................................................................................1268 Installation...................................................................................................1269 Fuel Pump and Gauge................................................................................................1270 Removal And Installation.......................................................................................1270 Exhaust System.........................................................................................................1271 foldout....................................................................................................................1273 QUICK REFERENCE INDEX.................................................................................................. 0 SUPER MULTIPLE JUNCTION (SMJ)..........................................................................................1273 Terminal Arrangement...............................................................................................1274 FUSE BLOCK - Junction Box (J/B)........................................................................................1275 FUSE AND FUSIBLE LINK BOX..............................................................................................1276 ELECTRICAL UNITS.......................................................................................................1277 JOINT CONNECTOR (J/C)..................................................................................................1278 gi.........................................................................................................................1279 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS......................................................................................................1279 PRECAUTIONS AND PREPARATION............................................................................................1280 Supplemental Restraint System (SRS) "AIR BAG"......................................................................1280 General Precautions................................................................................................1281 Precautions for Multiport Fuel Injection System or Engine Control System...........................................1283 Precautions for Three Way Catalyst.................................................................................1283 Precautions for Engine Oils........................................................................................1283 Precautions for Fuel...............................................................................................1284 Precautions for Air Conditioning ..................................................................................1284 HOW TO USE THIS MANUAL ................................................................................................1285 HOW TO READ WIRING DIAGRAMS ...........................................................................................1287 Sample/Wiring Diagrams - EXAMPL -.................................................................................1287 Description........................................................................................................1289 HOW TO CHECK TERMINAL..................................................................................................1295 Connector and Terminal Pin Kit.....................................................................................1295 How to Probe Connectors............................................................................................1295 How to Check Enlarged Contact Spring of Terminal...................................................................1296 Waterproof Connector Inspection....................................................................................1297 Terminal Lock Inspection...........................................................................................1297 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT.........................................................1298 Work Flow .........................................................................................................1298 Incident Simulation Tests .........................................................................................1299 Circuit Inspection.................................................................................................1301 HOW TO FOLLOW TROUBLE DIAGNOSES........................................................................................1308 How To Follow Flow Charts in Trouble Diagnoses.....................................................................1309 How to Follow Test Groups in Trouble Diagnoses.....................................................................1310 CONSULT CHECKING SYSTEM................................................................................................1313 Function and System Application ...................................................................................1313 Lithium Battery Replacement........................................................................................1313 Checking Equipment.................................................................................................1313 Loading Procedure..................................................................................................1314 CONSULT Data Link Connector (DLC) Circuit..........................................................................1314 IDENTIFICATION INFORMATION.............................................................................................1315 Model Variation....................................................................................................1315 Identification Number..............................................................................................1316 Dimensions ........................................................................................................1318 Wheels and Tires...................................................................................................1318 LIFTING POINT AND TOW TRUCK TOWING.....................................................................................1319 Pantograph Jack....................................................................................................1319 Garage Jack and Safety Stand.......................................................................................1320 2-pole Lift........................................................................................................1321 Tow Truck Towing...................................................................................................1322 4-Wheel DRIVE MODELS...........................................................................................1322 Towing Point.......................................................................................................1323 Vehicle Recovery (Freeing a stuck vehicle).....................................................................1323 TIGHTENING TORQUE OF STANDARD BOLTS....................................................................................1324 SAE J1930 TERMINOLOGY LIST.............................................................................................1325 ha.........................................................................................................................1329 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS......................................................................................................1329 PRECAUTIONS AND PREPARATION............................................................................................1330 Supplemental Restraint System (SRS) "AIR BAG"......................................................................1330 Precautions for Working with R-134a................................................................................1330 Contaminated Refrigerant.......................................................................................1331 General Refrigerant Precautions....................................................................................1331 Precautions for Refrigerant Connection.............................................................................1332 Precautions for Servicing Compressor...............................................................................1335 R-134a Service Tools and Equipment.................................................................................1336 Special Service Tools..............................................................................................1337 Commercial Service Tools...........................................................................................1338 Precautions for Service Equipment..................................................................................1339 DESCRIPTION............................................................................................................1341 Refrigeration Cycle................................................................................................1341 Control Operation..................................................................................................1342 Component Layout...................................................................................................1343 Discharge Air Flow.................................................................................................1344 Component Location.................................................................................................1345 Circuit Diagram....................................................................................................1347 Wiring Diagram -HEATER-............................................................................................1348 Wiring Diagram -A/C-...............................................................................................1349 Operational Check..................................................................................................1351 TROUBLE DIAGNOSES......................................................................................................1353 How to Perform Trouble Diagnoses for Quick and Accurate Repair.....................................................1353 Blower Motor Circuit...............................................................................................1354 Air Outlet.........................................................................................................1358 Intake Door........................................................................................................1360 Magnet Clutch Circuit..............................................................................................1361 Triple-Pressure Switch.........................................................................................1365 Trouble Diagnosis Procedure For Insufficient Cooling...............................................................1367 Performance Test Diagnoses.........................................................................................1369 Performance Chart..................................................................................................1371 Trouble Diagnoses for Abnormal Pressure............................................................................1372 Trouble Diagnosis for Insufficient Heating.........................................................................1375 Trouble Diagnosis for Noise........................................................................................1377 SERVICE PROCEDURES.....................................................................................................1378 Refrigerant Lines..................................................................................................1378 Checking Refrigerant Leaks.........................................................................................1379 R-134a Service Procedure...........................................................................................1383 Compressor Lubricant Quantity......................................................................................1384 Compressor Mounting................................................................................................1386 Belt Tension.......................................................................................................1386 Fast Idle Control Device (FICD)....................................................................................1386 Condenser..........................................................................................................1386 Compressor.........................................................................................................1388 Compressor Clutch..................................................................................................1388 Thermal Protector..................................................................................................1391 Heater Unit (Heater Core)..........................................................................................1392 Cooling Unit (A/C Evaporator)......................................................................................1393 Blower Case and Motor..............................................................................................1394 Fan Lever and Illumination Bulbs...................................................................................1395 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1396 General Specifications.............................................................................................1396 Inspection and Adjustment..........................................................................................1396 idx........................................................................................................................1397 QUICK REFERENCE INDEX.................................................................................................. 0 lc.........................................................................................................................1407 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS......................................................................................................1407 PREPARATION/PRECAUTION.................................................................................................1408 Special Service Tools..............................................................................................1408 Liquid Gasket Application Procedure................................................................................1409 ENGINE LUBRICATION SYSTEM..............................................................................................1410 Lubrication Circuit ...............................................................................................1410 Oil Pressure Check ................................................................................................1410 Oil Pump...........................................................................................................1411 Removal And Installation.......................................................................................1411 QUICK REFERENCE INDEX..........................................................................................1411 Disassembly And Assembly......................................................................................1411 Inspection.....................................................................................................1412 Regulator Valve Inspection.....................................................................................1412 Oil Filter ....................................................................................................1412 Oil Filter Bracket.............................................................................................1413 ENGINE COOLING SYSTEM..................................................................................................1414 Cooling Circuit ...................................................................................................1414 System Check.......................................................................................................1414 Checking Cooling System Hoses..................................................................................1414 Checking Cooling System For Leaks..............................................................................1414 Checking Radiator .............................................................................................1414 Checking Radiator Cap..........................................................................................1414 Water Pump ........................................................................................................1416 Removal And Installation.......................................................................................1416 Inspection ....................................................................................................1417 Thermostat ........................................................................................................1417 Removal .......................................................................................................1417 Inspection.....................................................................................................1417 Installation ..................................................................................................1418 Radiator ..........................................................................................................1418 Removal And Installation ......................................................................................1418 Cooling Fan (Crankshaft driven)....................................................................................1419 Removal And Installation ......................................................................................1419 Inspection ....................................................................................................1420 Refilling Engine Coolant...........................................................................................1420 Inspection.....................................................................................................1420 Overheating Cause Analysis.........................................................................................1421 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1422 Engine Lubrication System..............................................................................................1422 Oil pressure ......................................................................................................1422 Regulator valve ...................................................................................................1422 Oil pump ..........................................................................................................1422 Engine Cooling System..................................................................................................1422 Thermostat ........................................................................................................1422 Radiator...........................................................................................................1422 ma.........................................................................................................................1423 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS......................................................................................................1423 PRECAUTIONS AND PREPARATION............................................................................................1424 Supplemental Restraint System (SRS) " AIR BAG".....................................................................1424 Special Service Tool...............................................................................................1424 Commercial Service Tool............................................................................................1424 GENERAL MAINTENANCE ...................................................................................................1425 Schedule 1.........................................................................................................1428 Schedule 2.........................................................................................................1429 RECOMMENDED FLUIDS AND LUBRICANTS......................................................................................1430 Fluids and Lubricants .............................................................................................1430 SAE Viscosity Number...............................................................................................1431 Antifreeze Coolant Mixture Ratio...................................................................................1431 ENGINE MAINTENANCE.....................................................................................................1432 Checking Drive Belts...............................................................................................1432 Changing Engine Coolant............................................................................................1433 Checking Fuel Lines................................................................................................1435 Changing Fuel Filter...............................................................................................1435 Changing Air Cleaner Filter........................................................................................1436 Changing Engine Oil................................................................................................1436 Changing Oil Filter................................................................................................1437 Changing Spark Plugs...............................................................................................1437 Checking EVAP Vapor Lines..........................................................................................1439 CHASSIS AND BODY MAINTENANCE ..........................................................................................1440 Checking Exhaust System............................................................................................1440 Checking Clutch Fluid Level and Leaks..............................................................................1440 Checking M/T Oil...................................................................................................1440 Changing M/T Oil...................................................................................................1440 Checking Water Entry...............................................................................................1440 Checking A/T Fluid.................................................................................................1440 Changing A/T Fluid.................................................................................................1441 Checking Transfer Fluid............................................................................................1441 Changing Transfer Fluid............................................................................................1442 Checking Propeller Shaft...........................................................................................1442 Checking Differential Gear Oil.....................................................................................1442 Changing Differential Gear Oil.....................................................................................1443 Balancing Wheels ..................................................................................................1443 Tire Rotation .....................................................................................................1443 Checking Brake Fluid Level and Leaks...............................................................................1444 Checking Brake System..............................................................................................1444 Checking Disc Brake................................................................................................1444 Checking Drum Brake................................................................................................1444 Checking Steering Gear and Linkage ................................................................................1445 Checking Power Steering Fluid and Lines............................................................................1445 Lubricating Hood Latches, Locks and Hinges.........................................................................1446 Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters....................................................1447 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1448 Engine Maintenance ................................................................................................1448 Chassis and Body Maintenance.......................................................................................1448 mt.........................................................................................................................1449 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS......................................................................................................1449 PREPARATION............................................................................................................1450 Special Service Tools..............................................................................................1450 Commercial Service Tool............................................................................................1451 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING...................................................................1452 NVH Troubleshooting Chart..........................................................................................1452 DESCRIPTION............................................................................................................1453 Cross-sectional View...............................................................................................1453 ON-VEHICLE SERVICE.....................................................................................................1454 Position Switch Check..............................................................................................1454 REMOVAL AND INSTALLATION...............................................................................................1455 Removal............................................................................................................1455 Installation.......................................................................................................1456 MAJOR OVERHAUL.........................................................................................................1457 Case Components....................................................................................................1457 Gear Components....................................................................................................1458 Shift Control Components...........................................................................................1460 DISASSEMBLY............................................................................................................1461 Case Components....................................................................................................1461 Shift Control Components...........................................................................................1462 Gear Components....................................................................................................1463 INSPECTION.............................................................................................................1467 Shift Control Components...........................................................................................1467 Gear Components....................................................................................................1467 Gears And Shafts...............................................................................................1467 Synchronizers......................................................................................................1467 Bearings...........................................................................................................1468 ASSEMBLY...............................................................................................................1469 Gear Components....................................................................................................1469 Shift Control Components...........................................................................................1477 Case Components....................................................................................................1477 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1480 General Specifications.............................................................................................1480 Inspection and Adjustment..........................................................................................1481 Gear End Play......................................................................................................1481 Clearance Between Baulk Ring And Gear .............................................................................1481 Distance Between Rear Surface of Reverse...........................................................................1481 2nd and 3rd baulk ring.........................................................................................1481 Cone And Reverse Baulk Ring........................................................................................1481 Available Snap Ring................................................................................................1481 Main drive gear snap ring......................................................................................1481 Mainshaft front snap ring......................................................................................1481 Counter gear rear snap ring....................................................................................1482 Available C-Ring...................................................................................................1482 Mainshaft C-ring...............................................................................................1482 Available Shim And Washer..........................................................................................1482 Table for selecting proper counter gear front bearing thrust washer............................................1482 Reverse idler rear thrust washer...............................................................................1482 pd.........................................................................................................................1483 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS......................................................................................................1483 PREPARATION............................................................................................................1485 Special Service Tools..............................................................................................1485 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING...................................................................1489 NVH Troubleshooting Chart..........................................................................................1489 PROPELLER SHAFT........................................................................................................1490 On-Vehicle Service.................................................................................................1491 Removal and Installation...........................................................................................1491 Inspection.........................................................................................................1491 Disassembly........................................................................................................1492 Assembly...........................................................................................................1493 FINAL DRIVE............................................................................................................1495 ON-VEHICLE SERVICE.................................................................................................1495 Front Oil Seal Replacement.....................................................................................1495 (Front final drive: Model R200A)...........................................................................1495 (Rear final drive: Model H2338)............................................................................1495 REMOVAL AND INSTALLATION (Front final drive).......................................................................1497 Removal........................................................................................................1497 Installation...................................................................................................1497 REMOVAL AND INSTALLATION (Rear final drive)........................................................................1498 Removal........................................................................................................1498 Installation...................................................................................................1498 R200A..................................................................................................................1499 FRONT FINAL DRIVE..................................................................................................1499 DISASSEMBLY........................................................................................................1500 Pre-inspection.................................................................................................1500 Final Drive Housing............................................................................................1500 Differential Case..............................................................................................1503 Differential Side Shaft........................................................................................1503 INSPECTION.........................................................................................................1505 Ring Gear and Drive Pinion.....................................................................................1505 Differential Case Assembly.....................................................................................1505 Bearing........................................................................................................1505 ADJUSTMENT.........................................................................................................1506 Side Bearing Preload...........................................................................................1506 Pinion Gear Height and Pinion Bearing Preload..................................................................1507 Pinion Bearing Preload Washer Selection....................................................................1509 Pinion Height Adjusting Washer Selection...................................................................1510 Tooth Contact..................................................................................................1512 ASSEMBLY...........................................................................................................1513 Differential Side Shaft........................................................................................1513 Differential Case..............................................................................................1513 Final Drive Housing............................................................................................1515 H233B..................................................................................................................1519 REAR FINAL DRIVE ..................................................................................................1519 DISASSEMBLY........................................................................................................1520 Pre-inspection.................................................................................................1520 Differential Carrier...........................................................................................1520 Differential Case..............................................................................................1522 INSPECTION.........................................................................................................1524 Ring Gear and Drive Pinion.....................................................................................1524 Differential Case Assembly.....................................................................................1524 Bearing........................................................................................................1524 LIMITED SLIP DIFFERENTIAL..........................................................................................1525 Preparation for Disassembly....................................................................................1525 Checking Differential Torque...............................................................................1525 Disassembly....................................................................................................1525 Inspection.....................................................................................................1526 Contact Surfaces...........................................................................................1526 Disc And Plate.............................................................................................1526 Adjustment.....................................................................................................1527 Friction Disc And Friction Plate End Play..................................................................1527 Assembly.......................................................................................................1528 ADJUSTMENT.........................................................................................................1531 Pinion Gear Height.............................................................................................1531 Pinion Height Adjusting Washer Selection...................................................................1532 Tooth Contact..................................................................................................1534 ASSEMBLY...........................................................................................................1535 Differential Case..............................................................................................1535 Differential Carrier...........................................................................................1536 SERVICE DATA AND SPECIFICATIONS (SDS) .............................................................................1539 Propeller Shaft................................................................................................1539 General Specifications.....................................................................................1539 Inspection And Adjustment..............................................................................1539 Service data.......................................................................................1539 Snap ring..........................................................................................1539 Final Drive....................................................................................................1540 General Specifications.........................................................................................1540 Inspection And Adjustment (R200A)..............................................................................1540 Ring gear runout...........................................................................................1540 Side gear adjustment.......................................................................................1540 Side bearing adjustment....................................................................................1540 Inspection And Adjustment (H233B)..............................................................................1541 Ring gear runout...........................................................................................1541 -Additional service for LSD model- Differential torque adjustment..........................................1541 Drive pinion height adjustment.............................................................................1542 Drive pinion preload adjustment............................................................................1542 Total preload adjustment...................................................................................1542 ra.........................................................................................................................1543 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS......................................................................................................1543 PRECAUTIONS AND PREPARATION............................................................................................1544 Precautions........................................................................................................1544 Special Service Tools..............................................................................................1544 Commercial Service Tools...........................................................................................1545 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING...................................................................1546 NVH Troubleshooting Chart..........................................................................................1546 REAR AXLE AND REAR SUSPENSION..........................................................................................1547 ON-VEHICLE SERVICE.....................................................................................................1548 Rear Axle and Rear Suspension Parts................................................................................1548 Rear Wheel Bearing.................................................................................................1548 REAR AXLE..............................................................................................................1549 Components.........................................................................................................1549 Removal............................................................................................................1550 Inspection.........................................................................................................1552 Axle Shaft.....................................................................................................1552 Wheel Bearing .................................................................................................1552 Axle Case......................................................................................................1552 REAR SUSPENSION........................................................................................................1555 Shock Absorber.....................................................................................................1556 Removal and Installation.......................................................................................1556 Inspection.....................................................................................................1556 Leaf Spring........................................................................................................1556 Removal and Installation.......................................................................................1556 Inspection.....................................................................................................1557 Installation...................................................................................................1557 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1558 General Specifications.............................................................................................1558 Inspection and Adjustment..........................................................................................1558 rs.........................................................................................................................1559 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS......................................................................................................1559 PRECAUTIONS AND PREPARATION............................................................................................1560 Supplemental Restraint System (SRS) "AIR BAG"......................................................................1560 SEAT BELTS.............................................................................................................1561 Front Seat Belt....................................................................................................1562 Rear Seat Belt.....................................................................................................1563 Seat Belt Inspection...............................................................................................1564 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)....................................................................................1567 Precautions for SRS "AIR BAG" Service..............................................................................1567 Special Service Tools..............................................................................................1577 Description........................................................................................................1569 Passenger air bag deactivation switch..............................................................................1569 SRS Component Parts Location.......................................................................................1570 Maintenance Items..................................................................................................1571 Diagnosis Sensor Unit and Crash Zone Sensor........................................................................1572 Removal And Installation.......................................................................................1572 Air bag diagnosis sensor unit..............................................................................1572 Crash zone sensor..........................................................................................1572 Driver Air Bag Module and Spiral Cable.............................................................................1573 Pasenger Air Bag Module............................................................................................1577 Passenger Air Bag Deactivation Switch..............................................................................1579 Passenger Air Bag Deactivation Switch Lock Cylinder................................................................1579 Passenger Air Bag Deactivation Switch Indicator....................................................................1580 Disposal of Air Bag Module.........................................................................................1581 TROUBLE DIAGNOSES-Supplemental Restraint System (SRS)..................................................................1585 Trouble Diagnosis Introduction.....................................................................................1585 How to Perform Trouble Diagnoses for Quick and Accurate Repair.....................................................1588 Schematic..........................................................................................................1589 Wiring Diagram-SRS.................................................................................................1590 Passenger Air Bag Deactivation Switch Indicator Operation Check....................................................1592 SRS Operation Check................................................................................................1593 Trouble Diagnoses with CONSULT.....................................................................................1594 Trouble Diagnoses without CONSULT..................................................................................1603 Trouble Diagnoses: "AIR BAG" Warning Lamp Does Not Turn On.........................................................1607 Trouble Diagnoses: SRS Does Not Enter Diagnosis Mode Using Door Switch.............................................1609 COLLISION DIAGNOSIS....................................................................................................1610 st.........................................................................................................................1613 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS......................................................................................................1613 PRECAUTIONS AND PREPARATION............................................................................................1614 Supplemental Restrain System (SRS) "AIR BAG".......................................................................1614 Precautions for Steering System....................................................................................1614 Special Service Tools..............................................................................................1615 NOISE, VIBRATION AND HARSHNESS (NVH ) TROUBLESHOOTING..................................................................1617 NVH Troubleshooting Chart..........................................................................................1617 ON-VEHICLE SERVICE ....................................................................................................1618 Steering System....................................................................................................1618 Checking and Adjusting Drive Belts.................................................................................1618 Checking Fluid Level...............................................................................................1618 Checking Fluid Leakage.............................................................................................1619 Bleeding Hydraulic System..........................................................................................1619 Checking Steering Wheel Turning Force..............................................................................1620 Checking Steering Wheel Play.......................................................................................1620 Checking Neutral Position on Steering Wheel........................................................................1621 Checking.......................................................................................................1621 Checking Front Wheel Turning Angle.................................................................................1621 Checking Hydraulic System..........................................................................................1622 STEERING WHEEL AND STEERING COLUMN.....................................................................................1623 Steering Wheel.....................................................................................................1623 Removal And Installation.......................................................................................1623 Steering Column....................................................................................................1624 Removal........................................................................................................1624 Installation...................................................................................................1624 Disassembly and Assembly...........................................................................................1625 Tilt Mechanism.................................................................................................1626 Inspection.........................................................................................................1626 POWER STEERING SYSTEM (Model: PB59K)...................................................................................1627 Description........................................................................................................1627 POWER STEERING GEAR (Model: PB59K).....................................................................................1628 Removal and Installation...........................................................................................1628 Steering Gear..................................................................................................1628 Power Steering Gear Component......................................................................................1628 Pre-disassembly Inspection and Adjustment..........................................................................1629 Turning Torque Measurement.....................................................................................1629 Disassembly........................................................................................................1630 Assembly...........................................................................................................1631 POWER STEERING OIL PUMP................................................................................................1634 Disassembly and Assembly...........................................................................................1634 Pre-disassembly Inspection.........................................................................................1634 Inspection.........................................................................................................1635 Pulley And Pulley Shaft........................................................................................1635 Disassembly........................................................................................................1635 Assembly...........................................................................................................1636 STEERING LINKAGE.......................................................................................................1637 Removal and Installation...........................................................................................1637 Disassembly........................................................................................................1638 Idler Arm Assembly.............................................................................................1638 Cross Rod And Tie-Rod..........................................................................................1638 Inspection.........................................................................................................1639 Ball Joint And Swivel Joint....................................................................................1639 Idler Arm Assembly.............................................................................................1639 Cross Rod And Tie-Rod..........................................................................................1639 Fixing Location................................................................................................1639 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1640 General Specifications.............................................................................................1640 Inspection and Adjustment..........................................................................................1640 Steering Column Length.........................................................................................1640 Steering Linkage ..............................................................................................1640 Power Steering System (Model P659K)............................................................................1640 tf.........................................................................................................................1641 QUICK REFERENCE INDEX.................................................................................................. 0 TABLE OF CONTENTS......................................................................................................1641 PREPARATION............................................................................................................1642 Special Service Tools..............................................................................................1642 Commercial Service Tools...........................................................................................1643 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING...................................................................1644 NVH Troubleshooting Chart..........................................................................................1644 Transfer...........................................................................................................1644 DESCRIPTION............................................................................................................1645 Cross-sectional View...............................................................................................1645 ON-VEHICLE SERVICE.....................................................................................................1646 Replacing Oil Seal.....................................................................................................1646 Center Case Oil Seal...............................................................................................1646 Shift Shaft Oil Seal...............................................................................................1646 Rear Oil Seal......................................................................................................1647 REMOVAL AND INSTALLATION...............................................................................................1648 TRANSFER GEAR CONTROL .................................................................................................1649 MAJOR OVERHAUL.........................................................................................................1650 Case Components....................................................................................................1650 Gear Components....................................................................................................1651 Shift Control Components...........................................................................................1652 DISASSEMBLY............................................................................................................1653 REPAIR FOR COMPONENT PARTS.............................................................................................1658 Mainshaft..........................................................................................................1658 Front Drive Shaft..................................................................................................1660 Counter Gear.......................................................................................................1661 Main Gear..........................................................................................................1661 Front Case.........................................................................................................1663 Shift Shaft Oil Seal...........................................................................................1663 Front Case Cover...................................................................................................1663 Cover Oil Seal.................................................................................................1663 Bearing Retainer...................................................................................................1664 Oil Catcher....................................................................................................1664 Rear Case..........................................................................................................1664 Rear Oil Seal..................................................................................................1664 Air Breather...................................................................................................1664 Shift Control Components...........................................................................................1665 ASSEMBLY...............................................................................................................1666 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1673 General Specifications.............................................................................................1673 Inspection and Adjustment..........................................................................................1673
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