Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
2000 NISSAN FRONTIER D22 Series(2.4L KA Engine) Service Manual PDF DOWNLOAD
$24.95
2000 NISSAN FRONTIER D22 Series(2.4L KA Engine) Service Manual PDF DOWNLOAD
NISSAN FRONTIER MODEL D22 SERIES For vehicles equipped with the 2.4L, KA engine up to serial number 343314. The serial number is shown on the Vehicle Identification Number Plate
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
2000 NISSAN FRONTIER D22 Series(2.4L KA Engine) Service Manual PDF DOWNLOAD
FILE DETAILS:
2000 NISSAN FRONTIER D22 Series(2.4L KA Engine) Service Manual PDF DOWNLOAD
Language : English
Pages : 1521
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
Questions? Email us: [email protected]
DESCRIPTION:
2000 NISSAN FRONTIER D22 Series(2.4L KA Engine) Service Manual PDF DOWNLOAD
FOREWORD
- This manual contains maintenance and repair procedure for the 2000 NISSAN FRONTIER MODEL D22 SERIES For vehicles equipped with the 2.4L, KA engine
- In order to assure your safety and the efficient functioning of the vehicle, this manual should be read thoroughly.
- It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task.
- All information in this manual is based on the latest product information at the time of publication. The right is reserved to make changes in specifications and methods at any time without notice.
IMPORTANT SAFETY NOTICE
- The proper performance of service is essential for both the safety of the technician and the efficient functioning of the vehicle.
- The service methods in this Service Manual are described in such a manner that the service may be performed safely and accurately.
- Service varies with the procedures used, the skills of the technician and the tools and parts available.
- Accordingly, anyone using service procedures, tools or parts which are not specifically recommended by NISSAN must first be completely satisfied that neither personal safety nor the vehicle’s safety will be jeopardized by the service method selected.
TABLE OF CONTENTS:
2000 NISSAN FRONTIER D22 Series(2.4L KA Engine) Service Manual PDF DOWNLOAD
NISSAN FRONTIER MODEL D22 SERIES For vehicles equipped with the 2.4L, KA engine up to serial number 343314. The serial number is shown on the Vehicle Identification Number Plate
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 SUPER MULTIPLE JUNCTION (SMJ)......................................................................... 0 FUSE BLOCK — Junction Box (J/B)....................................................................... 2 FUSE AND FUSIBLE LINK BOX............................................................................. 3 ELECTRICAL UNITS...................................................................................... 4 JOINT CONNECTOR (J/C)................................................................................. 5 QUICK REFERENCE CHART................................................................................. 6 COMMENT SHEET......................................................................................... 3 at........................................................................................................ 5 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents..................................................................................... 5 PRECAUTIONS AND PREPARATION........................................................................... 6 Supplemental Restraint System (SRS) ‘‘AIRBAG''.................................................... 6 Precautions....................................................................................... 6 Service Notice or Precautions..................................................................... 7 Special Service Tools............................................................................. 8 OVERALL SYSTEM........................................................................................ 10 Circuit Diagram................................................................................... 10 Wiring Diagram.................................................................................... 11 Cross-Sectional View.............................................................................. 13 Hydraulic Control Circuits........................................................................ 14 Shift Mechanism................................................................................... 16 TROUBLE DIAGNOSIS — Basic Inspection.................................................................. 27 A/T Fluid Check................................................................................... 27 Stall Test........................................................................................ 27 Line Pressure Test................................................................................ 30 Road Test......................................................................................... 32 TROUBLE DIAGNOSIS — General Description............................................................... 34 Symptom Chart..................................................................................... 34 TROUBLE DIAGNOSIS FOR DTC P1550....................................................................... 38 Torque Converter Clutch Solenoid Valve............................................................ 38 TROUBLE DIAGNOSES..................................................................................... 40 Component Inspection.............................................................................. 40 TROUBLE DIAGNOSES — A/T Shift Lock System............................................................. 43 Description....................................................................................... 43 Shift Lock System Electrical Parts Location....................................................... 43 Wiring Diagram.................................................................................... 44 Diagnostic Procedure.............................................................................. 45 Shift Lock Rod.................................................................................... 47 Component Check................................................................................... 48 ON-VEHICLE SERVICE.................................................................................... 49 Control Valve Assembly and Accumulators Removal................................................... 49 Rear Oil Seal Replacement......................................................................... 49 Parking Components Inspection..................................................................... 50 Governor Valve.................................................................................... 50 Throttle Wire Adjustment.......................................................................... 50 Park/Neutral Position (PNP) Switch Adjustment..................................................... 51 Control Cable Adjustment.......................................................................... 51 REMOVAL AND INSTALLATION.............................................................................. 52 Removal........................................................................................... 53 Installation...................................................................................... 54 MAJOR OVERHAUL........................................................................................ 55 Oil Channel....................................................................................... 57 Locations of Needle Bearings, Thrust Washers and Snap Rings....................................... 58 DISASSEMBLY........................................................................................... 59 REPAIR FOR COMPONENT PARTS............................................................................ 70 Oil Pump.......................................................................................... 70 Control Valve Assembly............................................................................ 74 Control Valve Upper Body.......................................................................... 79 Control Valve Lower Body.......................................................................... 83 Governor Valve Assembly........................................................................... 85 Parking Gear...................................................................................... 85 Reverse Clutch.................................................................................... 86 High Clutch....................................................................................... 90 Forward and Overrun Clutches...................................................................... 92 Low & Reverse Brake............................................................................... 96 Forward Clutch Drum Assembly...................................................................... 99 Rear Internal Gear and Forward Clutch Hub......................................................... 101 Band Servo Piston Assembly........................................................................ 103 Parking Pawl Components........................................................................... 107 ASSEMBLY.............................................................................................. 109 Assembly (1)...................................................................................... 109 Adjustment........................................................................................ 117 Assembly (2)...................................................................................... 119 SERVICE DATA AND SPECIFICATIONS (SDS)................................................................. 126 SUPER MULTIPLE JUNCTION (SMJ)......................................................................... 0 FUSE BLOCK — Junction Box (J/B)....................................................................... 2 FUSE AND FUSIBLE LINK BOX............................................................................. 3 ELECTRICAL UNITS...................................................................................... 4 JOINT CONNECTOR (J/C)................................................................................. 5 br........................................................................................................ 131 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents..................................................................................... 131 PRECAUTIONS AND PREPARATION........................................................................... 133 Supplemental Restraint System (SRS) ‘‘AIR BAG’’ .................................................. 133 Precautions for Brake System...................................................................... 134 Commercial Service Tools.......................................................................... 134 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING.................................................. 135 NVH Troubleshooting Chart......................................................................... 135 ON-VEHICLE SERVICE.................................................................................... 136 Checking Brake Fluid Level........................................................................ 136 Checking Brake Line............................................................................... 136 Changing Brake Fluid.............................................................................. 136 Brake Burnishing Procedure........................................................................ 136 Bleeding Brake System............................................................................. 137 BRAKE HYDRAULIC LINE.................................................................................. 138 CONTROL VALVE......................................................................................... 140 Load Sensing Valve (2WD).......................................................................... 140 BRAKE HYDRAULIC LINE/CONTROL VALVE.................................................................... 142 Proportioning Valve (4WD)......................................................................... 142 BRAKE PEDAL AND BRACKET............................................................................... 143 Removal and Installation.......................................................................... 143 Inspection........................................................................................ 144 Adjustment........................................................................................ 144 MASTER CYLINDER....................................................................................... 145 Removal........................................................................................... 145 Disassembly....................................................................................... 145 Inspection........................................................................................ 146 Assembly.......................................................................................... 146 Installation...................................................................................... 147 BRAKE BOOSTER......................................................................................... 148 On-vehicle Service................................................................................ 148 Removal........................................................................................... 148 Inspection........................................................................................ 148 Installation...................................................................................... 149 VACUUM HOSE........................................................................................... 150 Removal and Installation.......................................................................... 150 Inspection........................................................................................ 150 FRONT DISC BRAKE...................................................................................... 151 Pad Replacement................................................................................... 151 Removal........................................................................................... 152 Disassembly....................................................................................... 153 Inspection — Caliper.............................................................................. 153 Inspection — Rotor................................................................................ 153 Assembly.......................................................................................... 154 Installation...................................................................................... 154 REAR DRUM BRAKE....................................................................................... 155 Removal........................................................................................... 156 Inspection — Wheel Cylinder....................................................................... 157 Wheel Cylinder Overhaul........................................................................... 157 Inspection — Drum................................................................................. 157 Inspection — Lining............................................................................... 157 Installation...................................................................................... 157 PARKING BRAKE CONTROL................................................................................. 159 Removal and Installation.......................................................................... 160 Inspection........................................................................................ 160 Adjustment........................................................................................ 160 2WD................................................................................................... 161 REAR WHEEL ANTI-LOCK BRAKE SYSTEM................................................................. 161 Purpose....................................................................................... 161 Operation..................................................................................... 161 ABS Hydraulic Circuit......................................................................... 161 System Components............................................................................. 162 System Description............................................................................ 162 Removal and Installation...................................................................... 163 TROUBLE DIAGNOSES................................................................................. 165 How to Perform Trouble Diagnoses for Quick and Accurate Repair................................ 165 Preliminary Check............................................................................. 167 Component Parts and Harness Connector Location................................................ 168 Schematic..................................................................................... 169 Wiring Diagram –ABS–.......................................................................... 170 Self-diagnosis................................................................................ 172 Main Power Supply and Ground Circuit Check.................................................... 175 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS....................................................... 176 Diagnostic Procedure 1........................................................................ 176 Diagnostic Procedure 2........................................................................ 176 Diagnostic Procedure 3........................................................................ 177 Diagnostic Procedure 4........................................................................ 178 Diagnostic Procedure 5........................................................................ 178 Diagnostic Procedure 6........................................................................ 178 Diagnostic Procedure 7 (Warning lamp flashing 5).............................................. 179 TROUBLE DIAGNOSES FOR SYMPTOMS.................................................................... 180 Diagnostic Procedure 8 (ABS works frequently)................................................. 180 Diagnostic Procedure 9 (Brake pedal stroke is large).......................................... 181 Diagnostic Procedure 10 (Long stopping distance).............................................. 181 Diagnostic Procedure 11 (ABS does not work.).................................................. 182 Diagnostic Procedure 12 (Pedal vibration or noise)............................................ 182 Electrical Components Inspection.............................................................. 183 4WD................................................................................................... 184 ANTI-LOCK BRAKE SYSTEM............................................................................ 184 Purpose....................................................................................... 184 Operation..................................................................................... 184 ABS Hydraulic Circuit......................................................................... 184 System Components............................................................................. 185 System Description............................................................................ 185 Removal and Installation...................................................................... 187 TROUBLE DIAGNOSES................................................................................. 190 How to Perform Trouble Diagnoses for Quick and Accurate Repair................................ 190 Preliminary Check............................................................................. 192 Component Parts and Harness Connector Location................................................ 193 Schematic..................................................................................... 194 Wiring Diagram — ABS —........................................................................ 195 Self-diagnosis................................................................................ 198 CONSULT....................................................................................... 201 CONSULT Inspection Procedure.................................................................. 202 Ground Circuit Check.......................................................................... 207 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS....................................................... 208 Diagnostic Procedure 1 (Wheel sensor or rotor)................................................ 208 Diagnostic Procedure 2 (ABS actuator solenoid valve and solenoid valve relay)................. 210 Diagnostic Procedure 3 (Motor relay or motor)................................................. 212 Diagnostic Procedure 4 (Low voltage).......................................................... 214 Diagnostic Procedure 5 (G sensor)............................................................. 215 Diagnostic Procedure 6 (Control unit)......................................................... 216 TROUBLE DIAGNOSES FOR SYMPTOMS.................................................................... 217 Diagnostic Procedure 7 (ABS works frequently.)................................................ 217 Diagnostic Procedure 8 (Unexpected pedal action).............................................. 218 Diagnostic Procedure 9 (Long stopping distance)............................................... 218 Diagnostic Procedure 10 (ABS does not work.).................................................. 219 Diagnostic Procedure 11 (Pedal vibration and noise)........................................... 219 Diagnostic Procedure 12 (Warning lamp does not come on when ignition switch is turned ON.).... 220 Diagnostic Procedure 13 (Warning lamp stays on when ignition switch is turned ON.)............ 222 Electrical Components Inspection.............................................................. 224 SERVICE DATA AND SPECIFICATIONS (SDS)................................................................. 225 General Specifications............................................................................ 225 Inspection and Adjustment......................................................................... 226 SUPER MULTIPLE JUNCTION (SMJ)......................................................................... 0 FUSE BLOCK — Junction Box (J/B)....................................................................... 2 FUSE AND FUSIBLE LINK BOX............................................................................. 3 ELECTRICAL UNITS...................................................................................... 4 JOINT CONNECTOR (J/C)................................................................................. 5 bt........................................................................................................ 227 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents..................................................................................... 227 PRECAUTIONS AND PREPARATION........................................................................... 229 Service Notice.................................................................................... 229 Supplemental Restraint System (SRS) ‘‘AIR BAG’’................................................... 229 PREPARATION........................................................................................... 230 Special Service Tools............................................................................. 230 Commercial Service Tools.......................................................................... 230 SQUEAK AND RATTLE TROUBLE DIAGNOSES................................................................... 231 Work Flow......................................................................................... 231 CUSTOMER INTERVIEW............................................................................ 231 DUPLICATE THE NOISE AND TEST DRIVE............................................................ 232 CHECK RELATED SERVICE BULLETINS............................................................... 232 LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE.................................................. 232 REPAIR THE CAUSE.............................................................................. 232 CONFIRM THE REPAIR............................................................................ 233 Generic Squeak and Rattle Troubleshooting......................................................... 233 INSTRUMENT PANEL.............................................................................. 233 CENTER CONSOLE................................................................................ 233 DOORS......................................................................................... 233 TRUNK......................................................................................... 233 SUNROOF AND HEADLINER......................................................................... 233 SEATS......................................................................................... 234 UNDERHOOD..................................................................................... 234 Diagnostic Worksheet.............................................................................. 235 GENERAL SERVICING..................................................................................... 237 Clip and Fastener................................................................................. 237 BODY END.............................................................................................. 239 Body Front End.................................................................................... 239 REMOVAL — Front bumper assembly............................................................... 239 Body Rear End..................................................................................... 242 REMOVAL — Rear bumper assembly................................................................ 242 DOOR.................................................................................................. 244 Front Door........................................................................................ 244 INSTRUMENT PANEL...................................................................................... 245 REMOVAL — Instrument panel assembly............................................................... 245 INTERIOR TRIM......................................................................................... 248 Side and Floor Trim............................................................................... 248 REMOVAL — Body side trim...................................................................... 248 King cab model............................................................................ 248 Standard cab model........................................................................ 248 Door Trim......................................................................................... 251 REMOVAL....................................................................................... 251 Door trim (Formed type)................................................................... 251 Roof Trim......................................................................................... 254 REMOVAL — Headlining.......................................................................... 254 EXTERIOR.............................................................................................. 256 Hood front sealing rubber......................................................................... 257 Cowl top seal and cowl top grille................................................................. 257 Windshield side molding........................................................................... 257 Windshield upper molding.......................................................................... 257 Sunroof weatherstrip and lid protector............................................................ 257 Drip weatherstrip................................................................................. 258 Body side welt.................................................................................... 258 Door weatherstrip................................................................................. 258 Door outside molding.............................................................................. 258 Drafter duct...................................................................................... 259 Over fender....................................................................................... 259 Rear combination lamp............................................................................. 259 SEAT.................................................................................................. 260 Front Seat........................................................................................ 260 Jump Seat — King Cab Model........................................................................ 263 SUNROOF............................................................................................... 264 WINDSHIELD AND WINDOWS................................................................................ 265 Windshield........................................................................................ 266 Side Window....................................................................................... 266 Back Window....................................................................................... 267 Rearview Mirror................................................................................... 268 MIRROR................................................................................................ 269 Door Mirror....................................................................................... 269 REMOVAL — Door mirror......................................................................... 269 CAB AND REAR BODY..................................................................................... 270 Body Mounting..................................................................................... 270 BODY ALIGNMENT........................................................................................ 272 Engine Compartment................................................................................ 272 MEASUREMENT................................................................................... 272 MEASUREMENT POINTS............................................................................ 273 Underbody......................................................................................... 274 MEASUREMENT................................................................................... 274 2WD-4WD (Short wheelbase) models.......................................................... 274 MEASUREMENT POINTS............................................................................ 275 2WD-4WD (Short wheelbase) models.......................................................... 275 MEASUREMENT................................................................................... 276 2WD-4WD (Long wheelbase) models........................................................... 276 MEASUREMENT POINTS............................................................................ 277 2WD-4WD (Long wheelbase) models........................................................... 277 cl........................................................................................................ 279 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents..................................................................................... 279 PRECAUTIONS AND PREPARATION........................................................................... 280 Precautions....................................................................................... 280 Special Service Tools............................................................................. 280 Commercial Service Tools.......................................................................... 280 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING.................................................. 281 NVH Troubleshooting Chart......................................................................... 281 CLUTCH SYSTEM......................................................................................... 282 Clutch Pedal...................................................................................... 283 INSPECTION AND ADJUSTMENT............................................................................. 284 Adjusting Clutch Pedal............................................................................ 284 Air Bleeding Procedure............................................................................ 285 HYDRAULIC CLUTCH CONTROL.............................................................................. 286 Clutch Master Cylinder (With clutch damper)....................................................... 286 Operating Cylinder................................................................................ 287 CLUTCH RELEASE MECHANISM.............................................................................. 288 CLUTCH DISC AND CLUTCH COVER.......................................................................... 291 Clutch Disc....................................................................................... 291 Clutch Cover and Flywheel......................................................................... 292 SERVICE DATA AND SPECIFICATIONS (SDS)................................................................. 293 General Specifications............................................................................ 293 Clutch Control System............................................................................. 293 Inspection and Adjustment......................................................................... 293 ec........................................................................................................ 295 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents..................................................................................... 295 DIAGNOSTIC TROUBLE CODE INDEX......................................................................... 298 Alphabetical & P No. Index for DTC................................................................ 298 PRECAUTIONS AND PREPARATION........................................................................... 300 Special Service Tools............................................................................. 300 Commercial Service Tools.......................................................................... 300 Supplemental Restraint System (SRS) ‘‘AIR BAG’’................................................... 302 Precautions for On Board Diagnostic (OBD) System of Engine........................................ 302 Engine Fuel & Emission Control System............................................................. 303 Precautions....................................................................................... 304 ENGINE AND EMISSION CONTROL OVERALL SYSTEM............................................................ 306 Circuit Diagram................................................................................... 306 Engine Control Component Parts Location........................................................... 307 System Diagram.................................................................................... 309 Vacuum Hose Drawing............................................................................... 310 System Chart...................................................................................... 311 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION.................................................. 312 Multiport Fuel Injection (MFI) System............................................................. 312 Distributor Ignition (DI) System.................................................................. 314 Air Conditioning Cut Control...................................................................... 315 Fuel Cut Control ................................................................................. 316 EVAPORATIVE EMISSION SYSTEM........................................................................... 317 Description....................................................................................... 317 Inspection........................................................................................ 317 Evaporative Emission Line Drawing................................................................. 320 POSITIVE CRANKCASE VENTILATION........................................................................ 322 Description....................................................................................... 322 Inspection........................................................................................ 322 BASIC SERVICE PROCEDURE............................................................................... 323 Fuel Pressure Release............................................................................. 323 Fuel Pressure Check............................................................................... 323 Fuel Pressure Regulator Check..................................................................... 323 Injector Removal and Installation................................................................. 324 Fast Idle Cam (FIC)............................................................................... 325 Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment.......................................... 326 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION................................................................ 332 Introduction...................................................................................... 332 Two Trip Detection Logic.......................................................................... 332 Emission-related Diagnostic Information........................................................... 333 Malfunction Indicator Lamp (MIL).................................................................. 343 OBD System Operation Chart........................................................................ 346 CONSULT........................................................................................... 351 Generic Scan Tool (GST)........................................................................... 362 TROUBLE DIAGNOSIS — Introduction...................................................................... 364 Introduction...................................................................................... 364 Diagnostic Worksheet.............................................................................. 364 TROUBLE DIAGNOSIS — Work Flow......................................................................... 366 Work Flow......................................................................................... 366 Description for Work Flow......................................................................... 367 TROUBLE DIAGNOSIS — Basic Inspection.................................................................. 368 Basic Inspection.................................................................................. 368 TROUBLE DIAGNOSIS — General Description............................................................... 374 Diagnostic Trouble Code (DTC) Inspection Priority Chart........................................... 374 Fail-Safe Chart................................................................................... 375 Symptom Matrix Chart.............................................................................. 376 CONSULT Reference Value in Data Monitor Mode...................................................... 379 Major Sensor Reference Graph in Data Monitor Mode................................................. 381 ECM Terminals and Reference Value................................................................. 383 TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT........................................................... 392 Description....................................................................................... 392 Common I/I Report Situations...................................................................... 392 Diagnostic Procedure.............................................................................. 392 TROUBLE DIAGNOSIS FOR POWER SUPPLY.................................................................... 393 Main Power Supply and Ground Circuit.............................................................. 393 TROUBLE DIAGNOSIS FOR DTC P0100....................................................................... 398 Mass Air Flow Sensor (MAFS)....................................................................... 398 TROUBLE DIAGNOSIS FOR DTC P0105....................................................................... 407 Absolute Pressure Sensor.......................................................................... 407 TROUBLE DIAGNOSIS FOR DTC P0110....................................................................... 414 Intake Air Temperature Sensor..................................................................... 414 TROUBLE DIAGNOSIS FOR DTC P0115....................................................................... 420 Engine Coolant Temperature Sensor (ECTS) (Circuit)................................................ 420 TROUBLE DIAGNOSIS FOR DTC P0120....................................................................... 425 Throttle Position Sensor.......................................................................... 425 TROUBLE DIAGNOSIS FOR DTC P0125....................................................................... 439 Engine Coolant Temperature (ECT) Sensor........................................................... 439 TROUBLE DIAGNOSIS FOR DTC P0130....................................................................... 444 Front Heated Oxygen Sensor (Circuit) (Front HO2S)................................................. 444 TROUBLE DIAGNOSIS FOR DTC P0131....................................................................... 451 Front Heated Oxygen Sensor (Lean Shift Monitoring) (Front HO2S)................................... 451 TROUBLE DIAGNOSIS FOR DTC P0132....................................................................... 458 Front Heated Oxygen Sensor (Rich Shift Monitoring) (Front HO2S)................................... 458 TROUBLE DIAGNOSIS FOR DTC P0133....................................................................... 465 Front Heated Oxygen Sensor (Response Monitoring) (Front HO2S)..................................... 465 TROUBLE DIAGNOSIS FOR DTC P0134....................................................................... 473 Front Heated Oxygen Sensor (High Voltage) (Front HO2S)............................................ 473 TROUBLE DIAGNOSIS FOR DTC P0135....................................................................... 480 Front Heated Oxygen Sensor Heater................................................................. 480 TROUBLE DIAGNOSIS FOR DTC P0137....................................................................... 484 Rear Heated Oxygen Sensor (Min. Voltage Monitoring) (Rear HO2S)................................... 484 TROUBLE DIAGNOSIS FOR DTC P0138....................................................................... 492 Rear Heated Oxygen Sensor (Max. Voltage Monitoring) (Rear HO2S)................................... 492 TROUBLE DIAGNOSIS FOR DTC P0139....................................................................... 500 Rear Heated Oxygen Sensor (Response Monitoring) (Rear HO2S)....................................... 500 TROUBLE DIAGNOSIS FOR DTC P0140....................................................................... 508 Rear Heated Oxygen Sensor (High Voltage) (Rear HO2S).............................................. 508 TROUBLE DIAGNOSIS FOR DTC P0141....................................................................... 514 Rear Heated Oxygen Sensor Heater.................................................................. 514 TROUBLE DIAGNOSIS FOR DTC P0171....................................................................... 518 Fuel Injection System Function (Lean side)........................................................ 518 TROUBLE DIAGNOSIS FOR DTC P0172....................................................................... 523 Fuel Injection System Function (Rich side)........................................................ 523 TROUBLE DIAGNOSIS FOR DTC P0180....................................................................... 528 Tank Fuel Temperature Sensor...................................................................... 528 TROUBLE DIAGNOSIS FOR DTC P0300 - P0304............................................................... 532 No.4 -1Cylinder Misfire, Multiple Cylinder Misfire................................................ 532 TROUBLE DIAGNOSIS FOR DTC P0325....................................................................... 537 Knock Sensor (KS)................................................................................. 537 TROUBLE DIAGNOSIS FOR DTC P0335....................................................................... 541 Crankshaft Position Sensor (CKPS) (OBD)........................................................... 541 TROUBLE DIAGNOSIS FOR DTC P0340....................................................................... 546 Camshaft Position Sensor (CMPS)................................................................... 546 TROUBLE DIAGNOSIS FOR DTC P0400....................................................................... 552 EGR Function (Close).............................................................................. 552 TROUBLE DIAGNOSIS FOR DTC P0402....................................................................... 560 EGRC-BPT Valve Function........................................................................... 560 TROUBLE DIAGNOSIS FOR DTC P0420....................................................................... 565 Three Way Catalyst Function....................................................................... 565 TROUBLE DIAGNOSIS FOR DTC P0440....................................................................... 570 Evaporative Emission (EVAP) Control System (Small Leak) (Negative Pressure)....................... 570 TROUBLE DIAGNOSIS FOR DTC P0443....................................................................... 580 Evaporative Emission (EVAP) Canister Purge Volume Control Solenoid Valve (Circuit)................ 580 TROUBLE DIAGNOSIS FOR DTC P0446....................................................................... 586 Evaporative Emission (EVAP) Canister Vent Control Valve (Circuit)................................. 586 TROUBLE DIAGNOSIS FOR DTC P0450....................................................................... 591 Evaporative Emission (EVAP) Control System Pressure Sensor........................................ 591 TROUBLE DIAGNOSIS FOR DTC P0500....................................................................... 597 Vehicle Speed Sensor (VSS)........................................................................ 597 TROUBLE DIAGNOSIS FOR DTC P0505....................................................................... 602 Idle Air Control Valve (IACV) — Auxiliary Air Control (AAC) Valve................................. 602 TROUBLE DIAGNOSIS FOR DTC P0510....................................................................... 608 Closed Throttle Position Switch................................................................... 608 TROUBLE DIAGNOSIS FOR DTC P0605....................................................................... 614 Engine Control Module (ECM)....................................................................... 614 TROUBLE DIAGNOSIS FOR DTC P1105....................................................................... 616 Manifold Absolute Pressure (MAP)/ Barometric Pressure (BARO) Switch Solenoid Valve................ 616 TROUBLE DIAGNOSIS FOR DTC P1148....................................................................... 625 Closed Loop Control............................................................................... 625 TROUBLE DIAGNOSIS FOR DTC P1320....................................................................... 627 Ignition Signal................................................................................... 627 TROUBLE DIAGNOSIS FOR DTC P1336....................................................................... 634 Crankshaft Position Sensor (CKPS) (OBD) (COG)..................................................... 634 TROUBLE DIAGNOSIS FOR DTC P1400....................................................................... 639 EGRC-Solenoid Valve............................................................................... 639 TROUBLE DIAGNOSIS FOR DTC P1401....................................................................... 644 EGR Temperature Sensor............................................................................ 644 TROUBLE DIAGNOSIS FOR DTC P1402....................................................................... 650 EGR Function (Open)............................................................................... 650 TROUBLE DIAGNOSIS FOR DTC P1440....................................................................... 657 Evaporative Emission (EVAP) Control System (Small Leak) (Positive Pressure)....................... 657 TROUBLE DIAGNOSIS FOR DTC P1444....................................................................... 667 Evaporative Emission (EVAP) Canister Purge Volume Control Solenoid Valve.......................... 667 TROUBLE DIAGNOSIS FOR DTC P1446....................................................................... 675 Evaporative Emission (EVAP) Canister Vent Control Valve (Close)................................... 675 TROUBLE DIAGNOSIS FOR DTC P1447....................................................................... 680 Evaporative Emission (EVAP) Control System Purge Flow Monitoring.................................. 680 TROUBLE DIAGNOSIS FOR DTC P1448....................................................................... 686 Evaporative Emission (EVAP) Canister Vent Control Valve (Open).................................... 686 TROUBLE DIAGNOSIS FOR DTC P1490....................................................................... 691 Vacuum Cut Valve Bypass Valve (Circuit)........................................................... 691 TROUBLE DIAGNOSIS FOR DTC P1491....................................................................... 696 Vacuum Cut Valve Bypass Valve..................................................................... 696 TROUBLE DIAGNOSIS FOR DTC P1706....................................................................... 701 Park/Neutral Position (PNP) Switch................................................................ 701 TROUBLE DIAGNOSIS FOR DTC P1775....................................................................... 706 Torque Converter Clutch Solenoid Valve (Circuit).................................................. 706 TROUBLE DIAGNOSIS FOR DTC P1776....................................................................... 710 Torque Converter Clutch Solenoid Valve............................................................ 710 TROUBLE DIAGNOSIS FOR OVERHEAT........................................................................ 714 Overheat.......................................................................................... 714 TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS............................................................ 717 Injector.......................................................................................... 717 Start Signal...................................................................................... 720 Fuel Pump......................................................................................... 723 Power Steering Oil Pressure Switch................................................................ 728 IACV-FICD Solenoid Valve.......................................................................... 731 MIL & Data Link Connectors........................................................................ 735 SERVICE DATA AND SPECIFICATIONS (SDS)................................................................. 736 General Specifications............................................................................ 736 Inspection and Adjustment......................................................................... 736 SUPER MULTIPLE JUNCTION (SMJ)......................................................................... 0 FUSE BLOCK — Junction Box (J/B)....................................................................... 2 FUSE AND FUSIBLE LINK BOX............................................................................. 3 ELECTRICAL UNITS...................................................................................... 4 JOINT CONNECTOR (J/C)................................................................................. 5 el........................................................................................................ 739 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents..................................................................................... 739 PRECAUTIONS AND PREPARATION........................................................................... 742 Supplemental Restraint System (SRS) ‘‘AIR BAG’’................................................... 742 HARNESS CONNECTOR..................................................................................... 743 Description....................................................................................... 743 STANDARDIZED RELAY.................................................................................... 745 Description....................................................................................... 745 POWER SUPPLY ROUTING.................................................................................. 748 Schematic......................................................................................... 748 Wiring Diagram — POWER —.......................................................................... 750 Fuse.............................................................................................. 755 Fusible Link...................................................................................... 755 Circuit Breaker Inspection........................................................................ 755 GROUND DISTRIBUTION................................................................................... 756 Main Harness...................................................................................... 756 Engine Room Harness............................................................................... 759 Engine Control Harness............................................................................ 761 Engine No. 2 Harness.............................................................................. 762 BATTERY............................................................................................... 763 How to Handle Battery............................................................................. 763 Service Data and Specifications (SDS)............................................................. 766 STARTING SYSTEM....................................................................................... 767 System Description................................................................................ 767 Wiring Diagram — START —.......................................................................... 769 Construction...................................................................................... 771 Removal and Installation.......................................................................... 773 Pinion/Clutch Check............................................................................... 773 Service Data and Specifications (SDS)............................................................. 773 CHARGING SYSTEM....................................................................................... 774 System Description................................................................................ 774 Wiring Diagram — CHARGE —......................................................................... 775 Trouble Diagnoses................................................................................. 776 Construction...................................................................................... 777 Removal and Installation.......................................................................... 778 Service Data and Specifications (SDS)............................................................. 778 COMBINATION SWITCH.................................................................................... 779 Check............................................................................................. 779 Replacement....................................................................................... 780 STEERING SWITCH....................................................................................... 781 Check............................................................................................. 781 HEADLAMP.............................................................................................. 782 System Description (For USA)...................................................................... 782 Wiring Diagram (For USA) — H/LAMP —............................................................... 783 Trouble Diagnoses................................................................................. 784 Bulb Replacement.................................................................................. 785 Aiming Adjustment................................................................................. 785 HEADLAMP — Daytime Light System —..................................................................... 788 System Description (For Canada)................................................................... 788 Operation (For Canada)............................................................................ 789 Schematic (For Canada)............................................................................ 790 Wiring Diagram (For Canada) — DTRL —.............................................................. 791 Trouble Diagnoses (For Canada).................................................................... 794 PARKING, LICENSE AND TAIL LAMPS....................................................................... 796 Wiring Diagram — TAIL/L —......................................................................... 796 STOP LAMP............................................................................................. 798 Wiring Diagram — STOP/L —......................................................................... 798 BACK-UP LAMP.......................................................................................... 799 Wiring Diagram — BACK/L —......................................................................... 799 FRONT FOG LAMP........................................................................................ 800 System Description................................................................................ 800 Wiring Diagram — F/FOG —.......................................................................... 801 Aiming Adjustment................................................................................. 802 Removal and Installation.......................................................................... 803 Bulb and Lens Replacement......................................................................... 803 TURN SIGNAL AND HAZARD WARNING LAMPS.................................................................. 804 System Description................................................................................ 804 Wiring Diagram — TURN —........................................................................... 806 Trouble Diagnoses................................................................................. 808 Electrical Components Inspection.................................................................. 808 ILLUMINATION.......................................................................................... 809 System Description................................................................................ 809 Wiring Diagram — ILL —............................................................................ 810 INTERIOR ROOM LAMP.................................................................................... 811 Component Parts and Harness Connector Location.................................................... 811 System Description................................................................................ 812 Wiring Diagram — ROOM/L —......................................................................... 814 Trouble Diagnoses (For models with power door locks).............................................. 817 SPOT LAMP............................................................................................. 818 Wiring Diagram — INT/L —.......................................................................... 818 METER AND GAUGES...................................................................................... 819 Component Parts and Harness Connector Location.................................................... 819 System Description................................................................................ 820 UNIFIED CONTROL METER......................................................................... 820 HOW TO CHANGE THE DISPLAY FOR ODO/TRIP METER.................................................. 820 Combination Meter................................................................................. 822 WITH TACHOMETER............................................................................... 822 WITHOUT TACHOMETER............................................................................ 823 Wiring Diagram — METER —.......................................................................... 824 Meter/gauge Operation and Odo/Trip Meter Segment Check in Diagnosis Mode.......................... 825 DIAGNOSIS FUNCTION............................................................................ 825 HOW TO ALTERNATE DIAGNOSIS MODE............................................................... 825 Flexible Print Circuit (FPC)...................................................................... 826 DISCONNECT.................................................................................... 826 CONNECT....................................................................................... 826 Trouble Diagnoses................................................................................. 827 PRELIMINARY CHECK............................................................................. 827 SYMPTOM CHART 1 (Malfunction is indicated in diagnosis mode).................................. 828 SYMPTOM CHART 2 (No malfunction is indicated in diagnosis mode)............................... 828 POWER SUPPLY AND GROUND CIRCUIT CHECK......................................................... 829 INSPECTION/VEHICLE SPEED SENSOR............................................................... 830 INSPECTION/ENGINE REVOLUTION SIGNAL (Models with tachometer).................................. 830 INSPECTION/FUEL TANK GAUGE.................................................................... 831 INSPECTION/THERMAL TRANSMITTER................................................................ 831 Electrical Components Inspection.................................................................. 832 METER/GAUGE RESISTANCE CHECK.................................................................. 832 FUEL TANK GAUGE UNIT CHECK.................................................................... 832 THERMAL TRANSMITTER CHECK..................................................................... 833 VEHICLE SPEED SENSOR SIGNAL CHECK............................................................. 833 WARNING LAMPS......................................................................................... 834 System Description................................................................................ 834 Schematic......................................................................................... 836 Wiring Diagram — WARN —........................................................................... 837 Electrical Components Inspection.................................................................. 840 A/T INDICATOR......................................................................................... 841 Wiring Diagram — AT/IND —......................................................................... 841 WARNING CHIME......................................................................................... 842 Component Parts and Harness Connector Location.................................................... 842 System Description................................................................................ 843 Wiring Diagram — CHIME —.......................................................................... 845 Trouble Diagnoses................................................................................. 847 Electrical Components Inspection.................................................................. 853 FRONT WIPER AND WASHER................................................................................ 854 System Description................................................................................ 854 Wiring Diagram — WIPER............................................................................ 856 Trouble Diagnoses (With intermittent wipers)...................................................... 858 Removal and Installation.......................................................................... 860 Washer Nozzle Adjustment.......................................................................... 861 Washer Tube Layout................................................................................ 861 HORN.................................................................................................. 862 Wiring Diagram — HORN —........................................................................... 862 CIGARETTE LIGHTER..................................................................................... 863 Wiring Diagram — CIGAR —.......................................................................... 863 AUDIO................................................................................................. 864 System Description................................................................................ 864 Wiring Diagram — AUDIO —.......................................................................... 865 Trouble Diagnoses................................................................................. 868 Inspection........................................................................................ 869 AUDIO ANTENNA......................................................................................... 870 Fixed Antenna Rod Replacement..................................................................... 870 REMOVAL....................................................................................... 870 INSTALLATION.................................................................................. 870 POWER DOOR MIRROR..................................................................................... 871 Wiring Diagram — MIRROR —......................................................................... 871 AUTOMATIC SPEED CONTROL DEVICE (ASCD)................................................................. 872 Component Parts and Harness Connector Location.................................................... 872 System Description................................................................................ 873 Schematic......................................................................................... 875 Wiring Diagram — ASCD —........................................................................... 876 Fail-Safe System Description...................................................................... 880 Fail-Safe System Check............................................................................ 881 Trouble Diagnoses................................................................................. 882 ASCD Wire Adjustment.............................................................................. 890 Electrical Components Inspection.................................................................. 891 POWER WINDOW.......................................................................................... 892 System Description................................................................................ 892 Wiring Diagram — WINDOW —......................................................................... 894 Trouble Diagnoses................................................................................. 896 POWER DOOR LOCK....................................................................................... 897 Component Parts and Harness Connector Location.................................................... 897 System Description................................................................................ 898 Schematic......................................................................................... 900 Wiring Diagram — D/LOCK —......................................................................... 901 Trouble Diagnoses................................................................................. 904 MULTI-REMOTE CONTROL SYSTEM........................................................................... 912 Component Parts and Harness Connector Location.................................................... 912 System Description................................................................................ 913 Schematic......................................................................................... 915 Wiring Diagram — MULTI —.......................................................................... 916 Trouble Diagnoses................................................................................. 919 Electrical Components Inspection.................................................................. 925 ID Code Entry Procedure........................................................................... 926 THEFT WARNING SYSTEM.................................................................................. 927 Component Parts and Harness Connector Location.................................................... 927 System Description................................................................................ 929 Schematic......................................................................................... 915 Wiring Diagram — MULTI —.......................................................................... 916 Trouble Diagnoses................................................................................. 919 Electrical Components Inspection.................................................................. 925 ID Code Entry Procedure........................................................................... 926 THEFT WARNING SYSTEM.................................................................................. 927 Component Parts and Harness Connector Location.................................................... 927 System Description................................................................................ 929 Schematic......................................................................................... 932 Wiring Diagram — THEFT —.......................................................................... 933 Trouble Diagnoses................................................................................. 936 SMART ENTRANCE CONTROL UNIT........................................................................... 947 Description GI.................................................................................... 947 Input/Output Operation Signal..................................................................... 948 Schematic......................................................................................... 950 LOCATION OF ELECTRICAL UNITS.......................................................................... 952 Engine Compartment................................................................................ 952 Passenger Compartment............................................................................. 953 HARNESS LAYOUT........................................................................................ 955 Outline........................................................................................... 955 How to Read Harness Layout........................................................................ 956 Main Harness...................................................................................... 958 Engine Room Harness............................................................................... 960 Engine Control Harness............................................................................ 964 Engine No. 2 Harness.............................................................................. 966 Chassis and Tail Harness.......................................................................... 968 Room Lamp Harness................................................................................. 969 Door Harness...................................................................................... 970 Air Bag Harness................................................................................... 971 BULB SPECIFICATIONS................................................................................... 972 Headlamps......................................................................................... 972 Exterior Lamps.................................................................................... 972 Interior Lamps.................................................................................... 972 WIRING DIAGRAM CODES (CELL CODES)..................................................................... 973 SUPER MULTIPLE JUNCTION (SMJ)......................................................................... 0 FUSE BLOCK — Junction Box (J/B)....................................................................... 2 FUSE AND FUSIBLE LINK BOX............................................................................. 3 ELECTRICAL UNITS...................................................................................... 4 JOINT CONNECTOR (J/C)................................................................................. 5 em........................................................................................................ 975 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents..................................................................................... 975 PRECAUTIONS AND PREPARATION........................................................................... 976 Supplemental Restraint System (SRS) "AIR BAG"..................................................... 976 Parts Requiring Angular Tightening................................................................ 976 Liquid Gasket Application Procedure............................................................... 976 Special Service Tools............................................................................. 978 Commercial Service Tools.......................................................................... 981 Commercial Service Tools.......................................................................... 982 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING.................................................. 983 NVH Troubleshooting Chart—Engine Noise............................................................ 984 OUTER COMPONENT PARTS................................................................................. 985 COMPRESSION PRESSURE.................................................................................. 988 Measurement of Compression Pressure............................................................... 988 OILPAN................................................................................................ 989 Removal........................................................................................... 989 Installation...................................................................................... 990 TIMING CHAIN.......................................................................................... 991 Removal........................................................................................... 993 Upper Timing Chain............................................................................ 993 Idler Sprocket................................................................................ 994 Lower Timing Chain............................................................................ 994 Inspection........................................................................................ 995 Installation...................................................................................... 996 Lower Timing Chain............................................................................ 996 Idler Sprocket................................................................................ 997 Upper Timing Chain............................................................................ 997 OIL SEAL REPLACEMENT.................................................................................. 999 Valve Oil Seal.................................................................................... 999 Oil Seal Installing Direction..................................................................... 999 Front Oil Seal.................................................................................... 999 Rear Oil Seal.....................................................................................1000 CYLINDER HEAD.........................................................................................1002 Removal...........................................................................................1003 Installation......................................................................................1003 Disassembly.......................................................................................1004 Inspection........................................................................................1005 Assembly..........................................................................................1010 Valve Clearance...................................................................................1010 Checking......................................................................................1010 Adjusting.....................................................................................1011 ENGINE REMOVAL........................................................................................1013 Removal...........................................................................................1014 Installation......................................................................................1015 CYLINDER BLOCK........................................................................................1016 Disassembly.......................................................................................1017 Inspection........................................................................................1017 Assembly..........................................................................................1023 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................1027 General Specifications............................................................................1027 Compression Pressure .........................................................................1027 Inspection and Adjustment.........................................................................1027 Cylinder Head.................................................................................1027 Valve.........................................................................................1027 Camshaft And Camshaft Bearing.................................................................1031 Piston, Piston Ring And Piston Pin............................................................1032 Connecting Rod................................................................................1032 fa........................................................................................................1035 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents.....................................................................................1035 PRECAUTIONS AND PREPARATION...........................................................................1036 Precautions.......................................................................................1036 Special Service Tools.............................................................................1036 Commercial Service Tools..........................................................................1037 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING..................................................1038 NVH Troubleshooting Chart.........................................................................1038 FRONT SUSPENSION SYSTEM...............................................................................1039 2WD...............................................................................................1039 4WD...............................................................................................1040 ON-VEHICLE SERVICE....................................................................................1041 Front Axle and Front Suspension Parts.............................................................1041 Front Wheel Bearing...............................................................................1041 Front Wheel Alignment.............................................................................1043 Drive Shaft.......................................................................................1048 FRONT AXLE............................................................................................1049 Manual-lock Free-running Hub — 4WD —..............................................................1051 Auto-lock Free-running Hub — 4WD —................................................................1052 Description...................................................................................1052 Inspection....................................................................................1053 Trouble Diagnosis For Noise...................................................................1054 Wheel Hub and Rotor Disc..........................................................................1054 Knuckle Spindle...................................................................................1056 Drive Shaft — 4WD —...............................................................................1059 FRONT SUSPENSION......................................................................................1064 Shock Absorber....................................................................................1067 Torsion Bar Spring................................................................................1066 Stabilizer Bar....................................................................................1068 Upper Link........................................................................................1069 Tension Rod.......................................................................................1070 Lower Link........................................................................................1071 Upper Ball Joint and Lower Ball Joint.............................................................1072 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................1073 General Specifications............................................................................1073 Inspection and Adjustment.........................................................................1073 fe........................................................................................................1077 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents.....................................................................................1077 PREPARATION...........................................................................................1078 Special Service Tool..............................................................................1078 ACCELERATOR CONTROL SYSTEM............................................................................1079 Adjusting Accelerator Wire........................................................................1079 FUEL SYSTEM...........................................................................................1080 Fuel Tank.........................................................................................1080 Fuel Pump and Gauge...............................................................................1083 EXHAUST SYSTEM........................................................................................1084 foldout...................................................................................................1087 QUICK REFERENCE INDEX................................................................................. 0 SUPER MULTIPLE JUNCTION (SMJ).........................................................................1087 FUSE BLOCK — Junction Box (J/B).......................................................................1089 FUSE AND FUSIBLE LINK BOX.............................................................................1090 ELECTRICAL UNITS......................................................................................1091 JOINT CONNECTOR (J/C).................................................................................1092 gi........................................................................................................1094 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents.....................................................................................1094 PRECAUTIONS AND PREPARATION...........................................................................1095 Supplemental Restraint System (SRS) ‘‘AIRBAG''....................................................1095 General Precautions...............................................................................1096 Precautions for Multiport Fuel Injection System or Engine Control System..........................1098 Precautions for Three Way Catalyst................................................................1098 Precautions for Engine Oils.......................................................................1098 Precautions for Fuel..............................................................................1099 Precautions for Air Conditioning..................................................................1099 HOW TO USE THIS MANUAL................................................................................1100 HOW TO READ WIRING DIAGRAMS...........................................................................1102 Sample/Wiring Diagram –EXAMPL– ...................................................................1102 Description.......................................................................................1104 HOW TO CHECK TERMINAL.................................................................................1110 Connector and Terminal Pin Kit....................................................................1110 How to Probe Connectors...........................................................................1110 How to Check Enlarged Contact Spring of Terminal..................................................1111 Water proof Connector Inspection..................................................................1112 Terminal Lock Inspection..........................................................................1112 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT.........................................1113 Work Flow.........................................................................................1113 Incident Simulation Tests.........................................................................1114 Circuit Inspection................................................................................1116 Control Unit Circuit Test.........................................................................1122 HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES.........................................................1123 How To Follow This Flow Chart.....................................................................1124 CONSULT CHECKING SYSTEM...............................................................................1126 Function and System Application...................................................................1126 Lithium Battery Replacement.......................................................................1126 Checking Equipment................................................................................1126 Loading Procedure.................................................................................1127 CONSULT Data Link Connector (DLC) Circuit.........................................................1127 IDENTIFICATION INFORMATION............................................................................1128 Identification Number.............................................................................1130 Model Variation...................................................................................1128 Dimensions........................................................................................1132 Wheels and Tires..................................................................................1132 LIFTING POINTS AND TOW TRUCK TOWING...................................................................1133 Pantograph Jack...................................................................................1133 Garage Jack and Safety Stand......................................................................1134 2-pole Lift.......................................................................................1135 Tow Truck Towing..................................................................................1136 2-WHEELDRIVE MODELS...........................................................................1136 4-WHEELDRIVE MODELS...........................................................................1137 Towing Point......................................................................................1138 Vehicle Recovery (Freeingastuckvehicle) ..........................................................1138 TIGHTENING TORQUE OF STANDARD BOLTS...................................................................1139 SAE J1930 TERMINOLOGY LIST............................................................................1140 ha........................................................................................................1144 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents.....................................................................................1144 PRECAUTIONS AND PREPARATION...........................................................................1145 Supplemental Restraint System (SRS) "AIR BAG".....................................................1145 Precautions for Working with R-134a...............................................................1145 Contaminated Refrigerant......................................................................1146 General Refrigerant Precautions...................................................................1146 Precautions for Refrigerant Connection............................................................1147 Precautions for Servicing Compressor..............................................................1150 R-134a Service Tools and Equipment................................................................1151 Special Service Tools.............................................................................1153 Commercial Service Tools..........................................................................1153 Precautions for Service Equipment.................................................................1154 DESCRIPTION...........................................................................................1156 Refrigeration Cycle...............................................................................1156 Control Operation.................................................................................1157 Component Layout..................................................................................1158 Discharge Air Flow................................................................................1159 Component Location................................................................................1160 Circuit Diagram...................................................................................1162 Wiring Diagram –HEATER–...........................................................................1163 Wiring Diagram –A/C–..............................................................................1164 Operational Check.................................................................................1166 TROUBLE DIAGNOSES.....................................................................................1168 How to Perform Trouble Diagnoses for Quick and Accurate Repair....................................1168 Blower Motor Circuit..............................................................................1169 Air Outlet........................................................................................1173 Intake Door.......................................................................................1175 Magnet Clutch Circuit.............................................................................1176 Trouble Diagnosis Procedure For Insufficient Cooling..............................................1182 Performance Test Diagnoses........................................................................1184 Performance Chart.................................................................................1186 Trouble Diagnoses for Abnormal Pressure...........................................................1187 Trouble Diagnosis for Insufficient Heating........................................................1190 Trouble Diagnosis for Noise.......................................................................1192 SERVICE PROCEDURES....................................................................................1193 Refrigerant Lines.................................................................................1193 Checking Refrigerant Leaks........................................................................1194 R-134a Service Procedure..........................................................................1197 Compressor Lubricant Quantity.....................................................................1199 Compressor Mounting...............................................................................1201 Belt Tension......................................................................................1201 Fast Idle Control Device (FICD)...................................................................1201 Condenser.........................................................................................1201 Compressor........................................................................................1202 Compressor Clutch.................................................................................1202 Thermal Protector.................................................................................1205 Heater Unit (Heater Core).........................................................................1206 Cooling Unit (A/C Evaporator).....................................................................1207 Blower Case and Motor.............................................................................1208 Fan Lever and Illumination Bulbs..................................................................1209 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................1210 General Specifications............................................................................1210 Inspection and Adjustment.........................................................................1210 SUPER MULTIPLE JUNCTION (SMJ)......................................................................... 0 FUSE BLOCK — Junction Box (J/B)....................................................................... 2 FUSE AND FUSIBLE LINK BOX............................................................................. 3 ELECTRICAL UNITS...................................................................................... 4 JOINT CONNECTOR (J/C)................................................................................. 5 idx.......................................................................................................1212 QUICK REFERENCE INDEX................................................................................. 0 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 lc........................................................................................................1220 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents.....................................................................................1220 PRECAUTIONS AND PREPARATION...........................................................................1221 Supplemental Restraint System (SRS) ‘‘AIRBAG''....................................................1221 Liquid Gasket Application Procedure...............................................................1221 Special Service Tools.............................................................................1222 ENGINE LUBRICATION SYSTEM.............................................................................1223 Lubrication Circuit...............................................................................1223 Oil Pressure Check................................................................................1224 Oil Pump..........................................................................................1224 ENGINE COOLING SYSTEM.................................................................................1226 Cooling Circuit...................................................................................1226 System Check......................................................................................1226 Water Pump........................................................................................1228 Removal.......................................................................................1228 Thermostat........................................................................................1229 Radiator..........................................................................................1230 Cooling Fan (Crankshaft driven)...................................................................1231 Inspection....................................................................................1231 Refilling engine coolant..................................................................1231 Radiator (Aluminum type)..........................................................................1232 Inspection....................................................................................1232 Overheating Cause Analysis........................................................................1233 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................1234 Engine Lubrication System.........................................................................1234 Engine Cooling System.............................................................................1234 ma........................................................................................................1236 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents.....................................................................................1236 PRECAUTIONS AND PREPARATION...........................................................................1237 Supplemental Restraint System (SRS) ‘‘AIR BAG’’...................................................1237 Special Service Tool..............................................................................1237 Commercial Service Tool...........................................................................1237 GENERAL MAINTENANCE...................................................................................1238 PERIODIC MAINTENANCE..................................................................................1240 Schedule 1........................................................................................1241 Schedule 2........................................................................................1242 RECOMMENDED FLUIDS AND LUBRICANTS.....................................................................1243 Fluids and Lubricants.............................................................................1243 SAE Viscosity Number..............................................................................1244 Antifreeze Coolant Mixture Ratio..................................................................1244 ENGINE MAINTENANCE....................................................................................1245 Checking Drive Belts..............................................................................1245 Changing Engine Coolant...........................................................................1247 –DRAINING ENGINE COOLANT–.....................................................................1247 –REFILLING ENGINE COOLANT–....................................................................1247 –FLUSHING COOLING SYSTEM–.....................................................................1248 Checking Fuel Lines...............................................................................1249 Changing Fuel Filter..............................................................................1249 Changing Air Cleaner Filter.......................................................................1249 Changing Engine Oil...............................................................................1250 Changing Oil Filter...............................................................................1250 Changing Spark Plugs..............................................................................1251 Checking EVAP Vapor Lines.........................................................................1252 Changing Positive Crankcase Ventilation (PCV) Filter..............................................1252 CHASSIS AND BODY MAINTENANCE..........................................................................1253 Checking Exhaust System...........................................................................1253 Checking Clutch Fluid Level and Leaks.............................................................1253 Checking M/T Oil..................................................................................1253 Changing M/T Oil..................................................................................1253 Checking Water Entry — For 4WD models.............................................................1253 Checking A/T Fluid................................................................................1253 Changing A/T Fluid................................................................................1254 Checking Transfer Fluid...........................................................................1254 Changing Transfer Fluid...........................................................................1255 Checking Propeller Shaft..........................................................................1255 Checking Differential Gear Oil....................................................................1255 Changing Differential Gear Oil....................................................................1256 Balancing Wheels..................................................................................1256 Tire Rotation.....................................................................................1256 Checking Brake Fluid Level and Leaks..............................................................1257 Checking Brake System.............................................................................1257 Checking Disc Brake...............................................................................1257 Checking Drum Brake...............................................................................1257 Checking Steering Gear and Linkage................................................................1258 Checking Power Steering Fluid and Lines...........................................................1258 Checking Steering Gear Oil Level and Leaks........................................................1258 Lubricating Hood Latches, Locks and Hinges........................................................1259 Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters...................................1260 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................1261 Engine Maintenance................................................................................1261 Chassis and Body Maintenance......................................................................1261 mt........................................................................................................1262 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents.....................................................................................1262 PREPARATION...........................................................................................1263 Special Service Tools.............................................................................1263 Commercial Service Tools..........................................................................1264 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING..................................................1265 NVH Troubleshooting Chart.........................................................................1265 DESCRIPTION...........................................................................................1266 Cross-sectional View — 2WD Model —................................................................1266 Cross-sectional View — 4WD Model —................................................................1267 ON-VEHICLE SERVICE....................................................................................1268 Replacing Rear Oil Seal — 2WD Model —.............................................................1268 Position Switch Check.............................................................................1268 REMOVAL AND INSTALLATION..............................................................................1269 MAJOR OVERHAUL........................................................................................1272 Case Components...................................................................................1272 Gear Components — 2WD Model —.....................................................................1273 Gear Components — 4WD Model —.....................................................................1274 Shift Control Components..........................................................................1275 DISASSEMBLY...........................................................................................1276 Case Components...................................................................................1276 Shift Control Components..........................................................................1276 Gear Components...................................................................................1277 INSPECTION............................................................................................1280 Shift Control Components..........................................................................1280 Gear Components...................................................................................1280 Gears And Shafts..............................................................................1280 Synchronizers.................................................................................1280 Bearings......................................................................................1281 ASSEMBLY..............................................................................................1282 Gear Components...................................................................................1282 Shift Control Components..........................................................................1288 Case Components...................................................................................1289 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................1292 General Specifications............................................................................1292 Inspection and Adjustment.........................................................................1293 pd........................................................................................................1296 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents.....................................................................................1296 PREPARATION...........................................................................................1298 Special Service Tools.............................................................................1298 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING..................................................1302 NVH Troubleshooting Chart.........................................................................1302 PROPELLER SHAFT.......................................................................................1303 PROPELLER SHAFT...................................................................................1303 On-vehicle Service............................................................................1305 Removal and Installation......................................................................1305 Inspection....................................................................................1305 Disassembly...................................................................................1306 Assembly......................................................................................1307 FINAL DRIVE...........................................................................................1309 ON-VEHICLE SERVICE................................................................................1309 Front Oil Seal Replacement (Front final drive: Model R180A)...................................1309 Rear Cover Gasket Replacement (Rear final drive: Model C200)..................................1309 REMOVAL AND INSTALLATION (Front final drive)......................................................1310 Removal.......................................................................................1310 Installation..................................................................................1310 REMOVAL AND INSTALLATION (Rear final drive).......................................................1311 Removal.......................................................................................1311 Installation..................................................................................1311 R180A.................................................................................................1312 FRONT FINAL DRIVE.................................................................................1312 DISASSEMBLY.......................................................................................1313 Pre-inspection................................................................................1313 Final Drive Housing...........................................................................1313 Differential Case.............................................................................1315 Extension Tube and Differential Side Shaft....................................................1316 INSPECTION........................................................................................1318 Ring Gear and Drive Pinion....................................................................1318 Differential Case Assembly....................................................................1318 Bearing.......................................................................................1318 ADJUSTMENT........................................................................................1319 Side Bearing Preload..........................................................................1319 Pinion Gear Height and Pinion Bearing Preload.................................................1320 Tooth Contact.................................................................................1324 ASSEMBLY..........................................................................................1325 Extension Tube and Differential Side Shaft....................................................1325 Differential Case.............................................................................1325 Final Drive Housing...........................................................................1326 H190A.................................................................................................1330 REAR FINAL DRIVE..................................................................................1330 DISASSEMBLY.......................................................................................1331 Pre-inspection................................................................................1331 Differential Carrier..........................................................................1331 Differential Case.............................................................................1333 INSPECTION........................................................................................1335 Ring Gear and Drive Pinion....................................................................1335 Differential Case Assembly....................................................................1335 Bearing.......................................................................................1335 ADJUSTMENT........................................................................................1336 Side Bearing Preload..........................................................................1336 Pinion Gear Height............................................................................1337 Tooth Contact.................................................................................1341 ASSEMBLY..........................................................................................1342 Differential Case.............................................................................1342 Differential Carrier..........................................................................1343 C200..................................................................................................1347 REAR FINAL DRIVE..................................................................................1347 2WD models....................................................................................1347 4WD models....................................................................................1348 DISASSEMBLY.......................................................................................1349 Pre-inspection................................................................................1349 Differential Carrier..........................................................................1349 Differential Case.............................................................................1351 INSPECTION........................................................................................1353 Ring Gear and Drive Pinion....................................................................1353 Differential Case Assembly....................................................................1353 Bearing.......................................................................................1353 ADJUSTMENT........................................................................................1354 Side Bearing Preload..........................................................................1354 Pinion Gear Height............................................................................1355 Tooth Contact.................................................................................1359 ASSEMBLY..........................................................................................1360 Differential Case.............................................................................1360 Differential Carrier..........................................................................1361 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................1365 Propeller Shaft...................................................................................1365 Final Drive.......................................................................................1366 General Specifications........................................................................1366 Inspection And Adjustment (R180A).............................................................1367 Inspection And Adjustment (H190A).............................................................1368 Inspection And Adjustment (C200)..............................................................1369 ra........................................................................................................1370 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents.....................................................................................1370 PRECAUTIONS AND PREPARATION...........................................................................1371 Precautions.......................................................................................1371 Special Service Tools.............................................................................1371 Commercial Service Tools..........................................................................1372 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLE SHOOTING.................................................1373 NVH Trouble shooting Chart........................................................................1373 REAR SUSPENSION SYSTEM................................................................................1374 2WD models........................................................................................1374 4WD models........................................................................................1374 ON-VEHICLE SERVICE....................................................................................1375 Rear Axle and Rear Suspension Parts...............................................................1375 Rear Wheel Bearing................................................................................1375 REAR AXLE.............................................................................................1376 Components........................................................................................1376 Removal...........................................................................................1377 Inspection........................................................................................1379 Axle Shaft....................................................................................1379 Wheel Bearing.................................................................................1379 Axle Case.....................................................................................1379 Installation — 2WD models —.......................................................................1379 Installation — 4WD models —.......................................................................1381 REAR SUSPENSION.......................................................................................1383 2WD models........................................................................................1383 4WD models........................................................................................1383 Shock Absorber....................................................................................1384 Removal And Installation......................................................................1384 Inspection....................................................................................1384 LeafSpring........................................................................................1384 Removal And Installation......................................................................1384 Inspection....................................................................................1385 Installation..................................................................................1385 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................1386 General Specifications............................................................................1386 Inspection and Adjustment.........................................................................1386 rs........................................................................................................1388 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents.....................................................................................1388 PRECAUTIONS AND PREPARATION...........................................................................1389 Supplemental Restraint System (SRS) "AIR BAG".....................................................1389 SEAT BELTS............................................................................................1390 Front Seat Belt...................................................................................1391 Rear Seat Belt....................................................................................1392 Seat Belt Inspection..............................................................................1393 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)...................................................................1396 Precautions for SRS ‘‘AIR BAG’’ Service...........................................................1396 Special Service Tools.............................................................................1397 Description.......................................................................................1398 Passenger air bag deactivation switch.............................................................1398 SRS Component Parts Location......................................................................1399 Maintenance Items.................................................................................1400 Diagnosis Sensor Unit and Crash Zone Sensor.......................................................1401 REMOVAL AND INSTALLATION......................................................................1401 Air bag diagnosis sensor unit.............................................................1401 Crash zone sensor (4WD models)............................................................1401 Driver Air Bag Module and Spiral Cable............................................................1402 Passenger Air Bag Module..........................................................................1406 Passenger Air Bag Deactivation Switch.............................................................1408 Passenger Air Bag Deactivation Switch Lock Cylinder...............................................1408 Passenger Air Bag Deactivation Switch Indicator...................................................1409 Disposal of Air Bag Module........................................................................1410 TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)...............................................1414 Trouble Diagnosis Introduction....................................................................1414 How to Perform Trouble Diagnoses for Quick and Accurate Repair....................................1417 Schematic.........................................................................................1418 Wiring Diagram — SRS —............................................................................1419 Passenger Air Bag Deactivation Switch Indicator Operation Check...................................1421 SRS Operation Check...............................................................................1422 Trouble Diagnoses with CONSULT....................................................................1423 Trouble Diagnoses without CONSULT.................................................................1432 Trouble Diagnoses: ‘‘AIR BAG’’ Warning Lamp Does Not Turn Off.....................................1436 Trouble Diagnoses: “AIR BAG” Warning Lamp Does Not Turn On........................................1437 Trouble Diagnoses: SRS Does Not Enter Diagnosis Mode Using Door Switch............................1438 COLLISION DIAGNOSIS...................................................................................1439 SUPER MULTIPLE JUNCTION (SMJ)......................................................................... 0 FUSE BLOCK — Junction Box (J/B)....................................................................... 2 FUSE AND FUSIBLE LINK BOX............................................................................. 3 ELECTRICAL UNITS...................................................................................... 4 JOINT CONNECTOR (J/C)................................................................................. 5 st........................................................................................................1442 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents.....................................................................................1442 PRECAUTIONS AND PREPARATION...........................................................................1444 Supplemental Restraint System (SRS) "AIR BAG".....................................................1444 Precautions for Steering System...................................................................1444 Special Service Tools.............................................................................1445 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING..................................................1447 NVH Troubleshooting Chart.........................................................................1447 ON-VEHICLE SERVICE....................................................................................1448 Steering System...................................................................................1448 Checking and Adjusting Drive Belts (For power steering)...........................................1448 Checking Fluid Level (For power steering).........................................................1448 Checking Fluid Leakage (For power steering).......................................................1449 Bleeding Hydraulic System (For power steering)....................................................1449 Checking Steering Wheel Turning Force (For power steering)........................................1450 Checking Steering Wheel Play......................................................................1450 Checking Neutral Position on Steering Wheel.......................................................1451 Checking......................................................................................1451 Checking Front Wheel Turning Angle................................................................1451 Checking Hydraulic System (For power steering)....................................................1452 STEERING WHEEL AND STEERING COLUMN....................................................................1453 Steering Wheel....................................................................................1453 Removal And Installation......................................................................1453 Steering Column...................................................................................1454 Removal.......................................................................................1454 Installation..................................................................................1454 Disassembly and Assembly..........................................................................1455 Tilt mechanism................................................................................1456 Inspection........................................................................................1456 MANUAL STEERING GEAR (Model: VB66K)...................................................................1457 Removal and Installation..........................................................................1457 Disassembly.......................................................................................1458 Assembly and Adjustment...........................................................................1458 Worm Gear Bearing Preload.....................................................................1458 Sector Shaft End Play.........................................................................1460 Steering Gear Preload And Backlash............................................................1460 Inspection........................................................................................1461 Sector Shaft..................................................................................1461 Steering Worm Assembly........................................................................1462 Bearing.......................................................................................1462 Oil Seals.....................................................................................1462 POWER STEERING SYSTEM (Model: PB48S)..................................................................1463 Description.......................................................................................1463 POWER STEERING GEAR (Model: PB48S)....................................................................1464 Removal and Installation..........................................................................1464 Steering Gear.................................................................................1464 Power Steering Gear Component.....................................................................1464 Pre-disassembly Inspection and Adjustment.........................................................1465 Turning Torque Mesurement.....................................................................1465 Disassembly.......................................................................................1466 Adjusting Screw Lock Nut O-Ring...............................................................1466 Sector Shaft Oil Seal.........................................................................1466 Rear Housing O-Ring...........................................................................1467 Rear Cover O-Ring And Oil Seal................................................................1467 Assembly..........................................................................................1468 Adjusting Screw Lock Nut O-Ring...............................................................1468 Sector Shaft Oil Seal.........................................................................1468 Sector Shaft End Play.........................................................................1469 Rear Cover O-Ring And Oil Seal................................................................1469 Rear Housing O-Ring...........................................................................1469 Sector Shaft..................................................................................1470 POWER STEERING SYSTEM (Model: PB59K)..................................................................1471 Description.......................................................................................1471 POWER STEERING GEAR (Model: PB59K)....................................................................1472 Removal and Installation..........................................................................1472 Steering Gear.................................................................................1472 Power Steering Gear Component.....................................................................1472 Pre-disassembly Inspection and Adjustment.........................................................1473 Turning Torque Measurement....................................................................1473 Disassembly.......................................................................................1474 Assembly..........................................................................................1475 POWER STEERING OIL PUMP...............................................................................1478 Disassembly and Assembly..........................................................................1478 Pre-disassembly Inspection........................................................................1478 Inspection........................................................................................1479 Pulley And Pulley Shaft.......................................................................1479 Disassembly.......................................................................................1479 Assembly..........................................................................................1480 STEERING LINKAGE......................................................................................1481 Removal and Installation..........................................................................1481 Disassembly.......................................................................................1482 Idler Arm Assembly............................................................................1482 Cross Rod And Tie-Rod.........................................................................1482 Inspection........................................................................................1483 Ball Joint And Swivel Joint...................................................................1483 Idler Arm Assembly............................................................................1483 Cross Rod And Tie-Rod.........................................................................1483 Fixing Location...............................................................................1483 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................1484 General Specifications............................................................................1484 Inspection and Adjustment.........................................................................1484 Steering Column Length........................................................................1484 Manual Steering Gear (Model: Vb66K)...........................................................1485 Steering Linkage..............................................................................1485 Power Steering System (Model: Pb48S)..........................................................1485 Power Steering System (Model: Pb59K)..........................................................1486 tf........................................................................................................1488 QUICK REFERENCE INDEX................................................................................. 0 Table of Contents.....................................................................................1488 PREPARATION...........................................................................................1489 Special Service Tools.............................................................................1489 Commercial Service Tools..........................................................................1490 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING..................................................1491 NVH Troubleshooting Chart.........................................................................1491 Transfer......................................................................................1491 DESCRIPTION...........................................................................................1492 Cross-sectional View..............................................................................1492 ON-VEHICLE SERVICE....................................................................................1493 Replacing OilSeal.................................................................................1493 Center Case Oil Seal..........................................................................1493 Shift Shaft Oil Seal..........................................................................1493 Rear Oil Seal.................................................................................1494 REMOVAL AND INSTALLATION..............................................................................1495 TRANSFER GEAR CONTROL.................................................................................1496 MAJOR OVERHAUL........................................................................................1497 Case Components...................................................................................1497 Gear Components...................................................................................1498 Shift Control Components..........................................................................1499 DISASSEMBLY...........................................................................................1500 REPAIR FOR COMPONENT PARTS............................................................................1505 Mainshaft.........................................................................................1505 Front Drive Shaft.................................................................................1507 Counter Gear......................................................................................1508 Main Gear.........................................................................................1508 Front Case........................................................................................1510 Shift Shaft Oil Seal..........................................................................1510 Front Case Cover..................................................................................1510 Cover Oil Seal................................................................................1510 Bearing Retainer..................................................................................1511 Oil Catcher...................................................................................1511 Center Case.......................................................................................1511 Removal.......................................................................................1511 Center case oil seal......................................................................1511 Installation..................................................................................1511 Center case oil seal......................................................................1511 Rear Case.........................................................................................1511 Rear Oil Seal.................................................................................1511 Air Breather..................................................................................1512 Shift Control Components..........................................................................1512 ASSEMBLY..............................................................................................1514 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................1521 General Specifications............................................................................1521 Inspection and Adjustment.........................................................................1521
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
G.P
