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2000 NISSAN FRONTIER D22 Series(3.3L VG Engine) Service Manual PDF DOWNLOAD
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2000 NISSAN FRONTIER D22 Series(3.3L VG Engine) Service Manual PDF DOWNLOAD
NISSAN FRONTIER MODEL D22 SERIES For vehicles equipped with the 3.3L, VG engine up to serial number 343314. The serial number is shown on the Vehicle Identification Number Plate. (Except Crew Cab and 2WD King Cab Models)
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Description
2000 NISSAN FRONTIER D22 Series(3.3L VG Engine) Service Manual PDF DOWNLOAD
FILE DETAILS:
2000 NISSAN FRONTIER D22 Series(3.3L VG Engine) Service Manual PDF DOWNLOAD
Language : English
Pages : 1808
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
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DESCRIPTION:
2000 NISSAN FRONTIER D22 Series(3.3L VG Engine) Service Manual PDF DOWNLOAD
FOREWORD
- This manual contains maintenance and repair procedures for the 2000 Nissan FRONTIER equipped with the 3.3L, VG engine. (Except Crew Cab and 2WD King Cab Models)
- 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(3.3L VG Engine) Service Manual PDF DOWNLOAD
NISSAN FRONTIER MODEL D22 SERIES For vehicles equipped with the 3.3L, VG engine up to serial number 343314. The serial number is shown on the Vehicle Identification Number Plate. (Except Crew Cab and 2WD King Cab Models)
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 GST Mode 6 - Test Value & Test Limit Chart............................................................................. 5 at......................................................................................................................... 6 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents...................................................................................................... 6 TROUBLE DIAGNOSIS - INDEX.............................................................................................. 9 Alphabetical & P No. Index for DTC................................................................................. 9 PRECAUTIONS............................................................................................................ 11 Precautions for Supplemental Restraint System (SRS) "AIR BAG"...................................................... 11 Precautions for On Board Diagnostic (OBD) System of A/T and Engine................................................. 11 Precautions........................................................................................................ 12 Service Notice or Precautions...................................................................................... 13 Wiring Diagrams and Trouble Diagnosis.............................................................................. 14 PREPARATION............................................................................................................ 15 Special Service Tools.............................................................................................. 15 OVERALL SYSTEM......................................................................................................... 17 A/T Electrical Parts Location...................................................................................... 17 Circuit Diagram.................................................................................................... 18 Cross-sectional View............................................................................................... 19 Hydraulic Control Circuit.......................................................................................... 20 Shift Mechanism.................................................................................................... 21 Control System..................................................................................................... 30 Control Mechanism.................................................................................................. 31 Control Valve...................................................................................................... 36 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION................................................................................. 38 Introduction....................................................................................................... 38 OBD-II Function for A/T System..................................................................................... 38 One or Two Trip Detection Logic of OBD-II.......................................................................... 38 OBD-II Diagnostic Trouble Code (DTC)............................................................................... 38 Malfunction Indicator Lamp (MIL)................................................................................... 42 CONSULT............................................................................................................ 42 Diagnostic Procedure Without CONSULT............................................................................... 51 TROUBLE DIAGNOSIS - INTRODUCTION....................................................................................... 58 Introduction....................................................................................................... 58 Work Flow.......................................................................................................... 62 TROUBLE DIAGNOSIS - BASIC INSPECTION................................................................................... 64 A/T Fluid Check.................................................................................................... 64 Stall Test......................................................................................................... 64 Line Pressure Test................................................................................................. 67 Road Test.......................................................................................................... 68 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION................................................................................ 86 Symptom Chart...................................................................................................... 86 TCM Terminals and Reference Value.................................................................................. 97 TROUBLE DIAGNOSIS FOR POWER SUPPLY..................................................................................... 101 Wiring Diagram - AT - MAIN......................................................................................... 101 DTC P0705 PARK/NEUTRAL POSITION SWITCH................................................................................. 104 Description........................................................................................................ 104 Wiring Diagram - AT - PNP/SW....................................................................................... 106 Diagnostic Procedure............................................................................................... 107 Component Inspection............................................................................................... 109 DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT......................................................................... 110 Description........................................................................................................ 110 Wiring Diagram - AT - FTS.......................................................................................... 112 Diagnostic Procedure............................................................................................... 113 Component Inspection............................................................................................... 115 DTC P0720 VEHICLE SPEED SENSOR.A/T (REVOLUTION SENSOR)................................................................. 116 Description........................................................................................................ 116 Wiring Diagram - AT - VSSA/T....................................................................................... 118 Diagnostic Procedure............................................................................................... 119 Component Inspection............................................................................................... 120 DTC P0725 ENGINE SPEED SIGNAL.......................................................................................... 121 Description........................................................................................................ 121 Wiring Diagram - AT - ENGSS........................................................................................ 123 Diagnostic Procedure............................................................................................... 124 DTC P0731 IMPROPER SHIFTING TO 1ST GEAR POSITION....................................................................... 126 Description........................................................................................................ 126 Wiring Diagram - AT - 1ST.......................................................................................... 129 Diagnostic Procedure............................................................................................... 130 Component Inspection............................................................................................... 131 DTC P0732 IMPROPER SHIFTING TO 2ND GEAR POSITION....................................................................... 132 Description........................................................................................................ 132 Wiring Diagram - AT - 2ND.......................................................................................... 135 Diagnostic Procedure............................................................................................... 136 Component Inspection............................................................................................... 137 DTC P0733 IMPROPER SHIFTING TO 3RD GEAR POSITION....................................................................... 138 Description........................................................................................................ 138 Wiring Diagram - AT - 3RD.......................................................................................... 141 Diagnostic Procedure............................................................................................... 142 Component Inspection............................................................................................... 143 DTC P0734 IMPROPER SHIFTING TO 4TH GEAR POSITION....................................................................... 144 Description........................................................................................................ 144 Wiring Diagram - AT - 4TH.......................................................................................... 148 Diagnostic Procedure............................................................................................... 149 Component Inspection............................................................................................... 154 DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE....................................................................... 155 Description........................................................................................................ 155 Wiring Diagram - AT - TCV.......................................................................................... 157 Diagnostic Procedure............................................................................................... 158 Component Inspection............................................................................................... 159 DTC P0744 IMPROPER LOCK-UP OPERATION................................................................................... 160 Description........................................................................................................ 160 Wiring Diagram - AT - TCCSIG....................................................................................... 163 Diagnostic Procedure............................................................................................... 164 Component Inspection............................................................................................... 169 DTC P0745 LINE PRESSURE SOLENOID VALVE................................................................................. 170 Description........................................................................................................ 170 Wiring Diagram - AT - LPSV......................................................................................... 172 Diagnostic Procedure............................................................................................... 173 Component Inspection............................................................................................... 174 DTC P0750 SHIFT SOLENOID VALVE A....................................................................................... 176 Description........................................................................................................ 176 Wiring Diagram - AT - SSV/A........................................................................................ 178 Diagnostic Procedure............................................................................................... 179 Component Inspection............................................................................................... 180 DTC P0755 SHIFT SOLENOID VALVE B....................................................................................... 181 Description........................................................................................................ 181 Wiring Diagram - AT - SSV/B........................................................................................ 183 Diagnostic Procedure............................................................................................... 184 Component Inspection............................................................................................... 185 DTC P1705 THROTTLE POSITION SENSOR..................................................................................... 186 Description........................................................................................................ 186 Wiring Diagram - AT - TPS.......................................................................................... 189 Diagnostic Procedure............................................................................................... 190 Component Inspection............................................................................................... 194 DTC P1760 OVERRUN CLUTCH SOLENOID VALVE................................................................................ 195 Description........................................................................................................ 195 Wiring Diagram - AT - OVRCSV....................................................................................... 197 Diagnostic Procedure............................................................................................... 198 Component Inspection............................................................................................... 199 DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE)........................................... 200 Description........................................................................................................ 200 Wiring Diagram - AT - BA/FTS....................................................................................... 202 Diagnostic Procedure............................................................................................... 203 Component Inspection............................................................................................... 205 VEHICLE SPEED SENSOR.MTR............................................................................................... 206 Description........................................................................................................ 206 Wiring Diagram - AT - VSSMTR....................................................................................... 208 Diagnostic Procedure............................................................................................... 209 DTC CONTROL UNIT (RAM), CONTROL UNIT (ROM)............................................................................. 210 Description........................................................................................................ 210 Diagnostic Procedure............................................................................................... 211 DTC CONTROL UNIT (EEPROM).............................................................................................. 212 Description........................................................................................................ 212 Diagnostic Procedure............................................................................................... 213 TROUBLE DIAGNOSES FOR SYMPTOMS......................................................................................... 214 Wiring Diagram - AT - NONDTC....................................................................................... 214 1. O/D OFF Indicator Lamp Does Not Come On......................................................................... 217 2. Engine Cannot Be Started In P and N Position.................................................................... 219 3. In "P" Position, Vehicle Moves Forward Or Backward When Pushed.................................................. 220 4. In N Position, Vehicle Moves.................................................................................... 221 5. Large Shock. N -> R Position.................................................................................... 223 6. Vehicle Does Not Creep Backward In R Position................................................................... 225 7. Vehicle Does Not Creep Forward In D, 2 Or 1 Position............................................................ 228 8. Vehicle Cannot Be Started From D1............................................................................... 231 9. A/T Does Not Shift: D1 -> D2 Or Does Not Kickdown: D4 -> D2..................................................... 234 10. A/T Does Not Shift: D2 -> D3................................................................................... 237 11. A/T Does Not Shift: D3 -> D4................................................................................... 240 12. A/T Does Not Perform Lock-up................................................................................... 243 13. A/T Does Not Hold Lock-up Condition............................................................................ 245 14. Lock-up Is Not Released........................................................................................ 247 15. Engine Speed Does Not Return To Idle (Light Braking D4 -> D3).................................................. 248 16. Vehicle Does Not Start From D1................................................................................. 250 17. A/T Does Not Shift: D4 -> D3, When Overdrive Control Switch ON -> OFF.......................................... 251 18. A/T Does Not Shift: D3 -> 22, When Selector Lever D -> 2 Position.............................................. 252 19. A/T Does Not Shift: 22 -> 11, When Selector Lever 2 -> 1 Position.............................................. 253 20. Vehicle Does Not Decelerate By Engine Brake.................................................................... 254 21. TCM Self-diagnosis Does Not Activate (PNP, Overdrive Control and Throttle Position Switches Circuit Checks).... 254 A/T SHIFT LOCK SYSTEM.................................................................................................. 262 Description........................................................................................................ 262 Wiring Diagram - SHIFT -........................................................................................... 263 Diagnostic Procedure............................................................................................... 264 Component Check.................................................................................................... 266 KEY INTERLOCK CABLE.................................................................................................... 267 Components......................................................................................................... 267 Removal............................................................................................................ 267 Installation....................................................................................................... 268 ON-VEHICLE SERVICE..................................................................................................... 269 Control Valve Assembly and Accumulators............................................................................ 269 Revolution Sensor Replacement...................................................................................... 270 Rear Oil Seal Replacement.......................................................................................... 270 Parking Components Inspection...................................................................................... 270 Park/Neutral Position (PNP) Switch Adjustment...................................................................... 270 Manual Control Linkage Adjustment.................................................................................. 271 REMOVAL AND INSTALLATION............................................................................................... 272 Removal............................................................................................................ 272 Installation....................................................................................................... 273 OVERHAUL............................................................................................................... 275 Components......................................................................................................... 275 Oil Channel........................................................................................................ 277 Locations of Needle Bearings, Thrust Washers and Snap Rings........................................................ 278 DISASSEMBLY............................................................................................................ 279 REPAIR FOR COMPONENT PARTS............................................................................................. 290 Oil Pump........................................................................................................... 290 Control Valve Assembly............................................................................................. 294 Control Valve Upper Body........................................................................................... 300 Control Valve Lower Body........................................................................................... 305 Reverse Clutch..................................................................................................... 307 High Clutch........................................................................................................ 311 Forward and Overrun Clutches....................................................................................... 313 Low & Reverse Brake................................................................................................ 317 Forward Clutch Drum Assembly....................................................................................... 321 Rear Internal Gear and Forward Clutch Hub.......................................................................... 323 Band Servo Piston Assembly......................................................................................... 326 Parking Pawl Components............................................................................................ 330 ASSEMBLY............................................................................................................... 332 Assembly (1)....................................................................................................... 332 Adjustment......................................................................................................... 339 Assembly (2)....................................................................................................... 342 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................. 349 General Specifications............................................................................................. 349 Shift Schedule..................................................................................................... 349 Stall Revolution................................................................................................... 349 Line Pressure...................................................................................................... 349 Return Springs..................................................................................................... 350 Accumulator O-ring................................................................................................. 351 Clutches and Brakes................................................................................................ 351 Oil Pump and Low One-way Clutch.................................................................................... 353 Total End Play..................................................................................................... 353 Reverse Clutch Drum End Play....................................................................................... 354 Removal and Installation........................................................................................... 354 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......................................................................................................................... 356 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents...................................................................................................... 356 PRECAUTIONS AND PREPARATION............................................................................................ 358 Supplemental Restraint System (SRS) ‘‘AIR BAG’’ GI................................................................. 358 Precautions for Brake System....................................................................................... 359 Commercial Service Tools........................................................................................... 359 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING................................................................... 360 NVH Troubleshooting Chart.......................................................................................... 360 ON-VEHICLE SERVICE..................................................................................................... 361 Checking Brake Fluid Level......................................................................................... 361 Checking Brake Line................................................................................................ 361 Changing Brake Fluid............................................................................................... 361 Brake Burnishing Procedure......................................................................................... 361 Bleeding Brake System.............................................................................................. 362 BRAKE HYDRAULIC LINE................................................................................................... 363 BRAKE HYDRAULIC LINE/CONTROL VALVE..................................................................................... 365 Proportioning Valve................................................................................................ 365 BRAKE PEDAL AND BRACKET................................................................................................ 366 Removal and Installation........................................................................................... 366 Inspection......................................................................................................... 367 Adjustment......................................................................................................... 367 MASTER CYLINDER........................................................................................................ 368 Removal............................................................................................................ 368 Disassembly........................................................................................................ 369 Inspection......................................................................................................... 369 Assembly........................................................................................................... 369 Installation....................................................................................................... 370 BRAKE BOOSTER.......................................................................................................... 371 On-vehicle Service................................................................................................. 371 Removal............................................................................................................ 371 Inspection......................................................................................................... 371 Installation....................................................................................................... 372 VACUUM HOSE............................................................................................................ 373 Removal and Installation........................................................................................... 373 Inspection......................................................................................................... 373 FRONT DISC BRAKE....................................................................................................... 374 Pad Replacement.................................................................................................... 374 Removal............................................................................................................ 375 Disassembly........................................................................................................ 376 Inspection — Caliper............................................................................................... 376 Inspection — Rotor................................................................................................. 376 Assembly........................................................................................................... 377 Installation....................................................................................................... 377 REAR DRUM BRAKE........................................................................................................ 378 Removal............................................................................................................ 379 Inspection — Wheel Cylinder........................................................................................ 380 Wheel Cylinder Overhaul............................................................................................ 380 Inspection — Drum.................................................................................................. 380 Inspection — Lining................................................................................................ 380 Installation....................................................................................................... 380 PARKING BRAKE CONTROL.................................................................................................. 382 Removal and Installation........................................................................................... 383 Inspection......................................................................................................... 383 Adjustment......................................................................................................... 383 ANTI-LOCK BRAKE SYSTEM................................................................................................. 384 Purpose............................................................................................................ 384 Operation.......................................................................................................... 384 ABS Hydraulic Circuit.............................................................................................. 384 System Components.................................................................................................. 385 System Description................................................................................................. 385 Removal and Installation........................................................................................... 387 TROUBLE DIAGNOSES...................................................................................................... 390 How to Perform Trouble Diagnoses for Quick and Accurate Repair GI.................................................. 390 Preliminary Check.................................................................................................. 392 Component Parts and Harness Connector Location..................................................................... 393 Schematic.......................................................................................................... 394 Wiring Diagram — ABS —............................................................................................. 395 Self-diagnosis..................................................................................................... 398 CONSULT............................................................................................................ 401 CONSULT Inspection Procedure....................................................................................... 402 Ground Circuit Check............................................................................................... 407 TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS............................................................................ 408 Diagnostic Procedure 1 (Wheel sensor or rotor)..................................................................... 408 Diagnostic Procedure 2 (ABS actuator solenoid valve and solenoid valve relay)...................................... 410 Diagnostic Procedure 3 (Motor relay or motor)...................................................................... 412 Diagnostic Procedure 4 (Low voltage)............................................................................... 414 Diagnostic Procedure 5 (G sensor).................................................................................. 415 Diagnostic Procedure 6 (Control unit).............................................................................. 416 TROUBLE DIAGNOSES FOR SYMPTOMS......................................................................................... 417 Diagnostic Procedure 7 (ABS works frequently.)..................................................................... 417 Diagnostic Procedure 8 (Unexpected pedal action)................................................................... 418 Diagnostic Procedure 9 (Long stopping distance).................................................................... 418 Diagnostic Procedure 10 (ABS does not work.)....................................................................... 419 Diagnostic Procedure 11 (Pedal vibration and noise)................................................................ 419 Diagnostic Procedure 12 (Warning lamp does not come on when ignition switch is turned ON.)......................... 420 Diagnostic Procedure 13 (Warning lamp stays on when ignition switch is turned ON.)................................. 422 Electrical Components Inspection................................................................................... 424 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................. 425 General Specifications............................................................................................. 425 Inspection and Adjustment.......................................................................................... 426 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......................................................................................................................... 428 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents...................................................................................................... 428 PRECAUTIONS AND PREPARATION............................................................................................ 430 Service Notice..................................................................................................... 430 Supplemental Restraint System (SRS) ‘‘AIR BAG’’.................................................................... 430 PREPARATION............................................................................................................ 431 Special Service Tools.............................................................................................. 431 Commercial Service Tools........................................................................................... 431 SQUEAK AND RATTLE TROUBLE DIAGNOSES.................................................................................... 432 Work Flow.......................................................................................................... 432 CUSTOMER INTERVIEW............................................................................................. 432 DUPLICATE THE NOISE AND TEST DRIVE............................................................................. 433 CHECK RELATED SERVICE BULLETINS................................................................................ 433 LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE................................................................... 433 REPAIR THE CAUSE............................................................................................... 433 CONFIRM THE REPAIR............................................................................................. 434 Generic Squeak and Rattle Troubleshooting.......................................................................... 434 INSTRUMENT PANEL............................................................................................... 434 CENTER CONSOLE................................................................................................. 434 DOORS.......................................................................................................... 434 TRUNK.......................................................................................................... 434 SUNROOF AND HEADLINER.......................................................................................... 434 SEATS.......................................................................................................... 435 UNDERHOOD...................................................................................................... 435 Diagnostic Worksheet............................................................................................... 436 GENERAL SERVICING...................................................................................................... 438 Clip and Fastener.................................................................................................. 438 BODY END............................................................................................................... 440 Body Front End..................................................................................................... 440 REMOVAL — Front bumper assembly................................................................................ 440 Body Rear End...................................................................................................... 443 REMOVAL — Rear bumper assembly................................................................................. 443 DOOR................................................................................................................... 445 Front Door......................................................................................................... 445 INSTRUMENT PANEL....................................................................................................... 446 REMOVAL — Instrument panel assembly................................................................................ 446 INTERIOR TRIM.......................................................................................................... 449 Side and Floor Trim................................................................................................ 449 REMOVAL — Body side trim....................................................................................... 449 King cab model............................................................................................. 449 Standard cab model......................................................................................... 449 Door Trim.......................................................................................................... 452 REMOVAL........................................................................................................ 452 Door trim (Formed type).................................................................................... 452 Roof Trim.......................................................................................................... 455 REMOVAL — Headlining........................................................................................... 455 EXTERIOR............................................................................................................... 457 1 Hood front sealing rubber....................................................................................... 458 2 Cowl top seal and cowl top grille................................................................................ 458 3 Windshield side molding.......................................................................................... 458 4 Windshield upper molding......................................................................................... 458 5 Sunroof weatherstrip and lid protector........................................................................... 458 6 Drip weatherstrip................................................................................................ 459 7 Body side welt................................................................................................... 459 8 Door weatherstrip................................................................................................ 459 9 Door outside molding............................................................................................. 459 10 Drafter duct.................................................................................................... 460 11 Over fender..................................................................................................... 460 12 Rear combination lamp........................................................................................... 460 SEAT................................................................................................................... 461 Front Seat......................................................................................................... 461 Jump Seat — King Cab Model......................................................................................... 463 SUNROOF................................................................................................................ 464 WINDSHIELD AND WINDOWS................................................................................................. 465 Windshield......................................................................................................... 466 Side Window........................................................................................................ 466 Back Window........................................................................................................ 467 Rearview Mirror.................................................................................................... 468 MIRROR................................................................................................................. 469 Door Mirror........................................................................................................ 469 REMOVAL — Door mirror.......................................................................................... 469 CAB AND REAR BODY...................................................................................................... 470 Body Mounting...................................................................................................... 470 BODY ALIGNMENT......................................................................................................... 471 Engine Compartment................................................................................................. 472 MEASUREMENT.................................................................................................... 472 MEASUREMENT POINTS............................................................................................. 473 Underbody.......................................................................................................... 474 MEASUREMENT.................................................................................................... 474 2WD 4WD (Short wheelbase) models........................................................................... 474 MEASUREMENT POINTS............................................................................................. 475 2WD 4WD (Short wheelbase) models........................................................................... 475 MEASUREMENT.................................................................................................... 476 2WD 4WD (Long wheelbase) models............................................................................ 476 MEASUREMENT POINTS............................................................................................. 477 2WD 4WD (Long wheelbase) models............................................................................ 477 cl......................................................................................................................... 478 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contens....................................................................................................... 478 PRECAUTIONS AND PREPARATION............................................................................................ 479 Precautions........................................................................................................ 479 Special Service Tools.............................................................................................. 479 Commercial Service Tools........................................................................................... 479 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING................................................................... 480 NVH Troubleshooting Chart.......................................................................................... 480 CLUTCH SYSTEM.......................................................................................................... 481 Clutch Pedal....................................................................................................... 482 INSPECTION AND ADJUSTMENT.............................................................................................. 483 Adjusting Clutch Pedal............................................................................................. 483 Air Bleeding Procedure............................................................................................. 484 HYDRAULIC CLUTCH CONTROL............................................................................................... 485 Clutch Master Cylinder (With clutch damper)........................................................................ 485 Operating Cylinder................................................................................................. 486 CLUTCH RELEASE MECHANISM............................................................................................... 487 CLUTCH DISC AND CLUTCH COVER........................................................................................... 489 Clutch Disc........................................................................................................ 489 Clutch Cover and Flywheel.......................................................................................... 490 SERVICE DATA AND SPECIFICATIONS (SDS).................................................................................. 491 General Specifications............................................................................................. 491 Clutch Control System.......................................................................................... 491 Inspection and Adjustment.......................................................................................... 491 ec......................................................................................................................... 492 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents...................................................................................................... 492 TROUBLE DIAGNOSIS - INDEX.............................................................................................. 499 Alphabetical & P No. Index for DTC................................................................................. 499 PRECAUTIONS............................................................................................................ 505 Supplemental Restraint System (SRS) "AIR BAG"...................................................................... 505 Precautions for On Board Diagnostic (OBD) System of Engine and A/T................................................. 505 Engine Fuel & Emission Control System.............................................................................. 506 Precautions........................................................................................................ 507 Wiring Diagrams and Trouble Diagnosis.............................................................................. 508 PREPARATION............................................................................................................ 509 Special Service Tools.............................................................................................. 509 Commercial Service Tools........................................................................................... 509 ENGINE AND EMISSION CONTROL OVERALL SYSTEM............................................................................. 511 Engine Control Component Parts Location............................................................................ 511 Circuit Diagram.................................................................................................... 513 System Diagram..................................................................................................... 514 Vacuum Hose Drawing................................................................................................ 515 System Chart....................................................................................................... 516 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION................................................................... 517 Multiport Fuel Injection (MFI) System.............................................................................. 517 Distributor Ignition (DI) System................................................................................... 519 Air Conditioning Cut Control....................................................................................... 520 Fuel Cut Control (at no load & high engine speed).................................................................. 521 Evaporative Emission System........................................................................................ 521 Positive Crankcase Ventilation..................................................................................... 527 BASIC SERVICE PROCEDURE................................................................................................ 528 Fuel Pressure Release.............................................................................................. 528 Fuel Pressure Check................................................................................................ 528 Fuel Pressure Regulator Check...................................................................................... 529 Injector........................................................................................................... 529 Fast Idle Cam (FIC)................................................................................................ 530 Idle Speed/Ignition Timing/Idle Mixture Ratio Adjustment........................................................... 532 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION................................................................................. 545 Introduction....................................................................................................... 545 Two Trip Detection Logic........................................................................................... 545 Emission-related Diagnostic Information............................................................................ 546 Malfunction Indicator Lamp (MIL)................................................................................... 558 OBD System Operation Chart......................................................................................... 562 CONSULT............................................................................................................ 567 Generic Scan Tool (GST)............................................................................................ 581 TROUBLE DIAGNOSIS - INTRODUCTION....................................................................................... 583 Introduction....................................................................................................... 583 Work Flow.......................................................................................................... 585 TROUBLE DIAGNOSIS - BASIC INSPECTION................................................................................... 587 Basic Inspection................................................................................................... 587 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION................................................................................ 604 DTC Inspection Priority Chart...................................................................................... 604 Fail-safe Chart.................................................................................................... 605 Symptom Matrix Chart............................................................................................... 606 CONSULT Reference Value in Data Monitor Mode....................................................................... 610 Major Sensor Reference Graph in Data Monitor Mode.................................................................. 612 ECM Terminals and Reference Value.................................................................................. 615 TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT............................................................................ 624 Description........................................................................................................ 624 Diagnostic Procedure............................................................................................... 624 TROUBLE DIAGNOSIS FOR POWER SUPPLY..................................................................................... 625 Main Power Supply and Ground Circuit............................................................................... 625 DTC P0100 MASS AIR FLOW SENSOR (MAFS).................................................................................. 632 Component Description.............................................................................................. 632 CONSULT Reference Value in Data Monitor Mode....................................................................... 632 ECM Terminals and Reference Value.................................................................................. 632 On Board Diagnosis Logic........................................................................................... 632 DTC Confirmation Procedure......................................................................................... 633 Overall Function Check............................................................................................. 636 Wiring Diagram..................................................................................................... 637 Diagnostic Procedure............................................................................................... 638 Component Inspection............................................................................................... 641 DTC P0105 ABSOLUTE PRESSURE SENSOR..................................................................................... 642 Component Description.............................................................................................. 642 On Board Diagnosis Logic........................................................................................... 642 DTC Confirmation Procedure......................................................................................... 642 Overall Function Check............................................................................................. 644 Wiring Diagram..................................................................................................... 645 Diagnostic Procedure............................................................................................... 646 Component Inspection............................................................................................... 652 DTC P0110 INTAKE AIR TEMPERATURE SENSOR................................................................................ 654 Component Description.............................................................................................. 654 On Board Diagnosis Logic........................................................................................... 654 DTC Confirmation Procedure......................................................................................... 654 Wiring Diagram..................................................................................................... 657 Diagnostic Procedure............................................................................................... 658 Component Inspection............................................................................................... 659 DTC P0115 ENGINE COOLANT TEMPERATURE SENSOR (ECTS) (CIRCUIT)........................................................... 661 Component Description.............................................................................................. 661 On Board Diagnosis Logic........................................................................................... 661 DTC Confirmation Procedure......................................................................................... 662 Wiring Diagram..................................................................................................... 663 Diagnostic Procedure............................................................................................... 664 Component Inspection............................................................................................... 665 DTC P0120 THROTTLE POSITION SENSOR..................................................................................... 666 Description........................................................................................................ 666 CONSULT Reference Value in Data Monitor Mode....................................................................... 666 ECM Terminals and Reference Value.................................................................................. 666 On Board Diagnosis Logic........................................................................................... 667 DTC Confirmation Procedure......................................................................................... 667 Wiring Diagram..................................................................................................... 672 Diagnostic Procedure............................................................................................... 673 Component Inspection............................................................................................... 677 DTC P0125 ENGINE COOLANT TEMPERATURE (ECT) SENSOR...................................................................... 679 Description........................................................................................................ 679 On Board Diagnosis Logic........................................................................................... 679 DTC Confirmation Procedure......................................................................................... 679 Wiring Diagram..................................................................................................... 681 Diagnostic Procedure............................................................................................... 682 Component Inspection............................................................................................... 683 DTC P0130 (RIGHT, -B1), P0150 (LEFT, -B2) FRONT HO2S (CIRCUIT)......................................................... 684 Component Description.............................................................................................. 684 CONSULT Reference Value in Data Monitor Mode....................................................................... 684 ECM Terminals and Reference Value.................................................................................. 684 On Board Diagnosis Logic........................................................................................... 685 DTC Confirmation Procedure......................................................................................... 685 Overall Function Check............................................................................................. 686 Wiring Diagram..................................................................................................... 687 Diagnostic Procedure............................................................................................... 689 Component Inspection............................................................................................... 691 DTC P0131 (RIGHT, -B1), P0151 (LEFT, -B2) FRONT HO2S (LEAN SHIFT MONITORING)........................................... 693 Component Description.............................................................................................. 693 CONSULT Reference Value in Data Monitor Mode....................................................................... 693 ECM Terminals and Reference Value.................................................................................. 693 On Board Diagnosis Logic........................................................................................... 694 DTC Confirmation Procedure......................................................................................... 694 Overall Function Check............................................................................................. 695 Diagnostic Procedure............................................................................................... 696 Component Inspection............................................................................................... 698 DTC P0132 (RIGHT, -B1), P0152 (LEFT, -B2) FRONT HO2S (RICH SHIFT MONITORING)........................................... 700 Component Description.............................................................................................. 700 CONSULT Reference Value in Data Monitor Mode....................................................................... 700 ECM Terminals and Reference Value.................................................................................. 700 On Board Diagnosis Logic........................................................................................... 701 DTC Confirmation Procedure......................................................................................... 701 Overall Function Check............................................................................................. 702 Diagnostic Procedure............................................................................................... 703 Component Inspection............................................................................................... 705 DTC P0133 (RIGHT, -B1), P0153 (LEFT, -B2) FRONT HO2S (RESPONSE MONITORING)............................................. 707 Component Description.............................................................................................. 707 CONSULT Reference Value in Data Monitor Mode....................................................................... 707 ECM Terminals and Reference Value.................................................................................. 707 On Board Diagnosis Logic........................................................................................... 708 DTC Confirmation Procedure......................................................................................... 708 Overall Function Check............................................................................................. 709 Wiring Diagram..................................................................................................... 710 Diagnostic Procedure............................................................................................... 712 Component Inspection............................................................................................... 716 DTC P0134 (RIGHT, -B1), P0154 (LEFT, -B2) FRONT HO2S (HIGH VOLTAGE).................................................... 718 Component Description.............................................................................................. 718 CONSULT Reference Value in Data Monitor Mode....................................................................... 718 ECM Terminals and Reference Value.................................................................................. 718 On Board Diagnosis Logic........................................................................................... 719 DTC Confirmation Procedure......................................................................................... 719 Wiring Diagram..................................................................................................... 721 Diagnostic Procedure............................................................................................... 723 Component Inspection............................................................................................... 724 DTC P0135 (RIGHT, -B1), P0155 (LEFT, -B2) FRONT HO2S HEATER............................................................ 726 Description........................................................................................................ 726 CONSULT Reference Value in Data Monitor Mode....................................................................... 726 ECM Terminals and Reference Value.................................................................................. 726 On Board Diagnosis Logic........................................................................................... 726 DTC Confirmation Procedure......................................................................................... 727 Wiring Diagram..................................................................................................... 728 Diagnostic Procedure............................................................................................... 730 Component Inspection............................................................................................... 732 DTC P0137 (RIGHT, -B1), P0157 (LEFT, -B2) REAR HO2S (MIN. VOLTAGE MONITORING).......................................... 733 Component Description.............................................................................................. 733 CONSULT Reference Value in Data Monitor Mode....................................................................... 733 ECM Terminals and Reference Value.................................................................................. 733 On Board Diagnosis Logic........................................................................................... 733 DTC Confirmation Procedure......................................................................................... 734 Overall Function Check............................................................................................. 735 Wiring Diagram..................................................................................................... 737 Diagnostic Procedure............................................................................................... 739 Component Inspection............................................................................................... 742 DTC P0138 (RIGHT, -B1), P0158 (LEFT, -B2) REAR HO2S (MAX. VOLTAGE MONITORING).......................................... 743 Component Description.............................................................................................. 743 CONSULT Reference Value in Data Monitor Mode....................................................................... 743 ECM Terminals and Reference Value.................................................................................. 743 On Board Diagnosis Logic........................................................................................... 743 DTC Confirmation Procedure......................................................................................... 744 Overall Function Check............................................................................................. 745 Wiring Diagram..................................................................................................... 746 Diagnostic Procedure............................................................................................... 748 Component Inspection............................................................................................... 750 DTC P0139 (RIGHT, -B1), P0159 (LEFT, -B2) REAR HO2S (RESPONSE MONITORING).............................................. 752 Component Description.............................................................................................. 752 CONSULT Reference Value in Data Monitor Mode....................................................................... 752 ECM Terminals and Reference Value.................................................................................. 752 On Board Diagnosis Logic........................................................................................... 752 DTC Confirmation Procedure......................................................................................... 753 Overall Function Check............................................................................................. 754 Wiring Diagram..................................................................................................... 755 Diagnostic Procedure............................................................................................... 757 Component Inspection............................................................................................... 760 DTC P0140 (RIGHT, -B1), P0160 (LEFT, -B2) REAR HO2S (HIGH VOLTAGE)..................................................... 761 Component Description.............................................................................................. 761 CONSULT Reference Value in Data Monitor Mode....................................................................... 761 ECM Terminals and Reference Value.................................................................................. 761 On Board Diagnosis Logic........................................................................................... 761 DTC Confirmation Procedure......................................................................................... 762 Overall Function Check............................................................................................. 762 Wiring Diagram..................................................................................................... 763 Diagnostic Procedure............................................................................................... 765 Component Inspection............................................................................................... 767 DTC P0141 (RIGHT, -B1), P0161 (LEFT, -B2) REAR HO2S HEATER............................................................. 769 Description........................................................................................................ 769 CONSULT Reference Value in Data Monitor Mode....................................................................... 769 ECM Terminals and Reference Value.................................................................................. 769 On Board Diagnosis Logic........................................................................................... 769 DTC Confirmation Procedure......................................................................................... 770 Wiring Diagram..................................................................................................... 771 Diagnostic Procedure............................................................................................... 773 Component Inspection............................................................................................... 775 DTC P0171 (RIGHT, -B1), P0174 (LEFT, -B2) FUEL INJECTION SYSTEM FUNCTION (LEAN)........................................ 776 On Board Diagnosis Logic........................................................................................... 776 DTC Confirmation Procedure......................................................................................... 776 Wiring Diagram..................................................................................................... 778 Diagnostic Procedure............................................................................................... 780 DTC P0172 (RIGHT, -B1), P0175 (LEFT, -B2) FUEL INJECTION SYSTEM FUNCTION (RICH)........................................ 785 On Board Diagnosis Logic........................................................................................... 785 DTC Confirmation Procedure......................................................................................... 785 Wiring Diagram..................................................................................................... 787 Diagnostic Procedure............................................................................................... 789 DTC P0180 TANK FUEL TEMPERATURE SENSOR................................................................................. 793 Component Description.............................................................................................. 793 On Board Diagnosis Logic........................................................................................... 793 DTC Confirmation Procedure......................................................................................... 793 Wiring Diagram..................................................................................................... 795 Diagnostic Procedure............................................................................................... 796 Component Inspection............................................................................................... 797 DTC P0217 ENGINE COOLANT OVERTEMPERATURE ENRICHMENT PROTECTION......................................................... 798 On Board Diagnosis Logic........................................................................................... 798 Overall Function Check............................................................................................. 798 Wiring Diagram..................................................................................................... 802 Diagnostic Procedure............................................................................................... 803 Main 12 Causes of Overheating...................................................................................... 810 Component Inspection............................................................................................... 811 DTC P0300 - P0306 NO. 6 - 1 CYLINDER MISFIRE, MULTIPLE CYLINDER MISFIRE................................................ 812 On Board Diagnosis Logic........................................................................................... 812 DTC Confirmation Procedure......................................................................................... 812 Diagnostic Procedure............................................................................................... 813 Component Inspection............................................................................................... 818 DTC P0325 KNOCK SENSOR (KS)............................................................................................ 819 Component Description.............................................................................................. 819 ECM Terminals and Reference Value.................................................................................. 819 On Board Diagnosis Logic........................................................................................... 819 DTC Confirmation Procedure......................................................................................... 819 Wiring Diagram..................................................................................................... 821 Diagnostic Procedure............................................................................................... 822 Component Inspection............................................................................................... 824 DTC P0335 CRANKSHAFT POSITION SENSOR (CKPS) (OBD)...................................................................... 825 Component Description.............................................................................................. 825 ECM Terminals and Reference Value.................................................................................. 825 On Board Diagnosis Logic........................................................................................... 825 DTC Confirmation Procedure......................................................................................... 826 Wiring Diagram..................................................................................................... 827 Diagnostic Procedure............................................................................................... 828 Component Inspection............................................................................................... 830 DTC P0340 CAMSHAFT POSITION SENSOR (CMPS).............................................................................. 831 Component Description.............................................................................................. 831 ECM Terminals and Reference Value.................................................................................. 831 On Board Diagnosis Logic........................................................................................... 832 DTC Confirmation Procedure......................................................................................... 832 Wiring Diagram..................................................................................................... 834 Diagnostic Procedure............................................................................................... 835 Component Inspection............................................................................................... 837 DTC P0400 EGR FUNCTION (CLOSE)......................................................................................... 839 Description........................................................................................................ 839 On Board Diagnosis Logic........................................................................................... 840 DTC Confirmation Procedure......................................................................................... 841 Overall Function Check............................................................................................. 842 Wiring Diagram..................................................................................................... 843 Diagnostic Procedure............................................................................................... 844 Component Inspection............................................................................................... 849 DTC P0402 EGRC-BPT VALVE FUNCTION...................................................................................... 850 Description........................................................................................................ 850 On Board Diagnosis Logic........................................................................................... 850 DTC Confirmation Procedure......................................................................................... 851 Overall Function Check............................................................................................. 852 Diagnostic Procedure............................................................................................... 852 Component Inspection............................................................................................... 854 DTC P0420 (RIGHT BANK, -B1), P0430 (LEFT BANK, -B2) THREE WAY CATALYST FUNCTION........................................ 855 On Board Diagnosis Logic........................................................................................... 855 DTC Confirmation Procedure......................................................................................... 855 Overall Function Check............................................................................................. 856 Diagnostic Procedure............................................................................................... 856 DTC P0440 EVAP CONTROL SYSTEM (SMALL LEAK) (NEGATIVE PRESSURE)......................................................... 859 On Board Diagnosis Logic........................................................................................... 859 DTC Confirmation Procedure......................................................................................... 860 Diagnostic Procedure............................................................................................... 861 DTC P0443 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE (CIRCUIT).................................................. 869 Description........................................................................................................ 869 CONSULT Reference Value in Data Monitor Mode....................................................................... 869 ECM Terminals and Reference Value.................................................................................. 870 On Board Diagnosis Logic........................................................................................... 870 DTC Confirmation Procedure......................................................................................... 870 Wiring Diagram..................................................................................................... 872 Diagnostic Procedure............................................................................................... 873 Component Inspection............................................................................................... 875 DTC P0446 EVAPORATIVE EMISSION (EVAP) CANISTER VENT CONTROL VALVE (CIRCUIT)............................................ 876 Component Description.............................................................................................. 876 CONSULT Reference Value in Data Monitor Mode....................................................................... 876 ECM Terminals and Reference Value.................................................................................. 876 On Board Diagnosis Logic........................................................................................... 876 DTC Confirmation Procedure......................................................................................... 876 Wiring Diagram..................................................................................................... 878 Diagnostic Procedure............................................................................................... 879 Component Inspection............................................................................................... 881 DTC P0450 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM PRESSURE SENSOR................................................... 883 Component Description.............................................................................................. 883 CONSULT Reference Value in Data Monitor Mode....................................................................... 883 ECM Terminals and Reference Value.................................................................................. 883 On Board Diagnosis Logic........................................................................................... 884 DTC Confirmation Procedure......................................................................................... 884 Wiring Diagram..................................................................................................... 886 Diagnostic Procedure............................................................................................... 887 Component Inspection............................................................................................... 891 DTC P0500 VEHICLE SPEED SENSOR (VSS)................................................................................... 892 Component Description.............................................................................................. 892 ECM Terminals and Reference Value.................................................................................. 892 On Board Diagnosis Logic........................................................................................... 892 DTC Confirmation Procedure......................................................................................... 892 Overall Function Check............................................................................................. 893 Wiring Diagram..................................................................................................... 895 Diagnostic Procedure............................................................................................... 896 DTC P0505 IDLE AIR CONTROL VALVE (IACV) - AUXILIARY AIR CONTROL (AAC) VALVE............................................ 897 Description........................................................................................................ 897 CONSULT Reference Value in Data Monitor Mode....................................................................... 898 ECM Terminals and Reference Value.................................................................................. 898 On Board Diagnosis Logic........................................................................................... 898 DTC Confirmation Procedure......................................................................................... 898 Wiring Diagram..................................................................................................... 901 Diagnostic Procedure............................................................................................... 902 Component Inspection............................................................................................... 904 DTC P0510 CLOSED THROTTLE POSITION SWITCH.............................................................................. 905 Component Description.............................................................................................. 905 CONSULT Reference Value in Data Monitor Mode....................................................................... 905 ECM Terminals and Reference Value.................................................................................. 905 On Board Diagnosis Logic........................................................................................... 905 DTC Confirmation Procedure......................................................................................... 906 Overall Function Check............................................................................................. 906 Wiring Diagram..................................................................................................... 907 Diagnostic Procedure............................................................................................... 908 Component Inspection............................................................................................... 910 DTC P0600 A/T CONTROL.................................................................................................. 912 System Description................................................................................................. 912 ECM Terminals and Reference Value.................................................................................. 912 On Board Diagnosis Logic........................................................................................... 912 DTC Confirmation Procedure......................................................................................... 912 Overall Function Check............................................................................................. 913 Wiring Diagram..................................................................................................... 914 Diagnostic Procedure............................................................................................... 915 DTC P0605 ECM.......................................................................................................... 917 Component Description.............................................................................................. 917 On Board Diagnosis Logic........................................................................................... 917 DTC Confirmation Procedure......................................................................................... 917 Diagnostic Procedure............................................................................................... 918 DTC P1105 MAP/BARO SWITCH SOLENOID VALVE............................................................................... 919 Description........................................................................................................ 919 CONSULT Reference Value in Data Monitor Mode....................................................................... 919 ECM Terminals and Reference Value.................................................................................. 920 On Board Diagnosis Logic........................................................................................... 920 DTC Confirmation Procedure......................................................................................... 921 Wiring Diagram..................................................................................................... 923 Diagnostic Procedure............................................................................................... 924 Component Inspection............................................................................................... 932 DTC P1148 (RIGHT BANK, -B1), P1168 (LEFT BANK, -B2) CLOSED LOOP CONTROL................................................ 933 On Board Diagnosis Logic........................................................................................... 933 DTC Confirmation Procedure......................................................................................... 933 Overall Function Check............................................................................................. 934 Diagnostic Procedure............................................................................................... 934 DTC P1320 IGNITION SIGNAL.............................................................................................. 935 Component Description.............................................................................................. 935 ECM Terminals and Reference Value.................................................................................. 935 On Board Diagnosis Logic........................................................................................... 936 DTC Confirmation Procedure......................................................................................... 936 Wiring Diagram..................................................................................................... 937 Diagnostic Procedure............................................................................................... 938 Component Inspection............................................................................................... 941 DTC P1336 CRANKSHAFT POSITION SENSOR (CKPS) (OBD) (COG)................................................................ 942 Component Description.............................................................................................. 942 ECM Terminals and Reference Value.................................................................................. 942 On Board Diagnosis Logic........................................................................................... 942 DTC Confirmation Procedure......................................................................................... 943 Wiring Diagram..................................................................................................... 944 Diagnostic Procedure............................................................................................... 945 Component Inspection............................................................................................... 947 DTC P1400 EGRC-SOLENOID VALVE.......................................................................................... 948 Component Description.............................................................................................. 948 CONSULT Reference Value in Data Monitor Mode....................................................................... 948 ECM Terminals and Reference Value.................................................................................. 948 On Board Diagnosis Logic........................................................................................... 948 DTC Confirmation Procedure......................................................................................... 948 Wiring Diagram..................................................................................................... 950 Diagnostic Procedure............................................................................................... 951 Component Inspection............................................................................................... 952 DTC P1401 EGR TEMPERATURE SENSOR....................................................................................... 953 Component Description.............................................................................................. 953 On Board Diagnosis Logic........................................................................................... 953 DTC Confirmation Procedure......................................................................................... 954 Overall Function Check............................................................................................. 956 Wiring Diagram..................................................................................................... 957 Diagnostic Procedure............................................................................................... 958 Component Inspection............................................................................................... 959 DTC P1402 EGR FUNCTION (OPEN).......................................................................................... 960 Description........................................................................................................ 960 On Board Diagnosis Logic........................................................................................... 961 DTC Confirmation Procedure......................................................................................... 961 Wiring Diagram..................................................................................................... 963 Diagnostic Procedure............................................................................................... 964 Component Inspection............................................................................................... 967 DTC P1440 EVAP CONTROL SYSTEM (SMALL LEAK) (POSITIVE PRESSURE)......................................................... 968 On Board Diagnosis Logic........................................................................................... 968 DTC Confirmation Procedure......................................................................................... 969 Diagnostic Procedure............................................................................................... 970 DTC P1444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE............................................................ 978 Description........................................................................................................ 978 CONSULT Reference Value in Data Monitor Mode....................................................................... 978 ECM Terminals and Reference Value.................................................................................. 979 On Board Diagnosis Logic........................................................................................... 979 DTC Confirmation Procedure......................................................................................... 980 Wiring Diagram..................................................................................................... 981 Diagnostic Procedure............................................................................................... 982 Component Inspection............................................................................................... 985 DTC P1446 EVAPORATIVE EMISSION (EVAP) CANISTER VENT CONTROL VALVE (CLOSE).............................................. 986 Component Description.............................................................................................. 986 CONSULT Reference Value in Data Monitor Mode....................................................................... 986 ECM Terminals and Reference Value.................................................................................. 986 On Board Diagnosis Logic........................................................................................... 986 DTC Confirmation Procedure......................................................................................... 987 Wiring Diagram..................................................................................................... 988 Diagnostic Procedure............................................................................................... 989 Component Inspection............................................................................................... 991 DTC P1447 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM PURGE FLOW MONITORING............................................. 992 System Description................................................................................................. 992 On Board Diagnosis Logic........................................................................................... 992 DTC Confirmation Procedure......................................................................................... 993 Overall Function Check............................................................................................. 993 Diagnostic Procedure............................................................................................... 995 DTC P1448 EVAPORATIVE EMISSION (EVAP) CANISTER VENT CONTROL VALVE (OPEN)...............................................1000 Component Description..............................................................................................1000 CONSULT Reference Value in Data Monitor Mode.......................................................................1000 ECM Terminals and Reference Value..................................................................................1000 On Board Diagnosis Logic...........................................................................................1000 DTC Confirmation Procedure.........................................................................................1001 Overall Function Check.............................................................................................1002 Wiring Diagram.....................................................................................................1003 Diagnostic Procedure...............................................................................................1004 Component Inspection...............................................................................................1006 DTC P1490 VACUUM CUT VALVE BYPASS VALVE (CIRCUIT)......................................................................1007 Description........................................................................................................1007 CONSULT Reference Value in Data Monitor Mode.......................................................................1007 ECM Terminals and Reference Value..................................................................................1007 On Board Diagnosis Logic...........................................................................................1008 DTC Confirmation Procedure.........................................................................................1008 Wiring Diagram.....................................................................................................1009 Diagnostic Procedure...............................................................................................1010 Component Inspection...............................................................................................1013 DTC P1491 VACUUM CUT VALVE BYPASS VALVE................................................................................1014 Description........................................................................................................1014 CONSULT Reference Value in Data Monitor Mode.......................................................................1014 ECM Terminals and Reference Value..................................................................................1014 On Board Diagnosis Logic...........................................................................................1015 DTC Confirmation Procedure.........................................................................................1016 Overall Function Check.............................................................................................1017 Wiring Diagram.....................................................................................................1018 Diagnostic Procedure...............................................................................................1019 Component Inspection...............................................................................................1022 DTC P1605 A/T DIAGNOSIS COMMUNICATION LINE.............................................................................1023 Component Description..............................................................................................1023 ECM Terminals and Reference Value..................................................................................1023 On Board Diagnosis Logic...........................................................................................1023 DTC Confirmation Procedure.........................................................................................1023 Wiring Diagram.....................................................................................................1024 Diagnostic Procedure...............................................................................................1025 DTC P1706 PARK/NEUTRAL POSITION (PNP) SWITCH...........................................................................1026 Component Description..............................................................................................1026 CONSULT Reference Value in Data Monitor Mode.......................................................................1026 ECM Terminals and Reference Value..................................................................................1026 On Board Diagnosis Logic...........................................................................................1026 DTC Confirmation Procedure.........................................................................................1026 Overall Function Check.............................................................................................1028 Wiring Diagram.....................................................................................................1029 Diagnostic Procedure...............................................................................................1030 INJECTOR...............................................................................................................1036 Component Description..............................................................................................1036 CONSULT Reference Value in Data Monitor Mode.......................................................................1036 ECM Terminals and Reference Value..................................................................................1036 Wiring Diagram.....................................................................................................1037 Diagnostic Procedure...............................................................................................1038 Component Inspection...............................................................................................1040 START SIGNAL...........................................................................................................1041 CONSULT Reference Value in Data Monitor Mode.......................................................................1041 ECM Terminals and Reference Value..................................................................................1041 Wiring Diagram.....................................................................................................1042 Diagnostic Procedure...............................................................................................1043 FUEL PUMP..............................................................................................................1046 System Description.................................................................................................1046 Component Description..............................................................................................1046 CONSULT Reference Value in Data Monitor Mode.......................................................................1046 ECM Terminals and Reference Value..................................................................................1046 Wiring Diagram.....................................................................................................1047 Diagnostic Procedure...............................................................................................1048 Component Inspection...............................................................................................1051 POWER STEERING OIL PRESSURE SWITCH.....................................................................................1052 Component Description..............................................................................................1052 CONSULT Reference Value in Data Monitor Mode.......................................................................1052 ECM Terminals and Reference Value..................................................................................1052 Wiring Diagram.....................................................................................................1053 Diagnostic Procedure...............................................................................................1054 Component Inspection...............................................................................................1057 IACV-FICD SOLENOID VALVE...............................................................................................1058 Component Description..............................................................................................1058 ECM Terminals and Reference Value..................................................................................1058 Wiring Diagram.....................................................................................................1059 Diagnostic Procedure...............................................................................................1060 Component Inspection...............................................................................................1063 MIL & DATA LINK CONNECTORS.............................................................................................1064 Wiring Diagram.....................................................................................................1064 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1065 Fuel Pressure Regulator............................................................................................1065 Idle Speed and Ignition Timing.....................................................................................1065 Ignition Coil......................................................................................................1065 Mass Air Flow Sensor...............................................................................................1065 Engine Coolant Temperature Sensor..................................................................................1065 EGR Temperature Sensor.............................................................................................1065 Front Heated Oxygen Sensor Heater..................................................................................1065 Fuel Pump..........................................................................................................1066 IACV-AAC Valve.....................................................................................................1066 Injector...........................................................................................................1066 Resistor...........................................................................................................1066 Throttle Position Sensor...........................................................................................1066 Calculated Load Value..............................................................................................1066 Intake Air Temperature Sensor......................................................................................1066 Rear Heated Oxygen Sensor Heater...................................................................................1066 Crankshaft Position Sensor (OBD)...................................................................................1066 Tank Fuel Temperature Sensor.......................................................................................1066 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.........................................................................................................................1068 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1068 PRECAUTIONS AND PREPARATION............................................................................................1071 Supplemental Restraint System (SRS) ‘‘AIR BAG’’....................................................................1071 HARNESS CONNECTOR......................................................................................................1072 Description........................................................................................................1072 STANDARDIZED RELAY.....................................................................................................1074 Description........................................................................................................1074 POWER SUPPLY ROUTING...................................................................................................1076 Schematic..........................................................................................................1076 Wiring Diagram — POWER —...........................................................................................1078 Fuse...............................................................................................................1083 Fusible Link.......................................................................................................1083 Circuit Breaker Inspection.........................................................................................1083 GROUND DISTRIBUTION....................................................................................................1084 Main Harness.......................................................................................................1084 Engine Room Harness................................................................................................1086 Engine Control Harness.............................................................................................1088 Generator Harness..................................................................................................1090 BATTERY................................................................................................................1091 How to Handle Battery..............................................................................................1091 Service Data and Specifications (SDS)..............................................................................1094 STARTING SYSTEM........................................................................................................1095 System Description.................................................................................................1095 Wiring Diagram — START —...........................................................................................1097 Construction.......................................................................................................1099 Removal and Installation...........................................................................................1100 Pinion/Clutch Check................................................................................................1100 Service Data and Specifications (SDS)..............................................................................1100 CHARGING SYSTEM........................................................................................................1101 System Description.................................................................................................1101 Wiring Diagram — CHARGE —..........................................................................................1102 Trouble Diagnoses..................................................................................................1103 Construction.......................................................................................................1104 Removal and Installation...........................................................................................1105 Service Data and Specifications (SDS)..............................................................................1105 COMBINATION SWITCH.....................................................................................................1106 Check..............................................................................................................1106 Replacement........................................................................................................1107 STEERING SWITCH........................................................................................................1108 Check..............................................................................................................1108 HEADLAMP...............................................................................................................1109 System Description (For USA).......................................................................................1109 Wiring Diagram (For USA) — H/LAMP —................................................................................1110 Trouble Diagnoses..................................................................................................1111 Bulb Replacement...................................................................................................1112 Aiming Adjustment..................................................................................................1112 HEADLAMP — Daytime Light System —......................................................................................1114 System Description (For Canada)....................................................................................1114 Operation (For Canada).............................................................................................1115 Schematic (For Canada).............................................................................................1116 Wiring Diagram (For Canada) — DTRL —...............................................................................1117 Trouble Diagnoses (For Canada).....................................................................................1120 Bulb Replacement...................................................................................................1121 Aiming Adjustment..................................................................................................1121 PARKING, LICENSE AND TAIL LAMPS........................................................................................1122 Wiring Diagram — TAIL/L —..........................................................................................1122 STOP LAMP..............................................................................................................1124 Wiring Diagram — STOP/L —..........................................................................................1124 BACK-UP LAMP...........................................................................................................1125 Wiring Diagram — BACK/L —..........................................................................................1125 FRONT FOG LAMP.........................................................................................................1126 System Description.................................................................................................1126 Wiring Diagram — F/FOG —...........................................................................................1127 Aiming Adjustment..................................................................................................1128 Removal and Installation...........................................................................................1129 Bulb and Lens Replacement..........................................................................................1129 TURN SIGNAL AND HAZARD WARNING LAMPS...................................................................................1130 System Description.................................................................................................1130 Wiring Diagram — TURN —............................................................................................1132 Trouble Diagnoses..................................................................................................1134 Electrical Components Inspection...................................................................................1134 ILLUMINATION...........................................................................................................1135 System Description.................................................................................................1135 Wiring Diagram — ILL —.............................................................................................1136 INTERIOR ROOM LAMP.....................................................................................................1137 Component Parts and Harness Connector Location.....................................................................1137 System Description.................................................................................................1138 Wiring Diagram — ROOM/L —..........................................................................................1140 Trouble Diagnoses (For models with power door locks)...............................................................1143 SPOT LAMP..............................................................................................................1144 Wiring Diagram — INT/L —...........................................................................................1144 METER AND GAUGES.......................................................................................................1145 Component Parts and Harness Connector Location.....................................................................1145 System Description.................................................................................................1146 Unified Control Meter..........................................................................................1146 How To Change The Display For Odo/Trip Meter...................................................................1146 Combination Meter..................................................................................................1148 With Tachometer................................................................................................1148 Without Tachometer.............................................................................................1149 Wiring Diagram — METER —...........................................................................................1150 Meter/gauge Operation and Odo/Trip Meter Segment Check in Diagnosis Mode...........................................1151 Diagnosis Function.............................................................................................1151 How To Alternate Diagnosis Mode................................................................................1151 Flexible Print Circuit (FPC).......................................................................................1152 Disconnect.....................................................................................................1152 Connect........................................................................................................1152 Trouble Diagnoses..................................................................................................1153 Preliminary Check..............................................................................................1153 Symptom Chart 1 (Malfunction is indicated in diagnosis mode)...................................................1154 Symptom Chart 2 (No malfunction is indicated in diagnosis mode)................................................1154 Power Supply And Ground Circuit Check..........................................................................1155 Inspection/Vehicle Speed Sensor................................................................................1156 Inspection/Engine Revolution Signal (Models with tachometer)...................................................1156 Inspection/Fuel Tank Gauge.....................................................................................1157 Inspection/Thermal Transmitter.................................................................................1157 Electrical Components Inspection...................................................................................1158 Meter/Gauge Resistance Check...................................................................................1158 Fuel Tank Gauge Unit Check.....................................................................................1158 Thermal Transmitter Check......................................................................................1159 Vehicle Speed Sensor Signal Check..............................................................................1159 WARNING LAMPS..........................................................................................................1160 System Description.................................................................................................1160 Schematic..........................................................................................................1162 Wiring Diagram — WARN —............................................................................................1163 Electrical Components Inspection...................................................................................1168 A/T INDICATOR..........................................................................................................1169 Wiring Diagram — AT/IND —..........................................................................................1169 WARNING CHIME..........................................................................................................1170 Component Parts and Harness Connector Location.....................................................................1170 System Description.................................................................................................1171 Wiring Diagram — CHIME —...........................................................................................1173 Trouble Diagnoses..................................................................................................1175 Electrical Components Inspection...................................................................................1181 FRONT WIPER AND WASHER.................................................................................................1182 System Description.................................................................................................1182 Wiring Diagram — WIPER —...........................................................................................1184 Trouble Diagnoses (With intermittent wipers).......................................................................1186 Removal and Installation...........................................................................................1188 Washer Nozzle Adjustment...........................................................................................1189 Washer Tube Layout.................................................................................................1189 HORN...................................................................................................................1190 Wiring Diagram — HORN —............................................................................................1190 CIGARETTE LIGHTER......................................................................................................1191 Wiring Diagram — CIGAR —...........................................................................................1191 AUDIO..................................................................................................................1192 System Description.................................................................................................1192 Base Audio System..............................................................................................1192 Premium Audio System...........................................................................................1192 Wiring Diagram — AUDIO —...........................................................................................1193 Trouble Diagnoses..................................................................................................1196 Inspection.........................................................................................................1197 AUDIO ANTENNA..........................................................................................................1199 Fixed Antenna Rod Replacement......................................................................................1199 Removal........................................................................................................1199 Installation...................................................................................................1199 POWER DOOR MIRROR......................................................................................................1200 Wiring Diagram — MIRROR —..........................................................................................1200 AUTOMATIC SPEED CONTROL DEVICE (ASCD)..................................................................................1201 Component Parts and Harness Connector Location.....................................................................1201 System Description.................................................................................................1202 Schematic..........................................................................................................1204 Wiring Diagram — ASCD —............................................................................................1205 Fail-Safe System Description.......................................................................................1209 Fail-Safe System Check.............................................................................................1210 Trouble Diagnoses..................................................................................................1211 ASCD Wire Adjustment...............................................................................................1219 Electrical Components Inspection...................................................................................1220 POWER WINDOW...........................................................................................................1221 System Description.................................................................................................1221 Wiring Diagram — WINDOW —..........................................................................................1223 Trouble Diagnoses..................................................................................................1225 POWER DOOR LOCK........................................................................................................1226 Component Parts and Harness Connector Location.....................................................................1226 System Description.................................................................................................1227 Schematic..........................................................................................................1229 Wiring Diagram — D/LOCK —..........................................................................................1230 Trouble Diagnoses..................................................................................................1233 MULTI-REMOTE CONTROL SYSTEM............................................................................................1241 Component Parts and Harness Connector Location.....................................................................1241 System Description.................................................................................................1242 Schematic..........................................................................................................1244 Wiring Diagram — MULTI —...........................................................................................1245 Trouble Diagnoses..................................................................................................1248 Electrical Components Inspection...................................................................................1254 ID Code Entry Procedure............................................................................................1255 THEFT WARNING SYSTEM...................................................................................................1256 Component Parts and Harness Connector Location.....................................................................1256 System Description.................................................................................................1258 Schematic..........................................................................................................1261 Wiring Diagram — THEFT —...........................................................................................1262 Trouble Diagnoses..................................................................................................1265 SMART ENTRANCE CONTROL UNIT............................................................................................1276 Description........................................................................................................1276 Input/Output Operation Signal......................................................................................1277 Schematic..........................................................................................................1278 LOCATION OF ELECTRICAL UNITS...........................................................................................1280 Engine Compartment.................................................................................................1280 Passenger Compartment..............................................................................................1281 HARNESS LAYOUT.........................................................................................................1283 Outline............................................................................................................1283 How to Read Harness Layout.........................................................................................1284 Main Harness.......................................................................................................1285 Engine Room Harness................................................................................................1287 Engine Control Harness.............................................................................................1290 Engine No. 2 Harness...............................................................................................1292 Chassis and Tail Harness...........................................................................................1293 Room Lamp Harness..................................................................................................1294 Door Harness.......................................................................................................1295 Air Bag Harness....................................................................................................1296 BULB SPECIFICATIONS....................................................................................................1297 Headlamps..........................................................................................................1297 Exterior Lamps.....................................................................................................1297 Interior Lamps.....................................................................................................1297 WIRING DIAGRAM CODES (CELL CODES)......................................................................................1298 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.........................................................................................................................1300 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1300 PRECAUTIONS............................................................................................................1302 Parts Requiring Angular Tightening.................................................................................1302 Liquid Gasket Application Procedure................................................................................1302 PREPARATION............................................................................................................1303 Special Service Tools..............................................................................................1303 Commercial Service Tools...........................................................................................1305 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING...................................................................1307 NVH Troubleshooting Chart — Engine Noise...........................................................................1308 OUTER COMPONENT PARTS..................................................................................................1309 COMPRESSION PRESSURE...................................................................................................1311 Measurement of Compression Pressure................................................................................1311 OIL PAN................................................................................................................1312 Removal............................................................................................................1312 Installation.......................................................................................................1313 TIMING BELT............................................................................................................1315 Removal............................................................................................................1316 Inspection.........................................................................................................1317 Belt Tensioner And Tensioner Spring............................................................................1318 Installation.......................................................................................................1318 Tension Adjustment.................................................................................................1319 After Belt Replacement.........................................................................................1319 After Engine Overhaul Or Engine Reassembly (With Rocker Covers Removed)........................................1319 OIL SEAL REPLACEMENT...................................................................................................1322 Valve Oil Seal.....................................................................................................1322 Oil Seal Installing Direction......................................................................................1322 Camshaft Oil Seal..................................................................................................1322 Front Oil Seal.....................................................................................................1323 Rear Oil Seal......................................................................................................1323 CYLINDER HEAD..........................................................................................................1324 Removal............................................................................................................1325 Disassembly........................................................................................................1327 Inspection.........................................................................................................1328 Cylinder Head Distortion.......................................................................................1328 Camshaft Visual Check..........................................................................................1328 Camshaft Runout................................................................................................1328 Camshaft Cam Height............................................................................................1328 Camshaft Journal Clearance.....................................................................................1329 Camshaft End Play..............................................................................................1329 Camshaft Sprocket Runout.......................................................................................1330 Valve Guide Clearance..........................................................................................1330 Valve Guide Replacement........................................................................................1330 Valve Seats....................................................................................................1331 Replacing Valve Seat For Service Parts.........................................................................1331 Valve Dimensions...............................................................................................1332 Valve Spring...................................................................................................1332 Squareness.................................................................................................1332 Pressure...................................................................................................1332 Rocker Shaft And Rocker Arm....................................................................................1333 Hydraulic Valve Lifter.........................................................................................1333 Assembly...........................................................................................................1333 Installation.......................................................................................................1334 ENGINE REMOVAL.........................................................................................................1338 Front Engine Mounting..............................................................................................1338 Rear Engine Mounting...............................................................................................1339 Removal............................................................................................................1340 CYLINDER BLOCK.........................................................................................................1341 Disassembly........................................................................................................1342 Piston And Crankshaft..........................................................................................1342 Inspection.........................................................................................................1342 Piston And Piston Pin Clearance................................................................................1342 Piston Ring Side Clearance.....................................................................................1343 Piston Ring End Gap............................................................................................1343 Connecting Rod Bend And Torsion................................................................................1343 Cylinder Block Distortion And Wear.............................................................................1344 Piston-To-Bore Clearance.......................................................................................1344 Crankshaft.....................................................................................................1346 Bearing Clearance..............................................................................................1346 Method A (Using bore gauge & micrometer)...................................................................1346 Connecting rod bearing (Big end)...............................................................................1348 Method B (Using plastigage)................................................................................1348 Connecting Rod Bushing Clearance (Small end)...................................................................1349 Replacement of Connecting Rod Bushing (Small end)..............................................................1349 Flywheel/Drive Plate Runout....................................................................................1349 Assembly...........................................................................................................1349 Piston.........................................................................................................1349 Crankshaft.....................................................................................................1350 Replacing Pilot Bushing (M/T) Or Pilot Converter (A/T).........................................................1351 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1352 General Specifications.............................................................................................1352 Inspection and Adjustment..........................................................................................1352 Cylinder Head..................................................................................................1352 Valve..........................................................................................................1353 Valve spring...............................................................................................1353 Hydraulic valve lifter.....................................................................................1353 Valve guide................................................................................................1353 Rocker shaft and rocker arm................................................................................1353 Intake valve seat..........................................................................................1354 Exhaust valve seat.........................................................................................1354 Camshaft And Camshaft Bearing..................................................................................1354 Cylinder Block.................................................................................................1355 Cylinder Block.................................................................................................1355 Connecting Rod.................................................................................................1356 Piston, Piston Ring And Piston Pin.............................................................................1356 Available piston...........................................................................................1356 Available piston...........................................................................................1356 Piston ring................................................................................................1356 Piston pin.................................................................................................1357 Crankshaft.....................................................................................................1357 Available Main Bearing.........................................................................................1357 No. 1 Main Bearing.............................................................................................1357 No. 2 And 3 Main Bearing.......................................................................................1357 No. 4 Main Bearing.............................................................................................1357 Under Size.....................................................................................................1358 Available Connecting Rod Bearing...............................................................................1358 Connecting rod bearing undersize...........................................................................1358 Miscellaneous Components.......................................................................................1358 Bearing clearance..........................................................................................1358 fa.........................................................................................................................1360 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1360 PRECAUTIONS AND PREPARATION............................................................................................1361 Precautions........................................................................................................1361 Special Service Tools..............................................................................................1361 Commercial Service Tools...........................................................................................1362 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING...................................................................1363 NVH Troubleshooting Chart..........................................................................................1363 FRONT SUSPENSION SYSTEM................................................................................................1364 ON-VEHICLE SERVICE.....................................................................................................1365 Front Axle and Front Suspension Parts..............................................................................1365 Front Wheel Bearing................................................................................................1365 Front Wheel Alignment..............................................................................................1366 Drive Shaft........................................................................................................1371 FRONT AXLE.............................................................................................................1372 Manual-lock Free-running Hub.......................................................................................1373 Auto-lock Free-running Hub.........................................................................................1374 Description....................................................................................................1374 Inspection.....................................................................................................1375 Trouble Diagnosis For Noise....................................................................................1376 Wheel Hub and Rotor Disc...........................................................................................1376 Knuckle Spindle....................................................................................................1378 Drive Shaft........................................................................................................1381 Shock Absorber.....................................................................................................1387 Torsion Bar Spring.................................................................................................1387 Stabilizer Bar.....................................................................................................1389 Upper Link.........................................................................................................1390 Lower Link.........................................................................................................1391 Upper Ball Joint and Lower Ball Joint..............................................................................1392 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1393 General Specifications.............................................................................................1393 Inspection and Adjustment..........................................................................................1393 fe.........................................................................................................................1396 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1396 PREPARATION............................................................................................................1397 Special Service Tools..............................................................................................1397 ACCELERATOR CONTROL SYSTEM.............................................................................................1398 Accelerator Control System.........................................................................................1398 Adjusting Accelerator Wire.........................................................................................1398 FUEL SYSTEM............................................................................................................1399 Fuel Tank..........................................................................................................1400 Removal........................................................................................................1400 Installation...................................................................................................1401 Fuel Pump and Gauge................................................................................................1402 Removal And Installation.......................................................................................1402 EXHAUST SYSTEM.........................................................................................................1403 foldout....................................................................................................................1406 QUICK REFERENCE INDEX.................................................................................................. 0 SUPER MULTIPLE JUNCTION (SMJ)..........................................................................................1406 FUSE BLOCK — Junction Box (J/B)........................................................................................1408 FUSE AND FUSIBLE LINK BOX..............................................................................................1409 ELECTRICAL UNITS.......................................................................................................1410 JOINT CONNECTOR (J/C)..................................................................................................1411 gi.........................................................................................................................1413 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1413 PRECAUTIONS AND PREPARATION............................................................................................1414 Supplemental Restraint System (SRS)‘‘AIR BAG"......................................................................1414 General Precautions................................................................................................1415 Precautions for Multiport Fuel Injection System or Engine Control System...........................................1417 Precautions for Three Way Catalyst.................................................................................1417 Precautions for Engine Oils........................................................................................1417 Precautions for Fuel...............................................................................................1418 Precautions for Air Conditioning...................................................................................1418 HOW TO USE THIS MANUAL.................................................................................................1419 HOW TO READ WIRING DIAGRAMS............................................................................................1421 Sample/Wiring Diagram – EXAMPL –...................................................................................1421 Description........................................................................................................1423 HOW TO CHECK TERMINAL..................................................................................................1429 Connector and Terminal Pin Kit.....................................................................................1429 How to Probe Connectors............................................................................................1429 How to Check Enlarged Contact Spring of Terminal...................................................................1430 Waterproof Connector Inspection....................................................................................1431 Terminal Lock Inspection...........................................................................................1431 HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT..........................................................1432 Work Flow..........................................................................................................1432 Incident Simulation Tests..........................................................................................1433 Circuit Inspection.................................................................................................1435 HOW TO FOLLOW TROUBLE DIAGNOSES........................................................................................1442 How To Follow Flow Charts in Trouble Diagnoses.....................................................................1443 How to Follow Test Groups in Trouble Diagnoses.....................................................................1444 CONSULT CHECKING SYSTEM................................................................................................1447 Function and System Application....................................................................................1447 Lithium Battery Replacement........................................................................................1447 Checking Equipment.................................................................................................1447 Loading Procedure..................................................................................................1448 CONSULT Data Link Connector (DLC) Circuit..........................................................................1448 IDENTIFICATION INFORMATION.............................................................................................1449 Model Variation....................................................................................................1449 Identification Number..............................................................................................1450 Dimensions.........................................................................................................1452 Wheels and Tires...................................................................................................1452 LIFTING POINTS AND TOW TRUCK TOWING....................................................................................1453 Pantograph Jack....................................................................................................1453 Garage Jack and Safety Stand.......................................................................................1454 2-pole Lift........................................................................................................1455 Tow Truck Towing...................................................................................................1456 4-WHEEL DRIVE MODELS...........................................................................................1456 Towing Point.......................................................................................................1457 Vehicle Recovery (Freeing a stuck vehicle).....................................................................1457 TIGHTENING TORQUE OF STANDARD BOLTS....................................................................................1458 SAE J1930 TERMINOLOGY LIST.............................................................................................1459 ha.........................................................................................................................1463 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1463 PRECAUTIONS AND PREPARATION............................................................................................1464 Supplemental Restraint System (SRS) ‘‘AIRBAG''.....................................................................1464 Precautions for Working with R-134a................................................................................1464 Contaminated Refrigerant.......................................................................................1465 General Refrigerant Precautions....................................................................................1465 Precautionsfor Refrigerant Connection..............................................................................1466 Precautions for Servicing Compressor...............................................................................1469 R-134a Service Tools and Equipment.................................................................................1470 Special Service Tools..............................................................................................1471 Commercial Service Tools...........................................................................................1472 Precautions for Service Equipment..................................................................................1473 DESCRIPTION............................................................................................................1475 Refrigeration Cycle................................................................................................1475 Control Operation..................................................................................................1476 Component Layout...................................................................................................1477 Discharge Air Flow.................................................................................................1478 Component Location.................................................................................................1479 Circuit Diagram....................................................................................................1481 Wiring Diagram – HEATER –..........................................................................................1482 Wiring Diagram – A/C – ............................................................................................1483 Operational Check..................................................................................................1485 TROUBLE DIAGNOSES......................................................................................................1487 How to Perform Trouble Diagnoses for Quick and Accurate Repair.....................................................1487 Blower Motor Circuit...............................................................................................1488 Air Outlet.........................................................................................................1492 Intake Door........................................................................................................1494 Magnet Clutch Circuit..............................................................................................1495 Triple-Pressure Switch.........................................................................................1499 Trouble Diagnosis Procedure For Insufficient Cooling...............................................................1501 Performance Test Diagnoses.........................................................................................1503 Performance Chart..................................................................................................1505 Trouble Diagnoses for Abnormal Pressure............................................................................1506 Trouble Diagnosis for Insufficient Heating.........................................................................1509 Trouble Diagnosis for Noise........................................................................................1511 SERVICE PROCEDURES.....................................................................................................1512 Refrigerant Lines..................................................................................................1512 Checking Refrigerant Leaks.........................................................................................1513 R-134a Service Procedure...........................................................................................1516 Compressor Lubricant Quantity......................................................................................1518 Compressor Mounting................................................................................................1520 Belt Tension.......................................................................................................1520 Fast Idle Control Device (FICD)....................................................................................1520 Condenser..........................................................................................................1520 Compressor.........................................................................................................1522 Compressor Clutch..................................................................................................1522 Thermal Protector..................................................................................................1525 Heater Unit (Heater Core)..........................................................................................1526 Cooling Unit (A/C Evaporator)......................................................................................1527 Blower Case and Motor..............................................................................................1528 Fan Lever and Illumination Bulbs...................................................................................1529 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1530 General Specifications.............................................................................................1530 Inspection and Adjustment..........................................................................................1530 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........................................................................................................................1531 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.........................................................................................................................1541 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1541 PREPARATION/PRECAUTION.................................................................................................1542 Special Service Tools..............................................................................................1542 Liquid Gasket Application Procedure................................................................................1543 ENGINE LUBRICATION SYSTEM..............................................................................................1544 Lubrication Circuit................................................................................................1544 Oil Pressure Check.................................................................................................1544 Oil Pump...........................................................................................................1545 Removal And Installation.......................................................................................1545 Disassembly And Assembly.......................................................................................1545 Inspection.....................................................................................................1546 Regulator Valve Inspection.....................................................................................1546 Oil Filter.....................................................................................................1546 Oil Filter Bracket.............................................................................................1547 ENGINE COOLING SYSTEM..................................................................................................1548 Cooling Circuit....................................................................................................1548 System Check.......................................................................................................1548 Checking Cooling System Hoses..................................................................................1548 Checking Cooling System For Leaks..............................................................................1548 Checking Radiator..............................................................................................1548 Checking Radiator Cap..........................................................................................1549 Water Pump.........................................................................................................1550 Removal And Installation.......................................................................................1550 Inspection.....................................................................................................1551 Thermostat.........................................................................................................1551 Removal........................................................................................................1551 Inspection.....................................................................................................1551 Installation...................................................................................................1552 Radiator...........................................................................................................1552 Removal And Installation.......................................................................................1552 Cooling Fan (Crank shaft driven)...................................................................................1553 Removal And Installation.......................................................................................1553 Inspection.....................................................................................................1554 Refilling Engine Coolant...........................................................................................1554 Inspection.....................................................................................................1554 Overheating Cause Analysis.........................................................................................1555 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1556 Engine Lubrication System..........................................................................................1556 Oil pressure...................................................................................................1556 Regulator valve................................................................................................1556 Oil pump.......................................................................................................1556 Engine Cooling System..............................................................................................1556 Thermostat.....................................................................................................1556 Radiator.......................................................................................................1556 ma.........................................................................................................................1557 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1557 PRECAUTIONS AND PREPARATION............................................................................................1558 Supplemental Restraint System (SRS) ‘‘AIR BAG’’....................................................................1558 Special Service Tool...............................................................................................1558 Commercial Service Tool............................................................................................1558 GENERAL MAINTENANCE....................................................................................................1559 PERIODIC MAINTENANCE...................................................................................................1561 Schedule 1.........................................................................................................1562 Schedule 2.........................................................................................................1563 RECOMMENDED FLUIDS AND LUBRICANTS......................................................................................1564 Fluids and Lubricants..............................................................................................1564 SAE Viscosity Number...............................................................................................1565 Antifreeze Coolant Mixture Ratio...................................................................................1565 ENGINE MAINTENANCE.....................................................................................................1566 Checking Drive Belts...............................................................................................1566 Changing Engine Coolant............................................................................................1567 Checking Fuel Lines................................................................................................1569 Changing Fuel Filter...............................................................................................1569 Changing Air Cleaner Filter........................................................................................1570 Changing Engine Oil................................................................................................1570 Changing Oil Filter................................................................................................1571 Changing Spark Plugs...............................................................................................1571 Checking EVAP Vapor Lines..........................................................................................1573 CHASSIS AND BODY MAINTENANCE...........................................................................................1574 Checking Exhaust System............................................................................................1574 Checking Clutch Fluid Level and Leaks..............................................................................1574 Checking M/T Oil...................................................................................................1574 Changing M/T Oil...................................................................................................1574 Checking Water Entry...............................................................................................1574 Checking A/T Fluid.................................................................................................1574 Changing A/T Fluid.................................................................................................1575 Checking Transfer Fluid............................................................................................1575 Changing Transfer Fluid............................................................................................1576 Checking Propeller Shaft...........................................................................................1576 Checking Differential Gear Oil.....................................................................................1576 Changing Differential Gear Oil.....................................................................................1577 Balancing Wheels...................................................................................................1577 Tire Rotation......................................................................................................1577 Checking Brake Fluid Level and Leaks...............................................................................1578 Checking Brake System..............................................................................................1578 Checking Disc Brake................................................................................................1578 Checking Drum Brake................................................................................................1578 Checking Steering Gear and Linkage.................................................................................1579 Checking Power Steering Fluid and Lines............................................................................1579 Lubricating Hood Latches, Locks and Hinges.........................................................................1580 Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters....................................................1581 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1582 Engine Maintenance.................................................................................................1582 Chassis and Body Maintenance.......................................................................................1582 mt.........................................................................................................................1583 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1583 PREPARATION............................................................................................................1584 Special Service Tools..............................................................................................1584 Commercial Service Tool............................................................................................1585 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING...................................................................1586 NVH Troubleshooting Chart..........................................................................................1586 DESCRIPTION............................................................................................................1587 Cross-sectional View...............................................................................................1587 ON-VEHICLE SERVICE.....................................................................................................1588 Position Switch Check..............................................................................................1588 REMOVAL AND INSTALLATION...............................................................................................1589 Removal............................................................................................................1589 Installation.......................................................................................................1590 MAJOR OVERHAUL.........................................................................................................1591 Case Components....................................................................................................1591 Gear Components....................................................................................................1592 Shift Control Components...........................................................................................1594 DISASSEMBLY............................................................................................................1595 Case Components....................................................................................................1595 Shift Control Components...........................................................................................1596 Gear Components....................................................................................................1597 INSPECTION.............................................................................................................1601 Shift Control Components...........................................................................................1601 Gear Components....................................................................................................1601 Gears And Shafts...............................................................................................1601 Synchronizers..................................................................................................1601 Bearings.......................................................................................................1602 ASSEMBLY...............................................................................................................1603 Gear Components....................................................................................................1603 Shift Control Components...........................................................................................1611 Case Components....................................................................................................1611 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1614 General Specifications.............................................................................................1614 Inspection and Adjustment..........................................................................................1615 Gear End Play..................................................................................................1615 Clearance Between Baulk Ring And Gear..........................................................................1615 2nd and 3rd baulk ring.....................................................................................1615 Distance Between Rear Surface of Reverse Cone And Reverse Baulk Ring...........................................1615 Available Snap Ring............................................................................................1615 Main drive gear snap ring..................................................................................1615 Mainshaft front snap ring..................................................................................1615 Counter gear rear snap ring................................................................................1616 Available C-Ring...............................................................................................1616 Mainshaft C-ring...........................................................................................1616 Available Shim And Washer......................................................................................1616 Table for selecting proper counter gear front bearing thrust washer........................................1616 Reverse idler rear thrust washer...........................................................................1616 pd.........................................................................................................................1617 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1617 PREPARATION............................................................................................................1619 Special Service Tools..............................................................................................1619 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING...................................................................1623 NVH Troubleshooting Chart..........................................................................................1623 PROPELLER SHAFT........................................................................................................1624 PROPELLER SHAFT....................................................................................................1624 On-vehicle Service.............................................................................................1625 Removal and Installation.......................................................................................1625 Inspection.....................................................................................................1625 Disassembly....................................................................................................1626 Assembly.......................................................................................................1627 FINAL DRIVE............................................................................................................1629 ON-VEHICLE SERVICE.................................................................................................1625 Front Oil Seal Replacement.....................................................................................1629 (Front final drive: Model R200A)...........................................................................1629 (Rear final drive: Model H233B)............................................................................1629 REMOVAL AND INSTALLATION (Front final drive).......................................................................1631 Removal........................................................................................................1631 Installation...................................................................................................1631 REMOVAL AND INSTALLATION (Rear final drive)........................................................................1632 Removal........................................................................................................1632 Installation...................................................................................................1632 R200A..................................................................................................................1633 FRONT FINAL DRIVE..................................................................................................1633 DISASSEMBLY........................................................................................................1634 Pre-inspection.................................................................................................1634 Final Drive Housing............................................................................................1634 Differential Case..............................................................................................1637 Differential Side Shaft........................................................................................1637 INSPECTION.........................................................................................................1639 Ring Gear and Drive Pinion.....................................................................................1639 Differential Case Assembly.....................................................................................1639 Bearing........................................................................................................1639 ADJUSTMENT.........................................................................................................1640 Side Bearing Preload...........................................................................................1640 Pinion Gear Height and Pinion Bearing Preload..................................................................1641 Pinion Bearing Preload Washer Selection....................................................................1643 Pinion Height Adjusting Washer Selection...................................................................1644 Tooth Contact..................................................................................................1646 ASSEMBLY...........................................................................................................1647 Differential Side Shaft........................................................................................1647 Differential Case..............................................................................................1647 Final Drive Housing............................................................................................1649 H233B..................................................................................................................1653 REAR FINAL DRIVE...................................................................................................1653 DISASSEMBLY........................................................................................................1654 Pre-inspection.................................................................................................1654 Differential Carrier...........................................................................................1654 Differential Case..............................................................................................1656 INSPECTION.........................................................................................................1658 Ring Gear and Drive Pinion.....................................................................................1658 Differential Case Assembly.....................................................................................1658 Bearing........................................................................................................1658 LIMITED SLIP DIFFERENTIAL..........................................................................................1659 Preparation for Disassembly....................................................................................1659 Checking Differential Torque...............................................................................1659 Disassembly....................................................................................................1659 Inspection.....................................................................................................1660 Contact Surfaces...........................................................................................1660 Disc And Plate.............................................................................................1660 Adjustment.....................................................................................................1661 Friction Disc And Friction Plate End Play..................................................................1661 Assembly.......................................................................................................1661 ADJUSTMENT.........................................................................................................1665 Pinion Gear Height.............................................................................................1665 Pinion Height Adjusting Washer Selection...................................................................1666 Tooth Contact..................................................................................................1668 ASSEMBLY...........................................................................................................1669 Differential Case..............................................................................................1669 Differential Carrier...........................................................................................1670 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1673 Propeller Shaft....................................................................................................1673 General Specifications.........................................................................................1673 Inspection And Adjustment......................................................................................1673 Service data...............................................................................................1673 Snap ring..................................................................................................1673 Final Drive........................................................................................................1674 General Specifications.............................................................................................1674 Inspection And Adjustment (R200A)..................................................................................1674 Ring gear runout...............................................................................................1674 Side gear adjustment...........................................................................................1674 Side bearing adjustment........................................................................................1674 Inspection And Adjustment (H233B)..................................................................................1675 Ring gear runout...............................................................................................1675 —Additional service for LSD model —............................................................................1675 Differential torque adjustment.................................................................................1675 Drive pinion height adjustment.................................................................................1676 Drive pinion preload adjustment................................................................................1676 Total preload adjustment.......................................................................................1676 ra.........................................................................................................................1677 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1677 PRECAUTIONS AND PREPARATION............................................................................................1678 Precautions........................................................................................................1678 Special Service Tools..............................................................................................1678 Commercial Service Tools...........................................................................................1679 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING...................................................................1680 NVH Troubleshooting Chart..........................................................................................1680 REAR AXLE AND REAR SUSPENSION..........................................................................................1681 ON-VEHICLE SERVICE....................................................................................................1682 Rear Axle and Rear Suspension Parts................................................................................1682 Rear Wheel Bearing.................................................................................................1682 REAR AXLE..............................................................................................................1683 Components.........................................................................................................1683 Removal............................................................................................................1684 Inspection.........................................................................................................1686 AxleShaft......................................................................................................1686 WheelBearing...................................................................................................1686 AxleCase.......................................................................................................1686 Installation.......................................................................................................1686 REAR SUSPENSION........................................................................................................1689 Shock Absorber.....................................................................................................1690 Removal And Installation.......................................................................................1690 Inspection.....................................................................................................1690 Leaf Spring........................................................................................................1690 Removal And Installation.......................................................................................1690 Inspection.....................................................................................................1691 Installation...................................................................................................1691 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1692 General Specifications.............................................................................................1692 Inspection and Adjustment..........................................................................................1692 rs.........................................................................................................................1693 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1693 PRECAUTIONS AND PREPARATION............................................................................................1694 Supplemental Restraint System (SRS) ‘‘AIR BAG''....................................................................1694 SEAT BELTS.............................................................................................................1695 Front Seat Belt....................................................................................................1696 Rear Seat Belt.....................................................................................................1697 Seat Belt Inspection...............................................................................................1698 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)....................................................................................1701 Precautions for SRS ‘‘AIR BAG'' Service............................................................................1701 Special Service Tools..............................................................................................1702 Description........................................................................................................1703 Passenger air bag deactivation switch..............................................................................1703 SRS Component Parts Location.......................................................................................1704 Maintenance Items..................................................................................................1705 Diagnosis Sensor Unit and Crash Zone Sensor........................................................................1706 Removal And Installation...........................................................................................1706 Air bag diagnosis sensor unit..................................................................................1706 Crash zone sensor..............................................................................................1706 Driver Air Bag Module and Spiral Cable.............................................................................1707 Passenger Air Bag Module...........................................................................................1710 Passenger Air Bag Deactivation Switch..............................................................................1712 Passenger Air Bag Deactivation Switch Lock Cylinder................................................................1712 Passenger Air Bag Deactivation Switch Indicator....................................................................1713 Disposal of Air Bag Module.........................................................................................1714 TROUBLE DIAGNOSES — Supplemental Restraint System (SRS)................................................................1718 Trouble Diagnosis Introduction.....................................................................................1718 How to Perform Trouble Diagnoses for Quick and Accurate Repair.....................................................1721 Schematic..........................................................................................................1722 Wiring Diagram — SRS —.............................................................................................1723 Passenger Air Bag Deactivation Switch Indicator Operation Check....................................................1725 SRS Operation Check................................................................................................1726 Trouble Diagnoses with CONSULT.....................................................................................1727 Trouble Diagnoses without CONSULT..................................................................................1736 Trouble Diagnoses: ‘‘AIR BAG ''Warning Lamp Does Not Turn Off......................................................1740 Trouble Diagnoses: ‘‘AIR BAG ''Warning Lamp Does Not Turn On.......................................................1741 Trouble Diagnoses: SRS Does Not Enter Diagnosis Mode Using Door Switch.............................................1742 COLLISION DIAGNOSIS................................................................................................1743 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.........................................................................................................................1747 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1747 PRECAUTIONS AND PREPARATION............................................................................................1748 Supplemental Restraint System (SRS) "AIR BAG"......................................................................1748 Precautions for Steering System....................................................................................1748 Special Service Tools..............................................................................................1749 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING...................................................................1751 NVH Troubleshooting Chart..........................................................................................1751 ON-VEHICLE SERVICE.....................................................................................................1752 Steering System....................................................................................................1752 Checking and Adjusting Drive Belts.................................................................................1752 Checking Fluid Level...............................................................................................1752 Checking Fluid Leakage.............................................................................................1753 Bleeding Hydraulic System..........................................................................................1753 Checking Steering Wheel Turning Force..............................................................................1754 Checking Steering Wheel Play.......................................................................................1754 Checking Neutral Position on Steering Wheel........................................................................1755 Checking.......................................................................................................1755 Checking Front Wheel Turning Angle.................................................................................1755 Checking Hydraulic System..........................................................................................1756 STEERING WHEEL AND STEERING COLUMN.....................................................................................1757 Steering Wheel.....................................................................................................1757 REMOVAL AND INSTALLATION.......................................................................................1757 Steering Column....................................................................................................1758 REMOVAL........................................................................................................1758 INSTALLATION...................................................................................................1758 Disassembly and Assembly...........................................................................................1759 Tilt mechanism.................................................................................................1760 Inspection.........................................................................................................1760 POWER STEERING SYSTEM (Model: PB59K)...................................................................................1761 Description........................................................................................................1761 POWER STEERING GEAR (Model: PB59K).....................................................................................1762 Removal and Installation...........................................................................................1762 STEERING GEAR..................................................................................................1762 Power Steering Gear Component......................................................................................1762 Pre-disassembly Inspection and Adjustment..........................................................................1763 TURNING TORQUE MEASUREMENT.....................................................................................1763 Disassembly........................................................................................................1764 Assembly...........................................................................................................1765 POWER STEERING OIL PUMP................................................................................................1768 Disassembly and Assembly...........................................................................................1768 Pre-disassembly Inspection.........................................................................................1768 Inspection.........................................................................................................1769 PULLEY AND PULLEY SHAFT........................................................................................1769 Disassembly........................................................................................................1769 Assembly...........................................................................................................1770 STEERING LINKAGE.......................................................................................................1771 Removal and Installation...........................................................................................1771 Disassembly........................................................................................................1772 IDLER ARM ASSEMBLY.............................................................................................1772 CROSS ROD AND TIE-ROD..........................................................................................1772 Inspection.........................................................................................................1773 BALL JOINT AND SWIVEL JOINT....................................................................................1773 IDLER ARM ASSEMBLY.............................................................................................1773 CROSS ROD AND TIE-ROD..........................................................................................1773 FIXING LOCATION................................................................................................1773 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1774 General Specifications.............................................................................................1774 Inspection and Adjustment..........................................................................................1774 STEERING COLUMN LENGTH.........................................................................................1774 STEERING LINKAGE...............................................................................................1774 POWER STEERING SYSTEM (Model: PB59K)...........................................................................1774 tf.........................................................................................................................1775 QUICK REFERENCE INDEX.................................................................................................. 0 Table of Contents......................................................................................................1775 PREPARATION............................................................................................................1776 Special Service Tools..............................................................................................1776 Commercial Service Tools...........................................................................................1777 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING...................................................................1778 NVH Troubleshooting Chart..........................................................................................1778 Transfer.......................................................................................................1778 DESCRIPTION............................................................................................................1779 Cross-sectional View...............................................................................................1779 ON-VEHICLE SERVICE.....................................................................................................1780 Replacing Oil Seal.................................................................................................1780 Center Case Oil Seal...........................................................................................1780 Shift Shaft Oil Seal...........................................................................................1780 Rear Oil Seal..................................................................................................1781 REMOVAL ANDI NSTALLATION...............................................................................................1782 TRANSFER GEAR CONTROL..................................................................................................1783 MAJOR OVERHAUL.........................................................................................................1784 Case Components....................................................................................................1784 Gear Components....................................................................................................1785 Shift Control Components...........................................................................................1786 DISASSEMBLY............................................................................................................1787 REPAIR FOR COMPONENT PARTS.............................................................................................1792 Mainshaft..........................................................................................................1792 Front Drive Shaft..................................................................................................1794 Counter Gear.......................................................................................................1795 Main Gear..........................................................................................................1795 Front Case.........................................................................................................1797 Shift Shaft Oil Seal...........................................................................................1797 Front Case Cover...................................................................................................1797 Cover Oil Seal.................................................................................................1797 Bearing Retainer...................................................................................................1798 Oil Catcher....................................................................................................1798 Center Case........................................................................................................1798 Removal........................................................................................................1798 Center case oil seal.......................................................................................1798 Installation...................................................................................................1798 Center case oil seal.......................................................................................1798 Rear Case..........................................................................................................1798 Rear Oil Seal..................................................................................................1798 Air Breather...................................................................................................1799 Shift Control Components...........................................................................................1799 ASSEMBLY...............................................................................................................1801 SERVICE DATA AND SPECIFICATIONS (SDS)..................................................................................1808 General Specifications.............................................................................................1808 Inspection and Adjustment..........................................................................................1808
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